RESEARCH NEWS milling machine and a four-axis robot , both fully equipped with voice control . This technology platform allows customers to test various microphones , headsets and voice commands in a range of different noise environments . We ’ ve discovered that testing the voice control in an actual machine environment is the fastest way of convincing our industry partners ,” he added .
The extensive customisation and integration support provided by Fraunhofer IDMT allows the speech recognizers to be individually adapted to specific speech commands and machine interfaces . This increases the effectiveness of the voice control and reduces the costs and effort required for integration .
“ In the industry working group , we are developing a basis for the operating interfaces of the next generation of industrial controllers . This basis will enable contactless and intuitive operation of multiple , complex machines ,” added Marvin Norda .
Danilo Hollosi , Head of Acoustic Event Detection , Fraunhofer IDMT .
How do they cope with the different types of noise found in production ?
“ We are currently putting our system to the test by evaluating a speech recognition study with over 160,000 spoken voice commands in different noise environments . As a general rule , it ’ s not the type of noise that is decisive , but the noise level in relation to the volume of the speaker at the point where the sound reaches the microphone . These kinds of research studies allow us to optimise our speech recognizer for use in industry and to make recommendations about acoustic systems – and the best positions for them in the workplace ,” continued Norda .
Speech recognition
But control manufacturers are also experimenting with voice control , aren ’ t they ?
“ The idea isn ’ t new and many control manufacturers have already put forward their own solutions . However , there has been little or no widespread industrialisation of voice control so far . Our aim is to optimise efficiency and robustness levels by consistently refining our speech recognizers for use in future production environments ,” added Marvin Norda . “ We successfully integrated our algorithms in a Beckhoff industrial controller based on a Windows or Linux platform . We are also developing similar solutions for all other well-known control manufacturers .”
The speech recognition software is not running from the cloud or on a separate PC , but on the controller in the machine itself .
“ Multi-machine operation is the pinnacle of voice control because of the complexity of the machine commands , the walking distances to the machines and the cognitive demands placed on the operator . Acoustically , however , there is no difference between operating just one or several machines simultaneously . Just like with a touchscreen , all you need is a master computer which routes the commands to the right machine ,” explained Marvin Norda .
Added value from acoustics
“ Our acoustic systems are competing with established technology . Structure-borne sound sensors integrated into the machine for the detection of chatter noise , for example , represent state-of-the-art technology . However , these sensors cannot record other , equally relevant process and machine status information . A microphone , on the other hand , installed in a suitable position in or around the machining area , can simultaneously monitor the main spindle bearing , the fan and the cooling lubricant supply , perform touch detection and record voice commands . The user value rises exponentially when our smart sensor technology is enhanced with AI-based algorithms ,” highlighted Prof . Dr . -Ing . Sven Lange .
Danilo Hollosi , Head of Acoustic Event Detection , Fraunhofer IDMT , is developing smart sensors with his team .
“ Our acoustic process monitoring is contactless and works with airborne or structure-borne sound . The smart sensor system can detect the clicking sound when plug connections engage . If there is no click , the acoustic monitoring system registers an error . The operator is informed , too , and the event is automatically documented . My team and I have developed AI-based algorithms for reliable audio analysis of all kinds of click sounds . Our solution has already proved itself in trials on the assembly of cable harnesses in the automotive industry ,” he explained .
Representatives from Fraunhofer IDMT and the working group ’ s partner companies will be at EMO Hannover in Germany ( 18-23 September 2023 ) to hold in-depth discussions on acoustics with customers , and to sound out new application scenarios . n
Split forming to reduce automotive emissions
As industry looks to embrace net-zero , automotive manufacturers are eager to find more efficient manufacturing process routes to reduce emissions and input material weight .
Alloy wheels , traditionally manufactured through casting or multi-stage forging and flow forming , can be energy-intensive and time-consuming to produce , with significant heat and machining required . The University of Strathclyde ’ s Advanced Forming Research Centre ( AFRC ), in the UK , has demonstrated the potential of hybrid split forming and flow forming to produce a lower carbon footprint , near-net shape alloy wheel for the automotive industry .
The AFRC ’ s Forging and Incremental Technologies team researched suitable alloy wheel geometries found in typical cars . This work was supported by the University of Strathclyde ’ s Motorsport team ( USM ).
Computer aided design ( CAD ) modelling of the demonstrator component was carried out before the team designed bespoke forming tooling . Following this , the team undertook a series of forming trials and successfully formed the component from a 15mm plate at ambient temperature . The starting blank is split before being flowformed in two directions to create the final wheel profile with a thickness of 3mm .
“ The alloy wheel component was formed in a cycle time of three minutes , compared to 10-30 minutes for the conventional process . No heating was required , which could yield significant energy savings , whilst eliminating joining methods substantially reduces machining requirements ,” said the AFRC .
The AFRC is now liaising with leading automotive manufacturers who are interested in embracing split and flow forming within their operations . Email :
nmis-enquiries @ strath . ac . uk n