UAS Cologne is building a compact technology demonstrator using conveyor technology from mk
Students at Cologne University of Applied Sciences experience Industry 4.0 at work. A compact demonstrator with a robot, conveyor technology and a camera system provides an interactive experience of complex production processes. Thanks to the support of the mk Technology Group, key concepts such as OEE can be taught in a practical, future-oriented way in the smallest of spaces!
The demands placed on engineers are changing rapidly, and the teaching must be adapted as a result. At Cologne University of Applied Sciences, students can not only understand modern production processes theoretically, but also experience them practically with an Industry 4.0 demonstrator. This was made possible through the support of committed industrial partners such as the mk Technology Group, which provided cost-effective conveyor technology and contributed technical expertise to its implementation.
"If you don't move with the times, you'll be left behind", an old adage that certainly applies to our young engineers. As early as 2019, warning bells were starting to ring for the Association of German Engineers (VDI). According to a VDI survey, only eleven percent of students surveyed stated that they felt well prepared for the challenges of the networked industry – for young professionals, the figure was just nine percent. This is why the Association of German Mechanical and Plant Engineering (VDMA) demands that universities keep pace with technological progress and adapt their curricula quickly. And the Cologne University of Applied Sciences is proof that the necessary changes can be made.
Yannick Liebertz, Research associate at the Laboratory for Manufacturing Systems Cologne (LFK) at UAS Cologne
„In order to better prepare students completing the Master's program in Mechanical Engineering for Industry 4.0 – that is, automation, IoT networking and AI – we have developed a demonstrator that allows them to practice these key technologies.“
"We often received feedback from industry that while graduates have a solid theoretical foundation in production management, there is still room for improvement in the practical implementation of digitally networked production processes", says Yannick Liebertz, research associate at the Laboratory for Manufacturing Systems Cologne (LFK) at Cologne University of Applied Sciences. "In order to better prepare students completing the Master's program in Mechanical Engineering for Industry 4.0 – that is, automation, IoT networking and AI – we have developed a demonstrator that allows them to practice these key technologies".
Industry 4.0 demonstrator simulates modern pick-and-place process
The demonstrator is a compact table, 900 mm wide and 1200 mm long, which can be moved on casters from lecture hall to lecture hall. A closed-loop process similar to that used in a real production environment is installed on this table. The central element is an articulated-arm robot that performs a pick-and-place task. It picks two discs with diameters of 100 mm and 150 mm one after the other and stacks them on top of each other on a conveyor belt. This is where the conveying path starts. At the end of this conveyor belt, the stack is transferred to a second conveying path running at a right angle. A camera is mounted above this second conveyor belt. The camera checks how precisely the discs are stacked. The IT system then classifies the stacks as good and bad. After this quality inspection, the stack is deflected a second time by 90 degrees onto a third conveyor belt, which runs towards the other side of the robot. On this belt, a stripper separates the discs. At the end of the conveying path, the robot can then pick up the separated discs. The process is then repeated.
Taught not only theoretically but also practically
The new demonstrator at Cologne University of Applied Sciences helps to familiarise students with the concepts of Industry 4.0. "Not only are all essential physical processes of automation technology covered – i.e., handling, material transport and quality inspection", says Liebertz. The system also makes it possible to analyse and optimise production processes in real time. All components, from robots to conveyor belts to cameras, are networked, so that the IT system can, for example, correlate cycle times, pass/fail ratios and availability in order to derive insights for improvement. For example, it would be possible to detect if the production speed were increased beyond a reasonable level, resulting in a decrease in product quality, i.e., the accuracy of the stack. "Through direct observation and analysis of process data, key concepts such as Overall Equipment Effectiveness (OEE) can be taught not only theoretically but also experienced practically". In the long term, the plan is to also use the demonstrator for project work, final theses and interdisciplinary teaching formats.
Committed to promoting young talent
The demonstrator is an example of how universities are successfully adapting their teaching to the Industry 4.0 era. However, this transformation is often challenging when the budget for new teaching resources is limited. Cologne University of Applied Sciences was also faced with the task of implementing the new system as cost-effectively as possible. The search for alternative automation technology providers was also complex. A traditional articulated-arm robot for industry, for example, can easily cost tens of thousands of euros and would have been too expensive. The project managers were therefore delighted when they found a cost-effective alternative in the Rebel from Cologne-based company igus – an articulated-arm robot that is largely made of high-performance plastic rather than metal.
Cologne University of Applied Sciences also received support from the mk Technology Group, which provided the mobile table for the demonstrator and the conveyor technology. "mk was very accommodating with the investment costs, which made the project's implementation within the given budget possible", says Liebertz. "We know how important the training of qualified young engineers is in times of a shortage of skilled workers", says Maik Kirchner, a materials handling expert at mk. "Therefore, it is a top priority to support innovative projects like this as an industrial partner, both financially and by lending our technical expertise".
The specialist knowledge of mk's experts was crucial, for example, when it came to compactness. The demonstrator needed to be as space-saving and as lightweight as possible so that one person could push it from lecture hall to lecture hall. The Rebel from igus fit the bill perfectly. Since the cobot is made of high-performance plastic, it weighs only eight kilogrammes. This lightweight construction method is the result of ongoing development by mk. The experts built the table using mk Series 40 profiles. These are lightweight and modular aluminium profiles with a grid dimension of 40 x 40 mm, which are suitable for lightweight machine frames, protective devices and assembly workstations.
Compact conveyor from mk boasts
Also mounted on the table are three GUF-P MINI belt conveyors, which mk developed specifically for transporting and separating small and lightweight materials. With widths from 50 to 300 mm, lengths from 350 to 3,000 mm, and an installation height of just 35 mm, the conveyors offer flexible application options in confined spaces. "mk's extensive expertise in the field of conveyor technology played a key role in further optimising the design of the demonstrator", explains Liebertz. "Thanks to targeted feedback and suggestions from mk, the technical details of the transport system were ideally tailored to the requirements of the cobot and the quality station".
A higher-level programmable logic controller (PLC) synchronises the motion sequences, ensuring smooth operation between the conveying path and the robot's pick-and-place task. When the Rebel picks up the separated discs, the control system ensures, for example, that the conveyor belts slow down at the end of the conveyor belt runout and that the discs centre themselves in a prism. This ensures that the robot always finds a stable and reproducible transfer window without being disrupted by excessively fast belt movements. The control system also makes it possible to test different process variants and change specific process parameters, which is particularly valuable for teaching and analysis.
"The solution impresses not only with its millimetre precision, but above all with its attractive price-performance ratio – an important factor for use in training and teaching", Liebertz concludes.
Thanks to the open structure and modular design, the system can also be flexibly and sustainably expanded in the future, for example with retrofittable Industry 4.0 components, additional camera systems or the use of AI. For instance, this enables the discs to be gripped in motion without stopping the conveyor system. It also allows for practical investigations of complex scenarios, such as analysing the stability of stacks under varying curve speeds and friction. This would allow us to determine how precise and fast we can be while still achieving very high process reliability at a reasonable cost. The platform therefore offers not only technical potential but also an ideal basis for teaching and further developing key skills in modern automation in a practical way.
With over 26,000 students, the Cologne University of Applied Sciences (UAS Cologne) is Germany's largest university of applied sciences and sees itself as a modern university of technology, art and science. In this dynamic environment, the Institute of Product Development and Engineering Design (IPK) is a key player in shaping the digital and sustainable transformation of mechanical and plant engineering.
Within the IPK, the Laboratory for Manufacturing Systems (LFK), headed by Prof. Dr.-Ing. Thomas Gartzen, focuses on practical research combining manufacturing technology and digital technologies. The LFK develops innovative solutions for intelligent and networked production systems, with a particular focus on the requirements of small and medium-sized enterprises (SMEs). Key areas of focus include Industrial IoT, artificial intelligence and digital human-machine interfaces. The goal is to make manufacturing processes future-proof, efficient and sustainable.
Thanks to many years of experience in research and cooperation projects as well as high agility and technical expertise, the LFK is a competent partner in the implementation of digital strategies and industrial innovations.