15 Years of Fraunhofer in Saxony-Anhalt

The Fascination of Technology: Virtual Worlds at the VDTC

Service Robots for the Lab

Developing the Power Stations of Tomorrow with Fraunhofer

IFFOCUSInteractive Human-Machine

2/2007

IFFOCUS 2/2007 3

Dear Readers

“Everything comes to him who hustleswhile he waits.” It's as if these wordsfrom the famed Thomas Alva Edisonwere meant for the researchers at theFraunhofer IFF in Magdeburg. Thanksto their researching spirit and dedica-tion, we are able to look back onfifteen years full of research projectswith abundant results and steadygrowth. We are proud that we havealready been able to move into oursecond new building, the VirtualDevelopment and Training CentreVDTC with its worldwide one-of-a-kind technical equipment and facili-ties.

Since our founding in 1992, we havebeen pursuing the goal of planningand operating factories and produc-tion systems more efficiently. Weperform applied research and devel -opment in the fields of virtual engi -neering, logistics, automation andprocess and plant management. Weprovide our clients and partners com -prehensive and customized researchand development services, from ideafinding to implementation up throughemployee training. I would particularlylike to express our gratitude to ourpartners: For the confidence they haveshown us in the past and for thepriceless experiences from our jointproject work.

The balance of this project work istruly remarkable. In these fifteenyears, we have jointly launched theapplication of many new develop-ments with our industry partners. Abrief review is allowed: In this issue,you will find out something about ourinstitute's beginnings. However, thefocus of attention is on the latestnews from research and development.IFFocus reports on the different wayshumans and technology are interact -ing at our institute, whether in thefield of virtual technologies or robot -ics. The fields of application for ourdevelopments are many and diverse:The automotive industry or machineryand plant manufacturing, the energysector or medical technol ogy, heavymachine tool manufactur ing or archi-tecture. All of our projects share onecommonality: People's lives ought tobe simplified and improved - withstate-of-the-art technological innova -tions.

I hope you enjoy this voyage ofdiscovery through virtual and realworlds

Your,

Prof. Michael Schenk

Prof. Michael Schenk Director of the Fraunhofer Institute for

Factory Operation and AutomationPhoto: Viktoria Kühne

Editor’s Page

News

615 Years of Research for the RealWorld: 15 Years of Fraunhofer inSaxony-Anhalt

7 Record Attendance at the 10th IFFScience Days

8Virtual Development, Engineering andTraining

"Plant Engineering of the Future"Meets in Magdeburg

9VDMA Meets at the VDTC

TÜV Rheinland and Fraunhofer IFFCooperate on Power StationTechnology

10Fraunhofer Hosts the Society for thePromotion of Renewable Energiesy

1124th German Logistics Congress inBerlin

Joint ACOD Booth at the IAA

12Philippine Ambassador VisitsMagdeburg

Second Long Night of Science InspiresMagdeburg's Residents

13E.ON Avacon Assumes Sponsorship ofState Competition Jugend forscht undSchüler experimentieren

Interview14"Many enterprises ought to takeadvantage of the VDTC - just notour competition!"Dr. Heinz Dürr, Chairman of theSupervisory Board at Dürr AG

Research andDevelopment16The Fascination of Technology:Virtual Worlds at the VDTCProf. Michael Schenk

22Virtual-interactive Training for RWEWilhelm Termath and Paul Mecking

26Developing the Power Plants ofTomorrow with the Fraunhofer IFFDr. Martin Endig

32New Opportunities for Enterprises:With Fraunhofer IFF through the EUFunding JungleKatrin Reschwamm

34Virtual Organ Models forEndoscopy SimulationDr. Rüdiger Mecke, Simon Adler andCora Wex, M.D.

In this issue ...

38Virtual Saxony-AnhaltAndreas Höpfner

44Assembly Assistance with Augment -ed Reality: Mobile Measurementand Testing Technology Providesan OverviewDirk Berndt; Dr. Rüdiger Mecke; Dr.Christian Teutsch and JohannesTümler

48Interactive Human and Machine:Service Robots Cooperating withHumans in the LabDr. Norbert Elkmann

Sharp Minds

52... with DoctoratesHonorary Doctorate for IFF DirectorMichael Schenk

Magna Cum Laude for Vadym Rusin

53VDI Medal of Honor for DeputyDirector Dr. Gerhard Müller

55Prof. Toluyev Follows Call to Riga

Best Paper Award at CLAWAR inSingapore

56VDI Honors President Pollmann

Changing of the Guard in the Processand Plant Engineering Business Unit

Gallery

58Impressions of Business, Research andTechnology

64

Outlook

66

Editorial Notes

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The Fraunhofer is alwaysdirecting its gaze forward:The researchers have madeit their job to continuouslydevelop new processes,technologies and systems,which simplify people'slives. The Magdeburg insti-tute's fifteenth birthdayalso allows a glance at thepast - at the beginnings ofthe institute's history:The research scene in thestill young capital city ischaracterized by Otto von

Guericke Technical Univer -sity with its image-definingSchool of Engi neering. Therenowned research center,FER Ingenieurgesellschaftfür Automatisierung GmbHMagdeburg, is additionallyshaping Saxony-Anhalt as acenter of research. Thus,this eastern state in theheart of Central Germanyhas the best prerequisites

for a Fraunhofer Institutegeared toward productionengineering. Prof. EberhardGottschalk, a respectedresearcher and teacherwell-known to theFraunhofer-Gesellschaft,has been working on theconcept to establish thisFraunhofer Institutetogether with colleaguesfrom the university inMagdeburg since 1990.With success - the nucleusfor the future Fraunhofer

institution is created withthe formation of aFraunhofer-Gesellschaftworking group at FER onJune 1, 1991. The result isunveiled half a year later:The provisional FraunhoferInstitution for Factory Oper -ation and Automation IFFheaded by Prof. EberhardGottschalk is founded inMagdeburg on January 1,1992. The new institutiontakes up quarters in an old,unrenovated building onMartinstrasse in the Magde -

burg neighborhood ofBuckau.The first successes start justa short time later in 1993.With BMW as a projectpartner, the researchersdemonstrate their capabili-ties even to the institutesin the western states.Especially in the difficulteconomic situation afterreunification, companiesfrom Saxony-Anhalt profitfrom the solutions fromresearch and development.Creating competitive advan-tages through a technologi-cal edge is already one ofthe institute's elementaryobjectives at that time.The services it providesconvince the Fraunhofer-Gesellschaft's Senate. In1993, the time limit is liftedwell before schedule andthe institution is elevated tothe status of an indepen-dent instituteThe number of employeescontinues rising over timeand the researchers areworking at three differentlocations. The new building

on Sandtorstrasse is intend -ed to change that. Aftertwo years of construction,the modern building isready to be occupied in1998. Logistics, automa-tion, virtual reality andprocess and plant engi -neering clearly crystallize asresearch specializations.Just three years later, theunflagging researchersdecide on their next bigstep: Planning for theVirtual Development andTraining Centre VDTCbegins in December 2001.With its second new build -ing within a few years, theFraunhofer IFF extends itsexpertise to virtual technol -ogies. The time comes onNovember 22, 2006.Following a big ceremony,the VDTC opens as a"Landmark in the Land ofIdeas" and the employeesstart work in the new facil -ity.In these fifteen years, theMagdeburg researchers andtheir partners from industrymake many exciting proj -

15 Years of Research for the Real World:15 Years of Fraunhofer in Saxony-Anhalt

The main building on Sandtorstrasse. Photo: Ali Moshiri

The history of the Fraunhofer IFF begins in this old, unrenovated buildingat Martinstr.10. This temporary location, nothing more than a stopgap

solution, is where successful development started.

IFFOCUS 2/2007 7

ects reality, e.g. clever logis -tics concepts for BoschSiemens Hausgeräte GmbH,facade cleaning robots forLeipzig's Exhibition Centerand Berlin Central TrainStation, the recovery ofenergy from biomass,virtual-interactive trainingfor Lufthansa pilots, qualityinspection for vehicle rims

and riveted joints on Airbusaircraft, factory planningfor Zeiss in Oberkochen andinspection and cleaningsystems for the Emschersewer system. These are buta few examples from animpressive list of references.You can look forward tomore in the future.

The 10th IFF Science Days broke a new visitor record withnearly 500 attendees from fourteen countries. The insti -tute's fifteenth anniversary was the centerpiece of theannual research conference and exhibition of Fraunhofer IFFachieve ments.

The 11th IFF Science Days will be held in Magdeburg on June 24-26.

The IFF Science Days revolved around two internationalconferences. Picking up the direction of past years, aconference entitled "Virtual Reality and Augmented Realityfor Engineering, Testing and Operating Technical Systems"was held for the fourth time. Integrating it in the confe-rence for the first time, Fraunhofer researchers presentedthe Virtual Development and Training Centre VDTC to theirguests who were thrilled at its worldwide one-of-a-kind360 degree large projection surface that displays virtualenvironments three-dimensionally.

The second conference "Logistics Intelligence in Manufac -turing and Transportation" took up another focus of re -

Record Attendance at the 10th IFF Science Days

search at the Fraunhofer IFF for the first time. Given thatCentral Germany is clearly developing into an up-and-coming logistics region, this was a timely topic. Interestwas concentrated on such topics as Innovation in Trans -portation, Logistics in Intelligent Manufacturing andInfrastructures for Intelligent Logistics. Events presentingother of the institute's fields of business rounded out theprogram. Thus, for instance, a workshop on "Robot Tech -nologies for Use in Everyday Environments" deliveredremarkable insight into new research work.

In recent years, the IFF Science Days have establishedthemselves as a recognized forum for experts from re -search and academia, business and industry and politics."We are extremely proud that our conference is so wellreceived. The keen interest shows how deeply the instituteis anchored in the business and research communities.Along with the large international presence, many businesspeople from Saxony-Anhalt also attend," says DirectorMichael Schenk pleased. The IFF Science Days' recipe forsuccess consists on the one hand of the successful mix ofexcellent speakers and on the other hand of the excitinginsights into current research work being undertaken bythe researchers together with their industry partners.

The dates for 2008 have already been scheduled: The11th IFF Science Days will be held from June 24 through26. The Fraunhofer IFF will be continuing its conferenceson virtual reality and logistics. In addition, the Magdeburgresearchers will introduce a new conference on servicerobotics.

Sensor-guided grinding and deburring with industrial robots – one of theFraunhofer IFF’s first industry projects was completed together with acompany in Wernigerode. The auto ma tion specialists engineered the

process and a speci al sensor for the robot. Photo: Industriefoto Dieck

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advantages of virtual devel -opment and engineering.Now, these technologiesshould also be increasinglyutilized by machinery andplant manufacturers inSaxony-Anhalt. That is theaim of the Virtual Develop -ment, Engineering andTraining Innovation Cluster.The Fraunhofer Institute forFactory Operation andAutomation IFF, Otto vonGuericke University Magde -burg, the Max PlanckInstitute for Dynamics ofComplex Technical Systemsand regional heavy machin -ery and plant manufactur -ers such as the toolmakerSchiess, are collaborating inthe cluster coordinated bythe Fraun hofer IFF."One task is to developnew methods and toolsthat support the integratedutilization of VE and VRthroughout the product lifecycle," explains Prof.Michael Schenk, Director ofthe Fraunhofer IFF. In addi-tion, intensified use of VRfor employee training andqualification is envisioned.

Saxony-Anhalt has one ofthe longest traditions as acenter of machinery manu-facturing. In 2005, the 176companies based hereemployed over 11000workers and had sales ofover 1.3 billion euros. TheInnovation Cluster intendsto further develop themachinery and plant manu-

facturing industry's alreadyexisting economic potential,promote ideas for newproducts and secure jobs.The collaborative project isbeing supported with atotal of 6 million euros. TheFraunhofer-Gesellschaft, theState of Saxony-Anhalt andindustry have each put up athird of the money.

Virtual reality shortensand simplifies the develop-ment of new products.The Virtual Development,Engineering and TrainingInnovation Cluster intendsto now make these technol -ogies far more accessible tomachinery and plant manu-facturers in Saxony-Anhalt.The Innovation Cluster waslaunched in Magdeburg onSeptember 19, 2007.New products are beingdeveloped on the computerever more frequently. Theyare digitally designed, engi -neered, tested and refined.Engineers can, for instance,test a new machine on thecomputer without having tofirst build expensive proto-types. Production flows canbe run through in an inter-active 3-D model, potentialerrors and weak pointsidentified and personneltrained. New methods andtechnologies such as virtualengineering (VE) and virtualreality (VR) make this pos -sible. So far, carmakershave chiefly exploited the

Virtual Development, Engineering and Training

Prof. Wehrspohn, Director of the Fraunhofer IWM in Halle, Prof. Buller,Fraunhofer-Gesellschaft Senior Vice President Research Planning, Dr.

Haseloff, Saxony-Anhalt Minister of Economics, and Prof. Schenk,Director of the Fraunhofer IFF in Magdeburg (l. to .r) announced in

September that two Fraunhofer Innovation Clusters will be established inSaxony-Anhalt. Photo: Viktoria Kühne

Virtual-interactive model of a heavy tool machine.

The industry will meet inMagdeburg's Maritim Hotelon March 6 and 7, 2008 forthe conference on "PlantEngineering of the Future",

which is held every twoyears. It's time again in2008 and this time theconference is being jointlyorganized by the

The plant engineering conference has established itself as a popularforum for experts. Photo: Viktoria Kühne

“Plant Engineering of the Future”Meets in Magdeburg

IFFOCUS 2/2007 9

Fraunhofer IFF, FASA and,for the first time, theCentral German BusinessInitiative. The partnersVDMA and VCI are alsoinvolved in the program.The conference on "PlantEngineering of the Future"has become a constant inthe schedule of events.Researchers, industry repsand politicians gather anddiscuss new trends andprospects for the chemicaland power plant manufac-turing industry. Attention isconcentrated on the bene-fits of virtual engineeringfor planning, engineering,qualification and safe plantoperation. At the confer -ence, applications from theVIDET (Virtual Development,Engineering and Training)

innovation cluster will bepresented, which vividlydemonstrate how virtualreality can shorten andsimplify the developmentof new plants.An accompanying exhibi-tion will inform visitorsabout innovative technolo-gies and applications. Anexchange for future profes-sionals will facilitate contactwith highly qualified stu -dents majoring in processengi neering or mechanicalengineering, for ex am ple.Some 200 attendees, pri -marily from all over Ger -many, are expected.To register and for informa-tion, visit www.tagung-anlagenbau.de

The VDMA Regional Office Saxony-Thuringia's Engineeringand Design Working Group and the VDMA Regional OfficeNorth East's Research and Development Working Groupheld a joint meeting at the Virtual Development and Train -ing Centre VDTC in Magdeburg on September 12, 2007.

Topics at this event were potential uses of virtual technolo-gies in machinery and plant manufacturing. The research,development and engineering experts took advantage ofthe opportunity to find out about the tremendous poten -

tials of VR technologies as part of the two working groups'activities. In the Elbe Dom with its 360° large projectionsurface, researchers from the Fraunhofer Institute inMagdeburg gave the visiting experts from the machinerymanufacturing industry a brief overview of the potentialsof virtual reality, focusing on virtual product developmentand virtual training. The two working groups' joint meetingwas primarily attended by VDMA member companies fromthe eastern states and Berlin and particularly by companieswanting to implement these innovations in mechanicalengineering.

VDMA Meets at the VDTC

VDMA working groups meet at the Fraun hofer in Magdeburg. L. to r:Prof. Michael Schenk from the Fraunhofer IFF, Tilo Sinner from VDMASaxony- T huringia, Georg Riescher from MAN Druckmaschinen AG and

Mathis Kuchejda from Franz Schmidt + Haensch GmbH. Photo: Anna-Kristina Wassilew

The plant engineering conference is a highly regarded meeting place forthe power and chemical industries. Experts discuss the latest trends and

prospects. Photo: Viktoria Kühne

savings," according toMichael Oelkers, Head ofTÜV Rheinland's SuppliersIndustry Division. "Ourcooperation will enable usto offer even more interest -ing products and servicesfor power station operatorsin the future," added Prof.Michael Schenk, Director ofthe Fraunhofer IFF: "New ITmethods to store and makestructured know-how avail -able will help secure know-how and contribute toinnovative solutions to

The Fraunhofer Institute forFactory Operation andAutomation IFF in Magde -burg and TÜV RheinlandIndustrie Service GmbHhave concluded a coopera-tion agreement to collabo-rate intensively. The organi -zations announced this atthe conference on "PowerStations" at the VirtualDevelopment and TrainingCenter (VDTC) in Septem -ber 2007."Preventing power stationoutages through innovativemaintenance strategies andprolonged inspection dead-lines is a real potential for

TÜV Rheinland and Fraunhofer IFFCooperate on Power StationTechnology

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The 17th meeting of the Society for the Promotion ofRenewable Energies (FEE) was held at the Fraunhofer IFFVDTC on December 10, 2007. Attendees from all overGermany traveled to Magdeburg in response to an invita-tion from the working group on "Biogases - Fuel Cells".The event revolved around the topic "Potentials ofOperating Fuel Cells with Gasification Gas". In theirpresentations, numerous speakers, including MartinPokojski from Vattenfall AG, Prof. Jürgen Karl from theTechnical University of Graz and Dr. Matthias Gohla,

Manager of the Fraunhofer IFF's Process and PlantEngineering Business Unit, supplied the attendees withplenty of ideas for the discussions that followed.

For some time now, the process and plant engineers at theFraunhofer IFF have been working on recovering energyfrom biomass. For example, in the joint project ProBio withthe Max Planck Institute for Dynamics of ComplexTechnical Systems in Magdeburg and the FraunhoferInstitute for Ceramic Technologies and Systems IKTS inDresden, the researchers are investigating how renewableraw materials can be used effectively and environmentallycompatibly in fuel cells to generate power. As a member ofthe FEE and given its technical back ground, the FraunhoferIFF was the right place to hold this conference. After all,attendees had the opportunity after the conference to tourthe Process and Plant Engineering Business Unit's labs andthe ProBio test setup in particular.

The FEE is a national association of innovative, mostlysmall and medium-sized enterprises, research institutionsand specialists in energy savings, renewable energies andrenewable raw materials. It promotes complex energysolutions and innovations as well as their rapid implemen-tation in practice.

operate technical productsmore efficiently, dependa-bly and economically. Notleast, this will benefit thegeneral public."

The Fraunhofer IFF is con -tributing its technical know-how in process and plantengineering, conditionmonitoring of technicalassets and IT to the newpartnership. TÜV Rheinlandrounds out the portfoliowith practical methods andtools for condition-basedmaintenance and inspectionextension based on itsexperiences with large-scalepower plants.

Minimizing necessary inter-ruptions of operation andincreasing plant availabilityis a great challenge fortoday’s supplier industry.With state-of-the-artconcepts for condition-based maintenance andinnovative IT tools, theFraunhofer IFF and TÜVRheinland are helping alltheir clients collectively tapexisting potentials in theircompanies right away - andto do so in compliance withregulations and with anenhanced level of dependa-bility.

Michael Oelkers, Head of TÜV Rheinland’s Suppliers Industry Division(middle), and Dr. Gerhard Müller, Deputy Director of the Fraunhofer IFF

(right), agreed at the conference on power stations to collaborateintensively. Photo: Viktoria Kühne

Fraunhofer Hosts the Society for thePromotion of Renewable Energies

Martin Pokojski von der Vattenfall AG was one of the Society for thePromotion of Renewable Energies’ speakers.

Photo: Viktoria Kühne

Part of the ProBio test setup in the Process and Plant EngineeringBusiness Unit’s lab. Photo: Viktoria Kühne

IFFOCUS 2/2007 11

Under the motto "Efficiency -Responsibility - Success",more than 3,500 attendeesfrom over forty-five countriesgathered in Berlin on October17 to 20 for the GermanLogistics Association's (BVL)annual major event. It is theindustry's most importantcongress by far. In herremarks, German ChancellorAngela Merkel stressed logis -tics' important role as a cross-industry branch of the econ -omy that "unites differentsectors and influences howGermany is represented inthe world."

Emphasizing "Value Addedin Europe", "Challenges inNew Euro pean Markets","Europe's Beacons in Sup -ply Chain Manage ment"and "Invest ments in Euro -pean Markets and Loca -tions", European themesran like a thread throughthe plenary event, discus -sions and presen tations.

Together with its partnersin the Eastern GermanAutomotive Cluster ACOD,the Fraunhofer IFF present -ed its service portfolio atthis year's IAA in Frankfurtam Main. Well-knownvehicle manufacturers aswell as ever more industrysuppliers present them -selves at this global motorshow, which is second onlyto the Detroit Motor Showin terms of size and impor-tance. Fraunhofer research -ers demonstrated to thepublic the potentials of vir -tual and augmented realityfor engineering, testing andoperating technical systems.ACOD is an associationdedicated to promoting anddeveloping the entire auto-motive industry in EasternGermany. Its members are

vehicle manufacturers, sup -pliers and service providersas well as research organi -zations, associations andother institutions. TheEastern German Automo -tive Cluster was created in2004 to bundle this sector'sregional activities in oneoverarching organizationand to create synergies forall of Eastern Germany. Asan active founding mem -ber, the Fraunhofer IFF hasbeen intensively involved inACOD from the start. Ajoint conference on VirtualEngineering in the Auto -motive Industry will be heldin Magdeburg during the11th IFF Science Days onJune 24 to 26, 2008.

24th German Logistics Congressin Berlin

Joint ACOD Booth at the IAA

The International Motor Show is one of the most important industry gettogethers worldwide. Photo: Steffen Masik

Magdeburg's FraunhoferInstitute for Factory Opera -tion and Automation IFFwas represented with itsown booth. Its presentationfocused on such topics aslow risk logis tics, securechains of goods and off-road navigation.The insti-tute in Magdeburg hasbeen successfully research -ing and developing RFIDsystems for over ten years.Its LogMotionLab is one ofthe best equipped RFID labsin Europe.

On the last day of theevent, Dr. Marc Schleyerfrom the University ofKarlsruhe was honored withthe German ResearchAward. Juror Prof. MichaelSchenk, Director of theFraunhofer IFF in Magde -burg, was thrilled atSchleyer's presentation andpraised the high level ofinnovation of his work.

Research Award ceremony at the 24th BVL Congress. Photo: BVL

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Magdeburg wants to know:With a record 10,000visitors, the Second LongNight of Science repeatedthe success of 2006 anddemonstrated that theidea of bringing inquisitiveindividuals together withexperts functions superbly.In 2007, science fans wereable to visit 15 locationswith 135 presentations

Magdeburg's Port ofScience was the start andend point of the SecondLong Night of Science.

Mayor Lutz Trümper andMinister of Education andCulture Jan-Hendrik Olbertzkicked everything off at5:30 p.m. and opened theknowledge rally. A shuttlebus transported visitors tothe labs, workshops andauditoria where hands-onand experiencable scienceand research awaited them.

Many interested visitorsbegan their tour at theVDTC, the cutting-edgetraining center for virtualtechnologies. In the ElbeDom with its 360° largeprojection surface, they

traveled through the virtualLutherstadt Eisleben andflew from the marketplacethrough alleyways to the tipof the church steeple. Inthe new institute building'slarge testing facility, theyexplored various test setupsthat demonstrated variouspotential applica tions ofvirtual technologies. In thefoyer of the VDTC, studentsfrom Werner von SiemensHigh School invited visitorsto experiment and exploreeveryday questions such aswhy microwaves need turn-tables or what color electri-city has.

Visitors were also ableto look over researchers'shoulders in the mainFraunhofer IFF buildingon Sandtorstrasse and findout about the researchorgani zation's new and

interest ing projects on atour of the Fraunhofer IFF'stesting facility. The expertsin formed the marvelingguests that a high-tech pigconceals a floating robotsystem to inspect the sub -terranean Emscher sewersystem. The RFID applica -tions that vividly demon -strated transponder-aidedlogistics were especiallypopular. The Fraunhoferspecialists did this veryconcretely and entertain -ingly in a card game "17and 4: Clever with RFID".

There was plenty to dis -cover on this evening. Apartfrom the VDTC and theFraunhofer Institute, otherfacilities such as the MaxPlank Institute, Otto vonGuericke University and theIdea Factory opened theirdoors.

Ambassador of the Republicof the Philippines DeliaDomingo-Albert visited theVDTC in July 2007. Duringher tour, she was informedabout the potentials ofvirtual-interactive trai ning

Philippine Ambassador VisitsMagdeburg

for machinery and plantmanufacturing and therecovery of energy frombiomass. The ambassadorwas especially inte rested inmo bile augmented realityfor worker assistance.

Augmented reality technology is presented to Delia Domingo-Albert(middle). Photo: Anna-Kristina Wassilew

Second Long Night of Science Inspires Magde burg’s Residents

Immersed in cyberspace: Magdeburg’s big and small residents discoverthe potentials of virtual reality. Photo: Viktoria Kühne

Record Registration Again in Saxony-AnhaltViva la curiosité! Research fever hasbroken out again and not just in Saxony-Anhalt's schools, vocational trainingfacili ties and universities. November 30was the deadline for entering thescientific-technical competition for youngpeople Jugend forscht und Schüler expe-rimentieren by which time interestedcontestants had to have registered aproject for the new competion.

Paralleling the national trend, the numberof projects submitted to the 43rd compe-tition rose slightly in Saxony-Anhalt too.Altogether 229 participants registered130 projects in seven fields: WorkingWorld, Biology, Chemistry, Earth andSpace Sciences, Mathematics/ComputerScience, Physics and Engineering. Thereare not any specified tasks. Contestantsare expected to develop an interestingproblem on their own and independentlysearch for a solution.

Sponsor company E.ON Avacon also seesthe new competition as very special chal-lenge. After ten years sponsoring one ofthree regional elimination rounds inSaxony-Anhalt, E.ON Avacon will sponsorthe state competition for the first time. Itwill be held at the Fraunhofer Institute inMagdeburg on April 1 and 2.

"We are looking forward to this newchallenge," says Director of HumanResources Peter Hecker underscoring thecompetition's significance. "We have torecognize and cultivate young people'stalents if we intend to be able to dealwith future challenges. Above all, wewant to systematically cultivate youngtalent in scientific and technical fields.The competition Jugend forscht is anexcellent framework for doing so."

E.ON Avacon AssumesSponsorship of StateCompetition Jugend forschtund Schüler experimentie-ren

5 p.m. on Tuesdays, April 8 - June 10, 2008,Magdeburg

2008 Logistics Guest Lecture Series

Logistics as a Field ofWork of the Future:Potentials, Implemen -tation Strategies andVisions

www.gvr-log.de

IFF

FraunhoferInstitut Fabrikbetriebund -automatisierung

Phot

o: W

oody

Ste

in

For instance, air flows, temperatureconditions in driers or painting robots'motion sequences can be represented.

Virtual reality enables us to tourvirtual factories during which time theresponsible individuals on the clientside and at Dürr can clarify technicalaspects during a project. What ismore, the one-to-one visualizationfacilitates the indentification andelimination of potential interfaceproblems in the concatenation ofprocesses at an early stage. The accessibility of a system can also bechecked and optimized - instrumentalin reducing maintenance times. Anextremely significant aspect is beingable to detect points of conflict veryearly on and recognize where structu-ral ele ments encroach on one anotherin space. Thus, for example, when wewere building a system in China, wewere able to identify 123 collisionsand duly modify the design. Realisticsimulations shorten the planning timefor paint shops. All in all, that meansnoticeable savings for our clientsthrough optimal plant layout andverified processes.

from which a reading of these costscan be taken. Dürr has been usingsimulation models for nearly ten years,even ones that function on the basisof virtual reality.

For what areas of applicationdoes your company use virtualtechnologies?

The idea of optimizing the processand preventing costs has always beenuppermost. In the meantime ourlarge-scale projects, virtual planning,engineering and simulation of thecomplete system have become stand -ard in our large-scale projects - it is anintegral part of quotes. We have evenintegrated the material flow and otherfundamental individual processes inour 3-D visualizations. Since theymake the complete process so muchmore understandable and easier toassess, we use virtual models to dis -cuss future systems together with ourclients during the phase of planningand technical clarification. This en a -bles our clients to already review suchparameters as body throughput orbuffer sizes long before ground haseven been broken. Integrating datafrom the process simulation enablesanalyzing the operations and conditi-ons of individual stations.

“Many enterprisesought to take advantageof the VDTC – just notour competition!”

The Dürr Group is one of theworld's leading suppliers ofproducts, systems and services,mainly for the automotive industry.As a systems supplier, the globallyoperating enterprise plans andbuilds paint shops and final assem-bly facilities. Advisory Board Chair -man and controlling shareholderDr. Heinz Dürr visited Magdeburgto find out more about the poten-tials of the Virtual Developmentand Training Centre VDTC. IFFOCUSEditor Anna-Kristina Wassilewconducted an interview with him.

Your company is one of theworld's leaders in automotivepaint systems. Dürr has built paintshops for VW all over the world,for example in Brazil, Poland andSlovakia. What do your clientsexpect from you?

State-the-art technologies at thelowest price. Our clients, includingmany OEM from the internationalautomotive industry, expect that oursuppliers always have the most ad -vanced technologies and also guaran-tee the requisite stability and reliabilitywhen they handle these new technol -ogies.

The costs per unit, namely a plant'stotal operating costs, are always moreimportant than the investment costs.We've developed a computer model

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Dr. Heinz Dürr, Chairman of the SupervisoryBoard at Dürr AG. Photo: Dürr AG

IFFOCUS 2/2007 15

How do you present virtual modelsof design engineering to yourclients?

Unfortunately, we don't have such agreat projection system as the ElbeDom at the VDTC. We stereoscopicallyproject visualizations onto a Power -wall measuring 2.30 m by 2.00 m oruse a conventional projector. The ElbeDom is naturally much larger andextraordinarily impressive - manyenterprises ought to take advantageof the VDTC- except our competitionof course. It's the Fraunhofer IFF's jobto widely advance the use of thesetechnological possibilities in the busi -ness community because hardly anyone company can afford such aunique technological infrastructure.Dürr sees ample starting points forcollaboration. I could, for example,absolutely imagine that we discuss thelatest paint shop models togetherwith our clients here in Magdeburg.Even a scale of 1:1 is possible here.

How does Dürr AG ensure itsinnovativeness?

We employ scouts whose sole job isto track down new technologies andprocesses. They are always hunting forinnovations.

Our notion of innovation is particularlyaimed at energy consumption. Wehave to save energy in order to cutcosts. This central theme will con -stantly preoccupy us in the comingyears. A paint shop has the dailyenergy consumption of an averagesmall town. That is why the topic ofthe digital factory also plays such amajor role. The virtual reality tool canthree-dimensionally visualize thecomplete painting process. We can,for example, infer how an autobody'stemperature will develop or what thepainting process itself will look like.Earlier, we had complex immersionprocedures in which ten percent ofthe paint dripped off of a body. In themeantime, we have achieved nearly100 percent efficiency - only threepercent of paint is lost today.

Always making something newhappen, never getting a moment’srest – that appears to be your mot-to. Is there a guiding principle youhave followed throughout yourprofessional career?

Never stand still. As an engineer, Ihave naturally always been enthusi -astic about technology. And technol -ogy is also going to have to solve our gravest problem, climate change. This

is a technical problem and in myopinion the most important job forengineers.

Brief C.V.

Dr. Heinz Dürr born in Stuttgart on July 16,1933

1967 – 1980 CEO of the family business OttoDürr

1980 – 1990 CEO of AEGDürr applies comprehensive reorgan -ization concepts to bring the strug -gling company out of the red.He is also on the board of Daimler-Benz AG from 1986 onward.

1991 – 1997CEO of the Deutsche Bundesbahnand the Deutsche Reichsbahn. Underhis management, both companiesmerge to form the Deutschen BahnAG in 1994. He is Chairman of theAdvisory Board at the Bahn AG from1997 onward.

1998 – presentChairman of the Advisory Board atDürr AG

Seit 1999Chairman of the Advisory Board atthe telecommunications firm KroneAG

2003Awarded the Order of Merit of theFederal Republic

Autobody painting in a robot line. Photo: Dürr AG

16 IFFOCUS 2/2007

The Fascination of Technology:Virtual Worlds at the VDTCProf. Michael Schenk

With the Fraunhofer IFF's expansion, the Virtual Development and Training Centre,VDTC, one of the world's leading research organizations in the field of virtual tech-nologies is located in Magdeburg's Port of Science. Its facilities and labs represent aunique concentration of pioneering, internationally advanced technology. This holdsenormous potentials for science and academia, the economy and society. Which inturn make it a significant factor in the global conpetition for the sharpest minds andthat slight edge it often takes for a state to be the leader in a key technology of thefuture

IFFOCUS 2/2007 17

Saxony-Anhalt's Minister PresidentWolfgang Böhmer wasn't about to letanyone or anything keep him fromopening the Magdeburg FraunhoferInstitute's new research center inNovember of 2006. The VirtualDevelopment and Training CentreVDTC is an exceptional innovationthat attests to Saxony-Anhalt's posi-tion as a center for advanced technol -ogies. It was promptly recognizedwith an award as a "Landmark in theLand of Ideas" during the ceremonymarking its opening. The FederalGovernment and the German businesscommunity initiated this honor foroutstanding "beacons" of Germany'sinnovative strength.

From just a short distance away fromthe building rising directly on thebanks of the Elbe, beholders quicklyregister that this is no ordinary re -search institute. Above all, the large,circular, luminescent blue complexintegrated in the rather sober glassand concrete structure gets noticedimmediately. The futuristic lookingwing aptly called the "Elbe Dom" is atesting facility for large scale presenta-

tion of interactive, three-dimensionalvisualizations. It is one of the various"holodecks" in the starship VDTC; butmore on that below.

Arriving in the reception hall, any lastdoubts about what kind of institute avisitor has entered are eliminated.Three-dimensional video projectionson the walls and artful, colored lightdisplays for indirect illumination de -liver clear hints. On its outside too,the VDTC is a high-tech, integratedand complex platform for the devel -opment and presentation of virtualenvironments. It is not however mere -ly a purely scientific research institu-tion intended solely for operation byand for the roughly 170 researcherswho work there. Rather, followingthe Fraunhofer-Gesellschaft's prin -ciples, it considers itself a professionalservice provider and partner for thebusiness community and society. TheVDTC likewise functions as a training,con ference and educational center forstudents, industry partners and exter-nal company employees, qualifyingthem in product and process engi -neering in virtual environments.

The Fraunhofer IFF Virtual Development and Training Centre VDTC in Magdeburg’s Port of Science. Photo: Anna-Kristina Wassilew

Phot

o: D

irk

Mah

ler

360 Degree Large ProjectionThe Elbe Dom is designed to presentlarge objects, e.g. as part of designreviews or for training sequences. Itcan represent machinery, plants,factories or even entire cities on ascale of 1:1.Revealing itself to be a completecylinder inside, the Dom is a manifestsuperlative of 3-D visualization tech-nology. With a diameter of 18 metersand a height of 6.5 meters, it housesa 360 degree projection surfacemeasuring over 327m². Six high-techlaser projectors from Jenoptik providean extremely sharp image of thehighest quality. The depth of field andcolor mapping surpass that of conven-tional projectors substantially.

The projectors present 3-D imagesmonoscopically. Thus, apart from thetwo-dimensional representation on

18 IFFOCUS 2/2007

the projection surface, the spatialeffect is chiefly produced by the 360degree projection surface surroundingthe viewer who consequently experi-ences a feeling of being situated inthe midst of a virtual environment.When the program provides for it,the viewer can reach any point in therepresentation. This form of visualdemonstration is best suited for layingout factories as well as visualizingurban and rural landscapes. It facili -tates easier planning for every work-flow in and on objects with largedimensions. Thus, for example, onealready successfully tested variant ofapplication is pilot and technical stafftraining on jumbo jets. A respectable48m², the visitor platform additionallyallows nearly everyone involved inengineering design to take part simul-taneously. Commonly used hardwareand intuitive user guidance make it

Unique Technical FacilitiesFor these purposes, the VDTC housesan excellent technological infrastruc-ture with a whole series of different,high-tech labs, designed on the onehand to research and develop appliedbasic technologies for virtual realitysystems and on the other hand toprovide customized, VR based ser -vices. This purposeful utilization anddevelopment of VR has generatedthree specific specializations that playa key role in the work of the VDTC.Design review involves viewing andsimply interacting with all types ofthree-dimensional models. It enablescomprehensively inspecting and analy-zing products, machinery, architectureand much more even before they areultimately manufactured or built.

Prototyping employs 3-D visualizationsfor new and advanced developmentsand takes particular advantage of thepossibility to interact and work crea -tively with the visualized objects tointensively test and improve themwhile they are still in the engineeringdesign phase.

Training uses virtual models to costeffectively conduct employee trainingfor cooperation partners from industrywith optimal flexibility.

The VDTC's individual labs and othertechnical facilities are differentlyequipped to match them to thesedifferent tasks. As a rule, equipmentand facilities are selected based onthe size and function of the objectbeing worked on.

Elbe Dom Contact:Steffen MasikVirtual Interactive TrainingTel. +49 (0) 391/4090-127Fax +49 (0) 391/4090-115Steffen.Masik@iff.fraunhofer.de

The Elbe Dom in the VDTC. Companies can examine their products and processes three-dimensionally in the 360 degree large projection lab. That makes ever more impressive views

possible, whether on a scale of 1:1 or magnified 1000 times. Photo: Viktoria Kühne

IFFOCUS 2/2007 19

tremendously easier to comprehendthe interelationships represented.

Immersion in Virtual Environ-mentsAnother lab is the so-called CAVE(Cave Automatic VirtualEnvironment). Rather inconspicuousfrom the outside, this "cube" isreally a high-tech mutisided projec-tion system.

While a length of 2.3 meters alongeach of its edges makes the CAVEsubstantially smaller than the ElbeDom, it does however have sizeablecapabilities. Among other thingsand unlike the Dom, the systemfunctions stereoscopically. Thisstereo representation conveys arealistic impression of seeing athree-dimensional object in spacedirectly in front of one’s self.Additional floor projection createsan even more realistic perceptionof space. This feature expands itsrange of use with an important,functional-interactive aspect. Itliterally allows users to interactivelyenter virtual reality. The completepanorama view with a viewbeneath makes it possible to designextremely realistic simulations ofmachinery and driver's cabs.

Its form, size and perfect 3-D visual -ization make the CAVE particularlysuited for fast design reviews ofsmaller contents such as machinery,interior architecture or assemblyoperations. As part of an integratedwork concept, i.e. in direct proxi-mity to design workplaces, it pri -marily serves as an individual workinstrument for smaller groups ofindividuals. This enables interactingwith the 3-D environment, e.g. witha tracking system.

There’s an ideal work environment for every simulation task: Stereo projection in teh CAVE creates aparticularly intense impression of immersion in a virtual world. Photo: Dirk Mahler.

Engineering virtual assembly processes is easy on the immersive engineering workstation. Photo: Viktoria Kühne

tools at the research institute, whichare particularly shown to their bestadvantage in development and train -ing.

Labs: Think Tanks for EngineersThe Virtual Engineering Joint Lab pro -vides a platform for applied research inthe field of integrated product andprocess development. Among otherthings, it serves to universally trainstudents, industry partners and em -ployees in the field of product devel -opment. To perform these tasks, theJoint Lab has training rooms equippedwith advanced technology and a com -puter lab with 12 CAD workstations.Strategic associations with Otto vonGuericke University Magdeburg'sSchool of Mechanical Engineering aswell as leading software manufac -turers and engineering service provi-ders ensure the Joint Lab has highscientific and technical standardsA small but potent think tank, it gearsits services particularly toward theneeds of small and medium-sizedenterprises. Its fields of work rangefrom the migration of CAD data to theformulation of complete concepts forproduct life cycle management (PLM).Above all, by focusing on applied re -search topics, it continuously producesnew tools for digital product develop-ment.

20 IFFOCUS 2/2007

The Computational Mechanics Lab(CML) is in turn based on another ideaintended to already make both theform and function of products andtheir components digitally availableduring development. This is done bycombining at the workstation imagesof three-dimen sionally visualizedmodels on the one hand and mathe-matical models on the other hand.This approach allows using the visual -ized machinery models for a multitudeof mechanical problems. When theelectrical, axis and machine controlsystems are added to the models,realistic machinery operation can bereproduced. When it is being con -verted into a real prototype, develop-ment can be virtually supported upthrough the finished product by inter-connecting already existing compo-nents and simulated models (hard-ware-in-the-loop).

Mixed RealitiesFor this purpose, the building alsohouses a 210 m2 large mixed realitytesting facility where such real ormixed reality systems can be installedas demonstrators or experimentalsetups. Existing machine tool controlsystems and operating units that havebeen coupled with virtual prototypesmake it possible to perform safe func-tional tests.

Engineering WorkstationAs the preceding examples demon-strate, interactivity with virtual reality isan integral element of the intentionsbehind representations at the Fraun -hofer IFF VDTC .The design concept for the immersiveengineering workstation follows thisintention too. In this case, immersionis supported by a stereoscopic presen-tation of the virtual contents on aprojection surface measuring 120 x 90centimeters. Intended as an individualworkstation for one person, it is par -ticularly suited for planning and testingengineering designs and thus consti -tutes an outstanding tool for proto -typing.

CAVE and Immersive EngineeringWorkstation Contact:Ronny FrankeVirtual Interactive TrainingTel. +49 (0) 391/4090-144Fax +49 (0) 391/4090-115Ronny.Franke@iff.fraunhofer.de

As in the CAVE or the Elbe Dom, thevariable handling allows engineers totake over the control of program runswith a tracking system. This allowsengineers to deal directly with a ma -chine or a workplace. They can thentest an object's functionality togetherwith the designer by taking individualparts "in their hands" or trying outoperational sequences. In addition, theparticular steps of a machine's con -struction can be minutely reproduced,thus enabling engineers to virtuallypredesign workplaces and test thelogic of their configuration.

These three workplaces, the Elbe Dom,the CAVE and the immersive engineer -ing workstation, are however only onepart of the VDTC's technologicallysophisticated equipment. They supple-ment a whole series of other labs and

Cleaning robot controller simulation. Photo: Bettina Rohrschneider

IFFOCUS 2/2007 21

A hexapod motion base supports ergo-nomic tests or driver training. Visualinteractive motion simulations withinterchangeable seat modules can berun on it to develop simulators. Testenvironments for the realistic use ofaugmented reality systems allowdesigning and assessing vision andtracking systems.

At present, the motion base's func-tions are being extended to make itusable in the future as a high-techdriving simulator. Thus, in conjunctionwith its three-dimensional environmentvisualization, it will be available forvehicle development at an importantstrategic point. Until now, the auto-motive industry has only been able torevert to few research and develop-ment resources in the domain of driverassistance systems and ergonomicadjustment. The VDTC has reacted tothis need and will also be able to sup -port its vehicle engineering partners inthis respect too.

To supplement all these labs andvisualization technologies, the staff notonly relies on laptops and workstationsbut also special 3-D monitors, whichexpand the classical engineering work-place and support work on 3-Ddesigns.

In addition, they also have handheldsat their disposal, which are outstand -ingly good especially for mobile visu -alization of interactive 3-D contents.Not least, these mobile aids are usedfor assembly instructions and plantdocumentation and as mobile assistantsystems for e-learning or training onreal assets.

They are frequently used to train em -ployees from external companies. Anumber of training rooms with state-of-the-art equipment are availablespecifically for this purpose. Combinedwith the VDTC's labs, these are idealconditions for conducting customiz -able training courses.

Encounter, Experience, LearnThe Virtual Development and TrainingCentre VDTC provides a large numberof the widest variety of outstandingopportunities to utilize and developvirtual technologies. All these fieldsof application have one thing incommon: They enable people topenetrate domains that would remainunattainable without this technology.They improve understanding of tech-nical sequences and interrelationships,provide invaluable services for thedevelopment and operation of techni-cal systems and simplify complicatedlearning processes. And they help saveimmense costs.

Further developing these virtualenvironments is a major undertaking.They have already established them-selves as aids in key sectors of indus -try. In the future, their capabilities willbe in demand in everyday life. We willlikely reencounter them in manyplaces. Less as a support for engineer -ing needs such as in industry andresearch but rather more in the back-ground, e.g. in art, the entertainmentand communications industry or in theservice sector. What is already certainnow is that they will especially help uswith learning. We will be dealing withthem anywhere complex interrelation -ships have to be communicated,stand ardized information has to beretrievable anytime and anyplace orthings have to be described, whichcould not be at all or only with greattime and effort without VR. In allprobability, the Virtual Develop mentand Training Centre VDTC will beinvolved in these innovations in oneway or another.

Contact:Prof. Michael SchenkDirector, Fraunhofer IFFTel. +49 (0) 391/4090-0Fax +49 (0) 391/4090-596Michael.Schenk@iff.fraunhofer.de

Employee training at the VDTC: For Schiess GmbH, Fraunhofer specialists coupled a real controlunit with the virtual interactive model of a heavy machine tool. Operators can complete trainingwithout having to interrupt ongoing production – entirely without risk to humans or machinery.

Photo: Viktoria Kühne

22 IFFOCUS 2/2007

Virtual-interactive Training for RWE

Wilhelm Termath and Paul Mecking

Virtual realities (VR) have many fields of practical application. In the future, they will provide us important services,particularly as an educational medium and knowledge storage system. One successful example is the interactivetraining scenario jointly developed by the Fraunhofer IFF and RWE, which has met with a great response above allamong technical specialists.

IFFOCUS 2/2007 23

"Our experts there were thrilled whenwe showed them this application forthe first time," according to PaulMecking from the Technik CenterPrimärtechnik of RWE Rhein-RuhrNetzservice GmbH. He is in charge ofjointly developing this new learningmedium for RWE. "Earlier, people hadto read and process vast quantities ofpaper. Today, one can look at thenecessary work step in a fraction ofthe time and every one has the samelevel of knowledge."

What he’s talking about is the firstprototype VR application for RWETechnik Center employee training. Alarge transformer and its disassemblyhave been visualized to the last detailand made available to the specialistsas the foundation for training in aninteractive, virtual environment. Thisscenario was jointly developed withthe researchers from the VirtualInteractive Training Business Unit ofthe Fraun hofer IFF in Magdeburg andwas intend ed to be evaluated by thespecialists in the end. That the visuali -zation is effective and extremely tech-nically precise was clear. Yet no oneanticipated such a unanimously posi-tive reaction from the experts.

RWE Technik Center Primärtechnikspecializes in high voltage equipmentand large transformers. For over thirtyyears, maintenance on power circuitbreakers, converters, disconnectorsand transformers in voltage levels of110 to 380 kV has been done inworkshops and on site in stations.To assure the quality of this work,employees are given comprehensiveand intensive training. Real-time infor-mation and technical support foremployees throughout the entireconcern supplement the qualificationprograms.

In the course of refining the com -pany's internal training concept, adecision was made to collaborate withthe experts from the Fraunhofer IFFVirtual Development and TrainingCentre VDTC. The reasons for doingso were the specific constraints of

ongoing technical operation, whichmake training in real situations quitedifficult

Thus a far-reaching problem is therelative inability to use the equipmentbeing operated, the transformers inthis case, for purposes of training forsafety reasons and because they areintegrated in national or internationalpower grid structures. Moreover, thepertinent safety regulations alwayshave to be strictly observed wheneverinspection, servicing, maintenance andimprovement work is done. This alsocomplicates training considerably.In addition, it is impossible to reallyobserve functional processes insideequipment. Therefore, specialists needa high degree of technical knowledgeand the ability to think abstractly tounderstand them.

In the end, the decades-long servicelife of the stations necessitates devel -oping the technical specialists' know-how for the company and make ituseful for future generations. THismust be done as simply, vividly andstandardized as possible.

The use of virtual technologies com -mended itself here. The Fraunhofer IFFhad already effectively demonstratedtheir potential for use as a high perfor-mance educational scenario andknowledge storage system repeatedly.

In a first step, the disassembly of alarge transformer is visualized on the"rail profile", i.e. it is prepared for therequirements of rail transport. The useof VR technology makes it possible tomap the operations in the minutestdetail and as a comprehensible proce-dure. Employees are introduced to allimportant points and tasks step bystep. Later, they have to handle thesealone with the support of this programin a special learning scenario. In addi-tion, they obtain insight into all thetransformer’s internal processes andthe functional correla tions of their

24 IFFOCUS 2/2007

particular jobs. In the past, such con -tents could only be taught veryabstractly. That took up considerablymore time and did not guarantee aconsistent level of knowl edge amongeveryone involved. On the other hand,visualizing the work steps facilitatestheir internalization much better andincreases the quality of training consi-derably.

Apart from the opportunity to train ona system that is normally inaccessible,the utilization of learning scenariosgenerates a whole series of otheradvantages: Practical training can beconducted largely anywhere andanytime with a flexible number oftrainees. Both the schedule of exer -cises and the focus on individual worksteps can be varied as desired. Errorsdo not have any negative consequen-ces in a virtual environment and all thework steps are transparent for everytrainee all the time. Moreover, theapplication of advanced technologieshas proven to be an additional motiva-tional factor for employees in theinformation age.

Not least, the system also gives largeconcerns with an international baseanother reason to be interested in it:Knowledge can almost always betransferred "culturally independently".This means standardized operationscan - when equipment of the samedesign is used - be applied everywherewithout any "translation problems".

Beyond their use as demonstration andlearning environments, interactivemodels will also be employed in thefuture as a medium to secure andtransfer experiential knowledge. Theextreme practicability of this wasdemonstrated with the creation of atraining scenario. Above all, the sumof experiences of the technician calledin for consulting ultimately yielded theperfect representation of an optimalsequence of operations. The positivefeedback confirms this in everyrespect.

The lock nuts are loosened from the conductor bolts.

A large 200 kV transformer in RWE’s Niederrhein switching station

IFFOCUS 2/2007 25

For RWE, the future path clearlyappears to point in the direction of VR."Our company is extremely receptiveto this medium," says the engineerMecking who is certain that "In thefuture, VR visualization will assume akey role in the advanced qualificationof internal technical personnel andspecialists. That enables us to fullyservice our stations ourselves withouthaving to rely on external companies.

It would even be conceivable to turn itat a later time into a service we offerexternally."

At any rate, the first uses of the virtuallearning scenarios at RWE's trainingcenter in Wanderath have gone verysuccessfully. Another interactive lear-ning scenario of the replacement of aBuchholz relay is now being prepared.

Thus the developers in Magdeburg willhave a strong partner in RWE in thefuture too. At the moment, they areone of the world's leading institutes inthe field of interactive virtuality

Not least, the Fraunhofer IFF's coope-ration with Otto von GuerickeUniversity has proven valuable whenpreparing and didactically developingsuch qualification programs. Collabor -ation is especially close with the Insti -tute for Vocational Education andHuman Resource Development in theTraining and Technology CompetenceCenter, which has its origins in a jointinitiative of the Prof. Michael Schenk,Director of the Fraunhofer Institute IFF,and Prof. Klaus Jenewein, Chair ofTechnology and Education. The part-ners have agreed to organize jointlysupported research and developmentprojects. These will continually bedeveloped in collaboration with boththe specialized research expertise onhand in Magdeburg and regionalbusiness.

Contact:Wilhelm TermathVirtual InteractiveTrainingTel. +49 (0) 391/4090-129Fax +49 (0) 391/4090-115Wilhelm.Termath@iff.fraunhofer.de

Paul Mecking is a safety engineer forthe Ruhr region at RWE Rhein-RuhrNetzservice GmbH in Wesel. His workat the Technik Center Primärtechnik is focused on transformer engineering.

Vivid and realistic: The virtual-interactive training scenario for RWE projected large-scale in the ElbeDom at the VDTC. Photo: Viktoria Kühne

26 IFFOCUS 2/2007

Dr. Martin Endig

What almost exclusively applied to the automotive and aircraft industry earlier, isnow also reality in plant engineering: The use of virtual technologies. Researchers atMagdeburg's Fraunhofer Institute are now utilizing software previously only used inother sectors to engineer process plants too. It substantially supports the develop-ment of power plants and the control of their operation. That provides invaluablebenefits: Simplified design engineering, greater efficiency and increased reliability.

Developing the Power Plants ofTomorrow with the Fraunhofer IFFVirtual Technologies for Power Plant Development and Operation

Phot

o: D

irk

Mah

ler

IFFOCUS 2/2007 27

No one is able to definitively say whatthe energy scene of the future willlook like. Climate change, dwindlingresources and the obligation to con -serve resources are however height -ening the demand for alternative,distributed energy supply solutions .Most notably, biomass power plantsare becoming more important in thisregard and could capture an everlarger share of the energy market inthe course of these developments.

The process and plant engineers at theFraunhofer IFF in Magdeburg work onthe development, engineering andimplementation of such process plantsto recover heat from biomass, specifi-cally for distributed use in the powerrange of 20 MW of rated thermaloutput. Particularly for small andmedium-sized enterprises, these plantsrepresent an economically interestingtechnological solution for energyconversion and even more so when, asthe researchers intend, they are combi-ned with cogeneration based on theorgan ic Rankine cycle (ORC) or evenmore highly efficient conversion tech-nologies.

In the future, the advantages of virtualtechnologies will be applied to thedevelopment and operation of suchplants. They are used to generate real -is tic models of plants and plant com -ponents. They make it possible toalready obtain meaningful results ontheir engineered design, cost effec-tiveness and reliability while they arebeing developed. Parallel to this, newsoftware tools allow completely docu-menting the entire development proc -ess by generating standardized, digitalproduct data. These are strong advan-tages over conventional methods ofdocumentation. They not only make itpossible to utilize feed materials moreefficiently during the entire phase ofplanning and construction.

By simplifying the entire documenta-tion process, they also make it easierto comply with the legal requirementsof plant operation. Power plant opera-tors will especially take notice of this

innovation since it will clearly helpthem reduce their liability risks in thefuture.

Virtal Technologies in Develop-ment: A Data Management DietThe use of virtual technologies has anumber of advantages. In addition tothe need to develop new, better andcustomized plants in ever shorter timeand launch them on markets as globalcompetition cuts production costs,developers and operators face anotherproblem. They are experiencing in -creasing difficulty meaningfully struc-turing and archiving the vast quantitiesof data material amassed in theprocess. This impedes extensively inte-gratively engineering developmentinformation into the further designprocess and later operation. That iswhy many companies are findingthemselves struggling with an oddsituation. On the one hand, they are indanger of drowning in the sea of dataand information. On the other hand,they are suffering from a lack of infor-mation because much of the compiledand stored data from development,maintenance and production cannot

be found again in the disarray of thefile systems. The consequences can belost hours of work because time is lostsearching for information and docu-ments and also diminished know-howtransfer. All-encompassing communi-cation between developers in acompany enabling them to exchangeinformation on the outcome of devel -opment in personal conversations isimpracticable in the day-to-dayroutine.

The application of virtual technologiesis intended to finally make thisproblem a thing of the past. In thefuture, they will make large parts ofplant development and data manage-ment significantly easier as the follo-wing two examples demonstrate.

On the one hand, virtual technologiesare able to directly support the designengineering process by means of 3-Dsimulations. This involves using thewidest variety of development tools,including both 3-D CAD systems toengineer the design of plants andplant components and simulationsystems to review process parameters.

Visual-interactive 3-D models support design decisions.

On the other hand, the systematicutilization of virtual technologies andthe detailed data acquired in thedevel opment and engineering processserves to organize product data mana-gement more leanly and thus moreeffectively. Along with the use ofspecific conventional developmentsoftware, this takes on special signifi-cance since the goal is the meaningfulreusability of all development data,information and documents both infurther development and subsequentprojects. Such a management software"diet" involves digitizing all the collec-ted data so that it can be subsequentlyprocessed with a structure based on astandardized product data model.

The standardized management andprovision of digital product data is thejob of product management systems(PDM systems). Until now, they havebeen commonly used in automotiveand mechanical engineering. Directlytransferring suitable product datatechnologies to process plant engi -

28 IFFOCUS 2/2007

neering is only feasible in part for onesimple reason: While the aforemen -tioned branches of industry primarilyfocus all their considerations on theproduct, plant engineering concen -trates all its efforts on the processesand thus only indirectly on the plantitself. This necessitates configuring adigital plant model that takes theprocess as its starting point. Processand plant engineers currently use thePDM system Windchill PDMLink to dojust this. Along with unified data andproject management, the specific goalhere is to use relevant up-to-date plantinformation to directly support suchprocesses as design reviews or evenbuilding consultations at a construc-tion site. In the future, this will enableusing up-to-date 3-D product data todirectly support the compilation oftechnical documents.

Virtual Technologies for Operation:Garantees for Greater ReliabilityNot only plant development but alsoplant operation will be able to profit

Thus, the simulation can already testthe functionality and efficiency of indi-vidual components by themselves andin interaction with the entire plantbeforehand. This way, engineers havein front of them a clear, three-dimen-sional image of the structure and theprocesses running in it. They are ableto freely and better decide wherechanges have to be made and wherethe desired optimum has already beenachieved. Tremendous time savingsand higher rates of effectiveness arethe outcome.

Fraunhofer IFF Industry Project

The Bodelschwingh-Haus diaconalinstitution had a biomass heatingplant built where it is located inWolmirstedt with the goal of sustain-ably organizing its energy supply onits own with an ecologically progres-sive and innovative solution based onrenewable energy sources. Forest andindustrial waste wood in the form ofuntreated woodchips is used as therenewable energy source.

Fraunhofer researchers employed thewidest variety of virtual technologiesto support the processes from plantdevelopment up through commis -sioning. For the first time ever, allproduct and project information wasconsolidated in a unified productdata storage system. This productinformation not only includes puredevelopment data but, in particular,also technical documents and thespecifications for technical documen-tation. This documentation can thenbe "automatically" converted intotechnical product documentation anoperator can use, the outcome beingnew support tools for the utilizationof technical documentation duringoperation.

3-D plant visualizations support design review tasks.

from using virtual technologies in thefuture. The core of work related to thisis particularly focused on supportingoperational reliability. The requisiteconditions have already been estab -lished in development in the form ofdigitized product data. Now, it is "onlystill" necessary to systematically applythese.

The tragic circumstance of present dayplant operation always seeming to beconnected with an apparent contradic-tion, i.e. earning a profit and simulta-neously complying with all legal regu-lations for operational safety, nolonger has to be an obstacle. On thecontrary!

The latest information managementstrategies can make a major contribu-tion here. They help make it possibleto take advantage of legal leeway andsimultaneously achieve value added foroperation. If, for example, mainten-ance strategies are devised on thebasis of unified information manage-ment, they make current conditionsand forecasts of conditions of techni-cal components accessible anytime.This facilitates both improved mainte -nance planning and improved informa-tion on operational reliability, whichultimately contributes to compliancewith legal requirements significantly.

PDM Systems as the Basis for Information and ExperienceStorage Systems However, a fundamental prerequisiteto the integrated use of new strategiesand technologies is the availability ofthe requisite know-how for operationas well as its digital storage and thususability. Among other places, thisknowledge is explicitly contained intechnical product documentation as

digitized information and implicitlyexists in the heads of companyemployees as know-how. Efficientlyutilizing this know-how presentscompanies a great challenge though:Setting up a universal information andknowledge storage system for theoperation of technical assets.

Magdeburg's Fraunhofer specialistsrely on such established virtual tech -

3-D CAD design for component engineerng based on Pro/ENGINEER.

Variety of ApplicationsApart from purely structured andlegally sound product data manage-ment, a host of other benefits fromthe utilization of virtual technologiesfor operation can be cited. Forinstance, standardized access portalsprovide everyone involved throughouta company non-redundant informationand experiential knowledge abouttechnical assets. In order to facilitateaccess to this knowledge, it can betransformed and filtered once morefor specific users and/or contexts

In addition, state-of-the-art virtualtechnologies simplify the communica-tion of technical knowledge. One suchtechnology is the Universal 3-D (U3D)data format, which allows mutually

30 IFFOCUS 2/2007

using and visualizing technical infor-mation as PDF documents.

Virtual reality (VR) technologies addi-tionally enable configuring virtualplants for purposes of different appli-cations. The wealth of digitized infor-mation can even be employed to inter-pret available data material forconcrete objectives

Ultimately, the potential uses of virtualtechnologies are vast and provide amultitude of options, e.g. interactiveassembly instructions in the form ofnew, interactive PDF documents tosupport maintenance work. InteractiveVR based training scenarios are alsoconceivable. They can be used in quali-fication actions in which not only the

nologies as PDM systems as the back-bone for the implementation of anappropriate system. These systemshave proven to support developmenttasks excellently. What is more, theyfacilitate the efficient managementand provision of large quantities ofdata, information and documents. Atthe same time, they readily supportthe reuse of digital product data fromengineering. Such data presenting aproduct includes 3-D CAD data, entiresimulation models and even "mere"results from already run simulations.

3-D process engineering visualization of a cyclone’s processes. Photo: Dirk Mahler

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actual plant design but also the proc -ess engineering has to be visualized.Today, the latter can be generated"automatically" by interpreting avail -able simulation results and combiningrelated 3-D CAD information

Ultimately, four fundamental realms ofprocess plant engineering are identifi -able in which virtual technologies willbe indispensible in the future:

1. Development and engineering,2. Information documentation,3. Information and knowledge

storage systems and4. Operator training.

A still far greater number of potentialapplications is conceivable in thefuture for this field of work alone.However, as a fundamental precondi-tion, the Frauhofer specialists favorcreating a universal information andknowledge storage system as thebackbone. This is the only foundationfor complete, cross-life cycle documen-tation of everything specific to a plant.In the future, it will be the basis forsuccessfully surviving the conflictbetween cost effectiveness and opera-tional relia bility.

Contact:Dr. Martin EndigProcess and Plant EngineeringBusiness UnitTel. +49 (0) 391/4090-120Fax +49 (0) 391/4090 93-120Martin.Endig@iff.fraunhofer.de

Bundesverband mittelständische Wirtschaft

Unternehmerverband Deutschlands e.V.

The Bundesverband mittelständische Wirtschaft is thecrossprofession and crossindustry, politically neutral asso-ciation representing small and mediumsized enterprisesbefore government, authorities, unions and large con -cerns. It provides extensive services locally, regionallyand internationally.

As the voice of SME, the BVMW is active on behalf ofover 150,000 small and mediumsized enterprises thatemploy around 4.3 million workers. In Saxony-Anhalt, theassociation supports over 3,000 small and mediumsizedenterprises from every sector. It is present betweenArendsee and Zeitz with twelve branch offices and viewsitself as a communication platform. The state office is theon site contact through which cooperative selfhelp is or -gani zed. Services include meetings of companies, thecreation of crossindustry networks and informationalevents.

Among others, BVMW services for its members includelegal aid in questions of labor, corporate, commercial andindustrial law. Its competition telephone provides imme-diate aid for cease and desist letters related to advertisingactivity. Experts provide support on information aboutbrands and help performing database searches and regi-stering brands and trademarks. BVMW has 20 permanentrepresentations abroad, for instance, in Warsaw, Bucha -rest, Zurich, Brussels, Dubai, Istanbul, Beijing undShanghai. It facilitates uncomplicated contacts to foreignpartner companies.

BVMW-Landesgeschäftsstelle Sachsen-AnhaltHumboldtstrasse 839122 MagdeburgGermanyTel.: 0391-6074099Fax: 0391-6074114Email: jutta.schubert@bvmw.de

BVMW

Advertisement

32 IFFOCUS 2/2007

European companies have access tocountless options to develop further,to grow or to join up with partners.Very few companies are aware of thispotential though. Even responsibleindividual in Brussels report there aretoo few mid-sized applicants. Thereasons are extremely wide-ranging:One lacks the know-how to deal withEU bureaucracy, another the moneyand another the staff. Large concernsor corporations principally apply tothe EU for project funding and theyare often supported by a team ofspecialists.

Various European Union supportprograms offer small and medium-sized enterprises opportunities to keeppace with global players in researchand development. In the projectsmE-MPOWER, the Fraunhofer IFFfacilitated small enterprises' access tothe European research scene. Industryassociations, innovation centers andacademic institutions are the linksbetween and the keys to enterprisesand research. They have the necessarybusiness as well as research contacts.These contact brokers are regularlyrepresented at trade fairs and work -shops where problems that can arisein the everyday corporate routine andadversely affect a firm's economicpower are frequently discussed,making these the ideal venues to takeadvantage of professional support toturn research interests into a fundedproject.

Amykor in Bitterfeld-Wolfen inSaxony-Anhalt was one of the firstcompanies that decided to enlist thehelp of Fraunhofer coaches from thesmE-MPOWER project. Amykor worksin the biotechnology sector andproduces soil adjuvants containingfungus spores that establish a symbi -otic relationship with plant roots toobtain higher yields. Amykor employ-ees have been working on a newproduct for some time. Fungus sporesare cultivated in small Petri dishes in a

New Opportunitiesfor Enterprises: With Fraunhofer IFFthrough the EUFunding Jungle

Katrin Reschwamm

Small and medium-sized enterprises make up the lion’s share ofthe European business scene. Ninety-nine percent of all companiesin the European Union are part this group and provide some seventy-five million people jobs. Strongly rooting these companiesin a region is extremely important, if only because they promoteindividual regions' development.That is why supporting these companies' potential for innovationis one of the top priorities of the European Union's various supportprograms. In the project smE-MPOWER, the Fraunhofer IFF devel -oped a new approach to facilitate small and medium-sized enter-prises' participation in international collaborative research.

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lab. Scaling from the lab up to massproduction will require both financialsupport and specific know-how toprepare a proper research proposal forsubmission to the EU.

Amykor became aware of the Fraun -hofer specialists at a trade show forsmall and medium-sized enterprises inSaxony-Anhalt. The two began collab -orating. smE-MPOWER coaches andAmykor executives discussed ideas inmany further talks. They ultimatelyformulated their ideas and plans as aresearch grant proposal and appliedfor funding.

The smE-MPOWER approach topotential projects relies on dividingso-called innovation programs intothree phases. Along with implement -ing a project and evaluating its results,closest attention is paid to the firstphase of preparing the project.

According to assessments of smE-MPOWER coaches from the Fraun -hofer IFF, this is where small andmedium-sized enterprises see thegreatest outlay of work and time. TheFraunhofer experts begin their supportthe moment a company approachesthem and requests it. The first task isto then find out in discussions whatcan be changed: Where is the poten-tial for innovation in the company?Which external partners are appro-priate? The coaches' support requiresextremely knowledge-intensive ser -vice. To provide a high level of serviceand broad cross-industry know-how,the Fraunhofer specialists utilize avirtual network to which all the inno-vation coaches contribute their spec -ialized knowledge and experiences.This guarantees the coaches continu -ously receive further qualification andhave an extensive base of knowledge.They can also revert to the network

when searching for appropriate part-ners for the innovation program.Thus, the experts formulate partnerrequests and address them to theentire virtual community. If a suitableconsortium has assembled from thecompany's business representatives,the partners and the coaches, theydevelop a customized innovationprogram for the company step-by-stepand concretize it until it becomes aresearch grant proposal.

This project preparation phase is verytime intensive and can last up to ayear. If a research grant proposal hasbeen formulated and is approved, theensuing project also has great chancesfor success. Depending on the innova-tion program's demands, a companycan decide whether it desires thecoaches’ continued support in thefollowing phases.

Based on its good experiences,Amykor intends to continue workingtogether with the smE-MPOWERcoaches. Dr. Roland Watzke, Manag -ing Director of Amykor explains that"As a medium-sized biotech companywe can't and don't intend to do with-out the Fraunhofer specialists' profes-sional support. Their support is worthits weight in gold, especially in thepreparation phase!"

In the long term, company partner -ships will develop beyond these inno-vation programs, which will boosttheir region's economic power andenhance small and medium-sizedenterprises' competitiveness.

Contact:Katrin ReschwammInternational Competence CenterLogisticsTel. +49 (0) 391/4090-625Fax +49 (0) 391/4090 93-901Katrin.Reschwamm@iff.fraunhofer.de

The biotech company Amykor develops novel products for a highly specialized market. Keepingabreast of the competition involves safeguarding the capacity to innovate. For small and

medium-sized enterprises, this is usually a question of financing. Photo: © Amykor

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As advances contribute new devices and methods to medical technology, physiciansand especially surgeons' training and work has changed considerably in recent years.Handling the increasingly sophisticated technical options requires a sound back -ground and routine when performing operations. Complications ought to be avoid -ed and patient satisfaction enhanced. In a joint project, researchers from the VirtualDevelopment and Training Centre VDTC and Otto von Guericke University SurgeryClinic are developing new methods tosimulate virtual operations.

Virtual Organ Models for Endoscopy SimulationDr. Rüdiger Mecke, Simon Adler and Cora Wex, M.D.

IFFOCUS 2/2007 35

However, nearly all existing trainingequipment has little relation to realityand contains poor models.

As in flight simulation, a medicaltrain ing simulator’s effectiveness alsodepends on the realism of the modelserving as its basis. One aspect ofsimulation that is difficult to achieve isthe haptics or transmission of thesensation of instruments. In a realoperation, organs possess specificresistances, which help surgeonsorient themselves and execute actionsso that no organs are injured. Assuch, these resistances are extremelyimportant for surgeons. Existing train -ing equipment has not been able torealistically reproduce the transmissionof such sensation.

Another emphasis is the realisticrepresentation of the virtual cameraimage. While most simulators provide"textbook situations", these do notsufficiently meet the requirements ofa comprehensive visualization.

The Fraunhofer IFF Virtual Develop -ment and Training Centre VDTC inMagdeburg is addressing this problemspecifically. The implementation oftechnologies that meet these stringentrequirements are being worked ontogether with several regional part-ners in a joint interdisciplinary project.

To meet the highest scientificdemands, they are cooperating withOtto von Guericke University Magde -burg's Medical School as well asdepartments from its schools ofengineering.

Realistic Tissue PropertiesGenerating and interactively visualiz -ing organ models with high opticalquality is a great technical challenge.On the one hand, the organs ought toappear as realistic as possible. On theother hand, it must be possible tointegrate various clinical pictures inthe models.

One method to calculate deformationson bodies and organs is to form themwith a mathematical system of tetra-hedron models. Every single tetrahe-dron is furnished with mechanicalproperties and has a specific relation -ship to the adjacent models. Manipu -lations that result in deforma tions onorgans can then be represented bychanging the tetrahedrons’ positionand deforming them.

This detection of collisions betweensurgical instruments and organs is adistinctive feature of the visualizedmodels. Not only can organs be de -formed but they can also be de -stroyed in their entirety or lastinglyaltered. Surgical procedures such asmaking incisions and transectingentail lasting alteration of organgeometry that must be reproduciblevirtually.The virtual system has to react flexiblyand appropriately without changingan organ's underlying physical andmechanical properties. Bleeding andtissue changes must also be detect -able.

The field of computer science employshierarchic structures such as sphere-trees for this visualization to detectcollisions rapidly. It is intended toafford an opportunity to rapidly inter-act using simulated instruments.

Once the three-dimensional organgeometry has been developed, theorgan's surface can be overlaid withphoto documentations as textures.Along with being able to simulatevarious clinical pictures (e.g. tumors)in a random configuration, anylighting situation can be represented.This is instrumental in enhancing theimpression of reality.

In the 1980s, a new method startedentering medicine's surgical disci -plines: Minimally invasive or button-hole surgery. It is applied in abdomi-nal surgery, vascular surgery, urologyand gynecology. Traumatology is alsoincreasingly employing minimally inva-sive methods to access body cavities.

These methods have number ofadvantages for patients. Instead oflarge surgical incisions, small puncturepoints can be selected, which scarsubstantially less as a result. So-calledtrepans through which surgical instru-ments can be inserted in a particularbody cavity are inserted into thesesmall openings. These surgical instru-ments are mounted on long rods witha grip surgeons use outside the bodyto move the instruments inside as aminiature camera displays the area ofthe body cavity on a monitor. Thisresults in faster healing, shorter hospi-tal stays, better eating and less consti-pation after an operation as well asless wound pain. Patients are mobileagain faster and better cosmeticresults contribute to general satisfac-tion.

The method's disadvantage is that itsubjects surgeons to a learning curvefor these techniques. The instrumentshave large lever arms, coordination isdifficult and a body cavity's contents,e.g. organs, are only indirectly visible,namely on a monitor. Unfortunately,present technical resources only allowthe transmission of a 2-D view.Surgeons must add the third dimen-sion in their imaginations.

This requires extensive practice hand-ling the instruments and special visualappearance as well as intense concen-tration. Yet dry runs remain difficultand not very realistic.

This is where surgical simulators canbe used as equipment to train sur -geons, much like flight simulators totrain pilots.

At least twenty-five images persecond must be represented in orderto obtain a realistic simulation. A real -istic sense of touch can be expectedat a clock-pulse rate of more than 100frames/second.

The complicated steps to computesuch organ models frequently reachthe limits of conventional computercapacity. Hence, new methodsare being developed and soft-ware tech niques optimizedto obtain better perfor-mance in the hardwareavailable.

Whenthis has beenaccomplished, the application of suchsimulations to train minimally invasivesurgery will move a little bit closer.Aside from providing young physicianstraining in manual and diagnosticskills, other potential applications defi-

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nitely exist for the future. Many teamsare work ing on problems of planningindividual operations on patients forinstance. Along with specific trainingfor individual and particularly difficultoperations, every single patient couldhave her or his clinical picture ex -plained on a virtual model and beshown the operation planned. While

much research is still required to doso, it seems certain that such a proce-dure will be possible in a few years.

Simulated HapticsThe use of haptic input devices thatfacilitate interaction with the repre-sented virtual body cavity and itscontents also adds to the overallsimulation.

The monitor is a surgeon's only orien-tation during minimally invasive proce-dures. Moreover, a surgeon uses theinstruments to feel the specific situa-tion in the surgical area. That is whyparticular importance is also attachedto haptic feedback, i.e. "feeling"tissue resistance, in the simulation.

It must enable the user of the surgicalinstruments to feel a virtual organ'sresistance through sensory force feed-back. That’s not all though. Inaddition, the system mustalso provide the usertactile feedback of organs'significant tissue prop -erties. A user alsoought to be able tofeel where diseasedtissue is located on anorgan and wherematerial is healthy.

The integration of suchspecial input devices inthe simulation software isextremely complex and in -volves a particular technicalchallenge for devel opers.Moreover, re searchers at theVDTC plan to extend the simulationto the adjacent tissue and organmaterial in the future. Consequently,when a procedure on an organ isreproduced, its physical interactionwith surrounding tissue and adjacentorgans can also be represented realis -tically.

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Contact:Dr. Rüdiger MeckeVirtual PrototypingTel. +49 (0) 391/4090-146Fax +49 (0) 391/4090-115Ruediger.Mecke@iff.fraunhofer.de

Dr. Cora Wex is a Surgery and VisceralSurgery Specialist at Uni versity HospitalMagdeburg.

IFF

FraunhoferInstitut Fabrikbetriebund -automatisierung

October 24 - December 5, 2007, Wednesdays at 5 p.m., Magdeburg

4th Guest Lecture Series

Virtual Reality: Humans and Machines in Inter active Dialog

October 24, 2007Virtual Design: Siemens’ Pers pectives in Product Development,Prof. Albert Gilg, Siemens AG, Munich

November 7, 2007How Does Virtual Reality Land in the OR?Prof. Dirk Bartz, Uni versity of Leipzig

November 14, 2007Networked Virtual Reality for Training and Educating National and International Fleets,Heike Kissner, Ray Sono AG, Bremen; Dr. Marco Zibull, Howaldtswerke-Deutsche Werft GmbH, Kiel

November 21, 2007Virtual Reality in Qualification for Technical Specialists, Paul Mecking, Jürgen Beuting, RWE Rhein-Ruhr Netzservice GmbH, Wesel

November 28, 2007Augmented Reality for Support of Industrial Plannningand Manufacturing Processes,Dr. Thomas Alt, metaio. Augmented Solutions GmbH, Munich

December 5, 2007AVIOR-VisIR: Night Vision Laser Projection System for InnovativeRealis tic Night Vision Training on SimulatorsDr. Hubert Burggraf, Rheinmetall Defence Electronics GmbH, Bremen

Photo: Dirk Mahler

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Virtual Saxony-AnhaltAndreas Höpfner

Who hasn't wanted to visit Martin Luther in his historic home orrearrange an entire city with a point of the finger? Now you can flyover Saxony-Anhalt without a plane, let entire factories rise up in aflash or stroll through neighborhoods that don't even exist.... All this is possible with the interactive, virtual 3-D projections at theFraunhofer IFF in Magdeburg.

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Saxony-Anhalt has regained its posi-tion as the center of innovative busi -ness it once was at the start of thetwentieth century. The state's econ -omy underwent a radical structuralchange after German Reunification.Regions changed, long-standing in -dustries disappeared and new oneswere established. Today, one of themost interesting business scenes inEurope for investors is right here.Excellent infrastructure, excellentsupport opportunities, excellentlytrained and highly motivated experts,close cooperation between the busi -ness and research communities andmarkedly high potential for growthprovide a foundation numerous well-known domestic and foreign compa-nies are already taking advantage of.

Cities are benefitting from this positive devel -opment too. Abundant in extremely significant cultural history, Saxony-Anhalt is can present itself as a region with a multitude of historical archi- tectural attractions in its towns andcities. Tourists from all over the worldcome to see the sites. Extensive rede-velopment and restructuring actionshave con tributed to this. Four locati-ons in the region are listed byUNESCO as World Cultural Heritage.

These processes are far from finishedthough. Numerous urban neighbor-hoods and even entire cities are stillwaiting on redevelopment to recap-

This active immersion in a virtual envi-ronment opens a hitherto unimaginedwealth of alternative uses for plan-ners, investors and government policy-makers.

This technology is based on the simpleconversion of two-dimensional plan-ning materials and CAD formats intothree-dimensional data. The methodsand tools used for this are alreadylargely automated. Therefore, three-dimensional views of cities and theirenvirons can be generated fromexisting source of data in next to notime, as long as it is reasonablycomplete. This guarantees that suit -able applications are produced bothextremely cost effectively and expe -ditiously.

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City Planning in CyberspaceIn the future, virtual technologies willbe critically important for the planningand presentation of complex buildingprojects. Their versatility pays for itselfimmensely, especially in the easternregion of Germany, which is under-going a radical structural changeunlike anything seen or documentedsince after the Second World War.The processes of adapting urbanstructures to basic economic condi -tions are not occurring gradually.Instead, new municipal profiles haveto be developed virtually overnight.Not least, the challenge is to intelli-gently redevelop a city while includingits entire infrastructure. At the sametime, such massive, rapid processes ofchange demand intensive citizen

ture their earlier quality of life andexploit the tourism potential frequent -ly on hand. New industries also con -tinue to locate here with regularity.Although the state can be proud ofeverything achieved and can point toample successes, many investmentoptions are still waiting to be takenadvantage of. Other financially stronginvestors are needed for this

Vigorous marketing measures are thekey to this. Among other things, theirquality is critical to the global compe-tition of attractive business locations.On the other hand, they also supportthe continuous expansion of thetourism industry, a branch of industrySaxony-Anhalt has understandablypledged to promote.

This makes urban redevelopmentextremely important. Successful, inno-vative city planning, a well-conceivedinfrastructure and contented residentsin redeveloped, urban environmentsoften significantly influence potentialinves tors when making decisions.Ultimate ly, they also create the settingfor the positive memories guests fromall over the world take home withthem from a visit to Saxony-Anhalt.

To support all these far-reaching andambitious projects, the Fraunhofer IFFhas developed a proven tool for prac-tical use in marketing projects andarchitectural planning. Its solution isinteractive, virtual technology thattenables photorealistically and ex -tremely effectively visualizing everydomain of architectural planning,from global macro views down torepresentations of the finest details.These applications are not only limitedto passive visualization though.They additionally make it possible tocreatively and actively manipulaterealistic representations of industrialstructures or urban architecture whileviewing them.

The virtual-interactive model of Lutherstadt Eisleben. The new visitor center is being built directlyopposite the birthplace of the Reformer Martin Luther. The virtual model provided the basis for

discussing various alternatives with the decision makers.

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involvement. However, such mam -moth projects can only be sustainablysuccessful when the various conceptsare sufficiently documented and thecommunication with everyone affec-ted is intensive.

This is precisely where the tools fromthe Fraunhofer IFF come in. Theirpotential applications enable thevarious actors and decision makers tosimultaneously and literally go intotheir plans. Future urban spaces canbe inspected even before the firststone has been moved. This providesa basis for developing a thoroughunderstanding of different designswithout having a background in archi-tecture and from an absolutely realis -tic view. Actors can discuss themtransparently and use the software'sintuitive and unlimited control to alterthem while viewing.

City planners have often resorted tothis technology with frequent success,for instance, in Lutherstadt Eisleben, acity on the UNESCO list of WorldCultural Heritage. It was applied todevelop various scenarios to adaptredevelopment and new constructionnecessary in the sensitive downtownto the surrounding architecture ascon scientiously as possible.Extensive urban building measureswere formulated and the new Fraun -hofer technology was applied as partof the International Building Exhibition(IBA) Urban Redevelopment. VR wasapplied here with great success andfacilitated structural changes withparticular diligence and architecturalquality. This is an important outcomesince poor architectural decisionscould jeopardize the status of theUNESCO World Cultural Heritage sitesin Saxony-Anhalt.

The redevelopment in LutherstadtEisleben is continuing though. Planshave been made to remodel the visi-tor center there in the near future.Then, tourists on Luther's trail willprofit from the intelligent use ofvirtual technology. A special presenta-tion system will enable visitors toimmerse in a vivid, three-dimensionalversion of the historical city in theReformer's day and thus experiencehistory up close.

3-D Presentations in LocationMarketingThe Fraunhofer’s new, highly flexiblevisualization system is however just asimportant for professional, state-of-the-art location marketing as it is forurban planning and tourism manage-ment. In this context, it represents anextremely high-end while cost effec-tive tool to three-dimensionallypresent siting options to potentialinvestors.

One model of successful applicationof this technology is in Zeitz. Once atypical eastern German case of indus -trial ruins and dilapidated infrastruc-ture in need of redevelopment, itbecame a model of effective site re -development with a connected sophis -ticated marketing campaign. The indi-viduals in charge took advantage ofthe opportunity to integrate a 3-Dvisualization in their presentationconcept to document the successfultransformation of the city into amodern location. Thus, an integrated,three-dimensional presentation ex -plicitly showed interested companiesthe scope of redevelopment and thefirms involved.

Zeitz Industrial Park also benefittedfrom using this tool for the purpose ofmarketing its industrial and commer-cial properties to investors at tradeshows. Potentially interested partiescould suddenly already inspect a

The World Heritage Site of Wittenberg also has a virtual-interactive model of its downtown.

tions, CD presentations andPowerPoint presentations or to greateffect in printed form in brochures,magazines and other publications.

Another effective means of present ingplants, factories or entire cities forexample is the Elbe Dom in the VirtualDevelopment and Training CentreVDTC. This highly advanced, three-dimensional presentation systemreproduces every item of large-scaleconstruction projects with absoluterealism and for discussion in a 360°panorama view on a projectionsurface measuring 327m². The systemenables planners and investors toalready "walk through" their projecttogether and obtain an astonishingly

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realistic overall impression based onthis before construction startsIncidentally, measured against theoverall volume of an analogous invest-ment, the costs of a virtual, interactivevisualization are negligible. Moreover,the collection of necessary data makesup a principal part. At any rate, suchdata is reusable and can therefore beused again in later applications with-out incurring new expenses.

Networking the Presentation ofComplex InformationThe potential uses and ideas for otherapplications of 3-D visualization go farbeyond what has been addressedhere. All this work is ultimately aimedat creating a virtual Saxony-Anhaltwith an all-encompassing representa-tion of its architecture, business,research, academics and culturaltreasures.

Networking and three-dimensionallyvisualizing all the specific informationwith relevance for and to the statewould produce a major value addedfor effective state marketing. An inter-connected presentation of Saxony-Anhalt's industrial scene with itsexisting centers of research is conceiv -able. At a glance, investors could seethe points where beneficial synergyeffects with research organizationsand other industries could open up. Inthe future, this support would enablethem to make their siting decisionsmuch faster and with far morecertainty.

Ultimately, such applications are infi -nitely variable and the viewing optionscover the entire range of scales.Starting with an animated camerazoom from space, a virtual flight overthe state from Stendal to Merseburgcan realistically represent every pointdesired, down to detailed interiorviews of castles and factories forexample. An integrated presentationof each of the products manufacturedsomewhere would be anotherwelcome means to boost local busi -nesses’ sales.

photorealistic 3-D view of their futureplants and facilities on a screen evenduring initial talks. This made it pos -sible during preliminary discussions torealistically estimate later dimensionsof intended investments as well aspotential infrastructural complicationsor adverse environmental impacts.Even precise information on costs at aselected site could already be providedin this first all-round presentation.The entire range of potential uses of3-D technology in presentationcampaigns is subject to hardly anyconstraints. It can be used just aseasily as a mobile system at tradeshows as for 3-D Internet presenta -

The virtual model of Zeitz Industrial Park is used, among other things, to attract investors.

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Such a virtual map has already beencreated for the energy industry. Ofvital importance to the initiators wasattractively representing the potentialfor the construction of power plantsthat utilize renewable energies inSaxony-Anhalt. Adding other indus -tries to the presentation and inter-connecting them is the next logicalstep.

Such animated contextual representa-tions are particularly attractive, notleast to approach international inves -tors. Local patriots may not like it butmany international partners are ofteninitially unaware of where Saxony-Anhalt is even located and what all ithas to offer. Such a high-tech toolwould enable creatively presenting thestate and its potentials in everyminute detail. Thus, it not only repre-sents an important aid for companiesdeciding whether to locate here, forwhich it may well be of interest butalso underscores Saxony-Anhalt’sreputation as an innovative locationthat naturally applies innovativemeans to present itself.

Contact:Andreas HöpfnerVirtual PrototypingTel. +49 (0) 391/4090-116Fax +49 (0) 391/4090-774Andreas.Hoepfner@iff.fraunhofer.de

Detail of the virtual energy map of Saxony-Anhalt. When one selects wind energy through thematrix, the system offers various locations such as Enercon here.

Virtual bird’s-eye view of Enercon’s premises in Magdeburg.

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Assembly Assistance with AugmentedReality: Mobile Measurement and Test -ing Technology Provides an Overview

Dirk Berndt, Dr. Rüdiger Mecke, Dr. Christian Teutsch and Johannes Tümler

Despite automation and computer controlled assembly lines, humans are still indispensi-ble in the manufacturing and assembly of certain industrial components. However, theyoccasionally also make mistakes. And these are very expensive sometimes. Now there's aninnovative, portable, virtual, just-in-time measurement and testing system from theFraunhofer Institute for Factory Operation and Automation. In the future, it will helpprevent human errors.

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Without a doubt, manufacturing ofindustrial goods is characterized by itsembededness in globalized productionflows. Competitive pressure is compel-ling many companies to adopt distrib -uted manufacturing of their productsin which national borders anddistances play only a subordinate role.This not only pertains to large inter -nationally operating companies buthas also been being practiced bymany small and medium-sized enter-prises for some time.

Individual components are manufac -tured at various facilities and thensubsequently transported to finalassembly, sometimes over very longdistances. Not only is this a logisticalchallenge but it also makes evengreater demands on engineers andassemblers in the respective plants.Manufacturing defects not detecteduntil the destination can generatetremendous costs. If technicians areunable to remedy a defect on site,these elements may have to be re -delivered. In the worst case, the entireproduction comes to a stop. Not least,this problem is particularly explosivefor expensive capital equipment as inthe motor vehicle, shipbuild ing, plantmanufacturing and aircraft industry.

The majority of all assembly processesare characterized by automatedexecution. Various components andassemblies are combined with oneanother and, after several work steps,finally subjected to a quality check.The error rate of such standardizedprocesses is relatively low and thedownstream inspections are reliableand highly effective. However, eco -nomic or technical reasons make itnecessary for humans to complete abroad range of assembly processes.This is particularly the case for ex -treme ly complex components withdifficult-to-access areas and a widevariety of variants. The disadvantagehere however is that errors are oftendetected only much later. Time inten-sive reworking or even new produc-tion is needed. As already mentioned,this incurs high costs.

The Fraunhofer Institute for FactoryOperation and Automation IFF tackledthis problem and developed anexceed ingly practicable solution aspart of a research project funded bythe state of Saxony-Anhalt. Technol -ogies were produced, which supportassemblers in their work with a port -able augmented reality system (ARsystem). A functional model is able togive its operator precise instructionsvirtually and in real time about thedifferent components and their speci-fied position on a workpiece. It simul-taneously checks the correctness ofinstallation and signals the user whenand where an error has occurred. Inparticular, small and medium-sizedenterprises from Saxony-Anhalt wereinvolved in the project. However, theresearch is also interesting for largercompanies. The European aircraftmanufacturer Airbus, with whichseveral fascinating and successfulprojects have already been completedin the past, absolutely sees potentialapplications for such a system.

The central task during developmentwas putting a measurement and test -ing system in people's hands withoutconstricting them during their work.Thus, it had to be especially light andtransportable, adapt to their move-ments and viewing directions andautonomously determine its own,constantly changing position vis-à-visa workpiece. Moreover, it must smooth ly integrate itself in the workprocess. Thus, it must be able totransmit uncomplicated and construc-tive information to operators withoutdistracting them from their work. Thedecision fell on a system worn byusers like a helmet and composed ofthree main components.

1. An AR system consisting of a headmounted display (HMD) and aninput device. The connectedcomputer equipment functionswirelessly and is carried separately.

2. An inspection camera that recordsthe assembly job.

3. Image processing detection soft-ware connected with the ARsystem and the camera.

This system developed at the Fraun -hofer IFF meets every expectation andfunctions as good as perfectly. Notonly does it enable its operator toavoid making assembly errors by andlarge but also to recheck precedingwork.

The basis for this is the automaticrecognition of individual componentswith the aid of their CAD data fedinto the software beforehand. Objectsare compared with it after it has beenrecorded and correlated with the rele-vant target specifications.

A worker wanting to install a com -ponent signals this to the system. Theinformation on the component's posi-tion is generated from the CAD modeland output on the display before theworker’s eyes. The display consists ofa semitransparent mirror onto whichrelevant data is projected. Similar tothe principle behind a pilot's helmet,assemblers always have an overviewof their environment and the comput -er data.

Should they make an error duringinstallation, this information is trans-mitted to them immediately and theycan correct it right then and there.Has a procedure been completed, theoperator receives information on thenext step to be executed.

The information the assembler re -ceives is limited to elementary graphicoptions and the display of characterchains. Thus only the name of thecomponent being installed and itscorrect position are overlaid duringthe assistant phase. A short textmessage at the corresponding posi-tion indicates potential errors. All thisis transmitted in real time so that anindividual does not sense any delay.This new, virtual technology provides

industrial manufacturers a number ofadvantages.

It primarily prevents errors in assemblyprocesses in which, now as before,humans are involved. The mobileinspection system is placed directly ona worker and completes the worker'sjob during the procedure. It visualizesevery important operation and thusmakes it nearly impossible to uninten-tionally deviate from the specifiedwork steps. Thus it also enablesworkers to check places on complexworkpieces where this was not easilydone previously.

This flexibility additionally allows agreater diversity of product shapessince the linkage to rigid assemblylines and downstream external, fixedinspection machinery can be dis -pensed with. When a product chang -es, the recognition software for theAR system is replaced without anyado and work can be continued with-out major interruptions. These pro -grams are generated uncomplicatedlyand quickly.

46 IFFOCUS 2/2007

In spite of everything, this systemcannot replace humans however. Nowas before, an individual must have anoverview of all operations. Only socan potentially occurring softwareerrors be reacted to and a check bechecked. It will however make anindividual's work on factory floors andin assembly shopss considerablyeasier.

Industrial manufacturers can lookforward to having such an aid at theirdisposal in the future. It is extremelycost effective, by and large guaranteesproduction defects are prevented andthus helps sustainably reduce logisticaland financial outlays. Such a systempays for itself quickly espe cially whencapital equipment is expensive orproducts have complex manufacturingchains and long deliv ery channels.

Contact:Dirk BerndtMeasurement and Testing TechnologyBusiness UnitTel. +49 (0) 391/4090-224Fax +49 (0) 391/4090 93-224Dirk.Berndt@iff.fraunhofer.de

Attached part assembly check test scenario.

View of an image of an attached partgenerated from CAD.

View of an image of an attached partgenerated with the inspection system.

48 IFFOCUS 2/2007

Interactive Human andMachine: Service RobotsCooperating withHumans in the Lab

Dr. Norbert Elkmann

Multifunctional assistant robots interacting with humans previously belonged to the realm ofscience fiction but not for much longer. In the joint project LISA funded by the BMBF, theFraunhofer IFF is collaborating with well-known partners to develop a service robot suitablefor everyday use in the life science sector. It reacts to speech, navigates fully autonomouslyand is extremely flexible. This high-tech system makes direct teamwork between robots andhumans practicable and meets the stringent safety requirements for the first time.

IFFOCUS 2/2007 49

better, more precisely and more reli -ably than humans. As subsystems,they inconspicuously perform theirwork in our computerized environ-ment every day. Of late, they evenclumsily roll around our feet as comi-cal vacuum automatons or theyamuse us as dancing dwarves inastronaut outfits in presentations atJapanese trade shows.

However, we still don't have a genu -inely multifunctional, interactive robotfor everyday use, which, equippedwith a manipulator, freely moves inhuman surroundings and autono-mously performs its services. In thepast, such approaches have repeatedlyfailed to be commercially successfulbecause the systems' were insuffi-ciently suited to everyday routines,had limited functionality or safety andhad a negative cost-benefit ratio.

So that this does not always remainso, as coordinator and project partner,the Fraunhofer IFF is collaboratingwith well-known business and indus -try partners in the joint project LISA.The consortium is pursuing the devel -opment of an advanced, interactingservice robot for the life sciencesector.

It will take over routine and transporttasks in research labs and indepen-dently load the different measurementand test stations. In addition, it will beable to monitor the frequently verytightly scheduled test procedures,inform staff of problematic situationsor intervene itself. All the while, therobot will intensively interact with thehuman staff with which it completelyshares its work area.

The utility of such a system in the lifescience sector is indisputable.

A preponderant share of work inbiotechnological and pharmaceuticalresearch still has to be performedmanually, specifically the preparationof tests and loading of certain sta -tions, e.g. incubators, microscopes,

autoclaves and pipetting stations.Until now, lab technicians' continualneed of equipment and stations fornew tests (and variable test procedu-res) stood in the way of automation.The use of assistant systems enablesflexibly interlinking stations. Thisproduces "virtual" production lineswhile completely retaining the func-tions for normal lab operation. Newstations (instruments, etc.) can easilybe integrated in operation withouthaving to retrofit or expensivelyupgrade and integrate a stationaryautomated station. Moreover, givenlab technicians' frequent handling ofhazardous substances, assistantsystems are ideal for such work andtransport (even in cold rooms andsafety zones and labs). Along withreducing work for staff that isharmful or critical to health, the useof assistant robots minimizes the riskof contaminated specimens andimproves sterility.

Above all, flexibility, intuitive opera -bility and safety are crucial to theacceptance of a mobile and autono-mous assistant robot so intensivelyintegrated in the rhythm of a labstaff's work. Hence, these aspects areparticular priorities during its develop-ment.

For these reasons, great effort wasmade to select the simplest variant foruser navigation, which would notprove to be a needless hindrance in alab's everyday business. Previous assi-stant systems were typically toocomplicated to use and often requiredknowledge of programming to breakin the system or issue it commands.Hence, the choice fell on naturalspeech input and output as well as adisplay with intuitive user navigation.Staff uses it to easily communicatewith the assistant robot in completesentences, while it addresses itshuman colleagues the same way.

Fantasy lets everything appear quitesimple: White service robots assidu -ously zip up and down a researchinstitute's corridors. Small service unitsunwaveringly circle researchers andtheir guests, always on the lookoutfor a favor they can do for them,while their humanoid-looking side-kicks at the door patiently wait tohelp visitors into their coats. Naturally,a mobile security system is standingoutside. It automatically scans the

access rights of everyone entering thebuilding before allowing them to pass.As already said, that is only how it isin fantasy.

Actually, robots have come to assisthumans in many needs, yet so farentirely differently than science fictionauthors imagine. For instance, indus -trial robots have been successfully per -forming their services on factory floorsfor years. They take over a wide vari -ety of tasks they can complete far

particular tasks to be completed.

Later, analysis of 2-D laser scannerdata, a combined 2-D and 3-D camerasystem and highly sensitive collisiondetection sensors orient the robot inspace.

Since the assistant system is mountedon a mobile platform and movesfreely when in use, particular atten-tion was paid to safety requirements.Their fulfillment is a fundamentalprerequisite to the robot's use asintended. This not only pertains toprotecting lab staff from being pinnedor hit by the mobile platform and themanipulator but also preventing smallglass bottles of chemicals or other labutensils from being knocked over.Hence, an extensive safety sensor

50 IFFOCUS 2/2007

system is integrated in the assistantsystem.

Developing the manipulator's inherentsafety, i.e. the robot's action arm, wasparticularly complicated. This facilita-tes its typical handling functions. It isoutfitted with various collision detec-tion and avoidance systems so that itsmovements neither harm humans normaterials. It was furnished with a"tactile skin" - one of the FraunhoferIFF's own developments. This is apressure-sensitive surface that pre -cisely informs the system where andhow strongly there is contact. It is anextremely elegant and innovative solu-tion to a special problem, which willenjoy further application.

What would happen though if,despite every measure, the robot wereunable to avoid a collision? In thatcase, its optimized engineering andthe actuator selected and designedensure damage is prevented. Thekinetic energy generated is so lowthat even contact cannot injure anindividual.

The project's prospects for successhave been assessed as exceedinglypositive. Biotechnology is one of thekey technologies of the twenty-firstcentury with corresponding signifi-cance for the economy. While meth -ods to increase throughput exist for alarge number of life science researchenterprises, these commercial ap -proaches are however not yet im -plementable. Their procedures andtest series often vary widely andfrequently must be rapidly adapted tocurrent test results. The use of assis -tant systems is far more expedient forsuch firms than other automatedsystems or strategies to increasethroughput and effectiveness. Theirautonomous and highly flexible use intime and space makes these systemsparticularly efficient, frees lab techni -cians from relatively unproductivetransport tasks and makes lab workpossible around the clock.

Should the system not clearly under-stand, it asks a specific question.

Other tasks are allocated to thedisplay by entering commands. Thus,it also visualizes the system's state andoperations. Moreover, it assumes animportant function in the navigationand the allocation of its work areasbefore the first use of the robot.

Similar to humans, it navigates by firstof all orienting itself in space andcontinuously correlating its positionwith the recorded spatial data. To doso, an integrated 3-D laser scannermodels the environment in threedimensions. In turn, the informationgen erated is visualized and output onthe display. This is the basis for alloca-ting its future work areas and the

Artificial skin for LISA. Markus Fritzsche developed a tactile, i.e. pressure-sensitive, surface. Photo: Viktoria Kühne

IFFOCUS 2/2007 51

In addition, it relieves staff from workharmful to health and ensures testsare conducted continuously andreproducibly. It promises optimalconditions to adhere to scheduledtimes in test procedures and potentialfor flexible and efficient applications -

from single tests to high throughputoperation. Moreover, it does so withthe same lab layout and improved labconditions for sterility and avoidanceof contamination.

Thus, practical use of a first genera-tion interactive assistant robot is morethan probable in the foreseeablefuture. Its easy user navigation andincorporation of all safety regulationsmake it one of the first complex inter-active robot systems that freely movein humans' immediate environmentand cooperates with them. What ismore, not only its positive cost-benefitratio make it cost effective. The ex -periences from its development anduse will additionally benefit applica -tions in other domains. Thus, itsdevel opment is only the first step tofurther generations of robot systemsthat we will surely soon encounter ineveryday life.

Support

This research and development pro ject is being supported by the FederalMinistry of Education and Research(BMBF) within its framework concepts"Research for the Production ofTomorrow" (Project referencenumber: 02PB2170 to 02PB2177) and supervised by the ProjectManage ment Agency Forschungs -zentrum (PTKA-PFT).

Contact:Dr. Norbert ElkmannRobotic Systems Business UnitTel. +49 (0) 391/4090-222Fax +49 (0) 391/4090-93-222Norbert.Elkmann@iff.fraunhofer.de

The collision detection and avoidance system has already been registered for a patent. Markus Fritzsche and project manager Dr. Norbert Elkmann presented it to the professional world

for the first time at the 11th IFF Science Days. Photo: Viktoria Kühne

S H A R P M I N D S

. . . W I T H D O C T O R A T E S

52 IFFOCUS 2/2007

The Moscow State Automobile and Road TechnicalUniversity MADI awarded Prof. Michael Schenk anhonorary doctorate on June 27, 2007. MADI Rector Prof.Vjacheslav Prikhodko traveled to Magdeburg just for thisoccasion and conferred the title of "Honorary Doctor ofTechnical Sciences" on the logistics expert during thefestivities marking the fifteenth anniversary of theFraunhofer IFF.

Prof. Michael Schenk majored in mathematics at Magde -burg Technical College. After earning his doc torate infactory planning, he completed his habilitation inproduction planning and control. In 1992, he assumedthe management of the Department of Logistics andProduction Process Control at the newly founded Fraun -hofer Institute for Factory Operation and Automa tion IFFin Magdeburg. The Fraunhofer-Gesellschaft's Senate put him in chargeof the institute's management in 1994, the same yearhe was appointed honorary professor. In 2003, he received a call as university professor for logisticssystems. Prof. Schenk has also headed the Insti tute ofLogistics and Material Handling Systems ILM at Otto vonGuericke University Magdeburg since October 2006 andis addi tionally VDI State Representative of Saxony-Anhalt.

Honorary Doctorate for IFF DirectorMichael Schenk

Vadym Rusin is just thirty-one, yet been workingnonetheless as a researchmanager at the FraunhoferIFF for many years. He hasnow received his doctoratewith high academic honorsfor his dissertation on"Adaptive Control ofRobotic Systems in ContactTasks".

The foundation for hiscareer in Germany was laidwith Siemens's organizationof the Department ofGerman Engineering at theUniversity in Donetsk. Thenative of Ukraine decidedearly on to complete hisdegree in Germany. As

preparation, he came toMagdeburg for the firsttime in 1995 for a languagecourse. Three years later, hewrote his Diplom thesis inthe city on the Elbe. HisMaster's degree followed in1999. His seminar papersled Dr. Rusin to the Fraun -hofer researchers at anearly stage. In the midst ofestablishing the institute,the researchers were stillhoused in a provisionallocation in Magdeburg'sBuckau neighborhood atthat time and were juststarting to work on plansfor the institute building onSandtorstrasse.

Dr. Vadym Rusin. Photo: Viktoria Kühne

Magna Cum Laude for Vadym Rusin

MADI Rector Prof. Vjacheslav Prikhodko (left) awards FraunhoferDirector Prof. Michael Schenk (middle) an honorary doctorate

from the State Tech nical University in Moscow. Dr. Frank Wende is on the right. Photo: © Viktoria Kühne

Automation andFactory Operation. In1992, he became thehead of the De part -ment of Main tenanceand Service Manage -ment at the FraunhoferInstitute for FactoryOperation and Auto -mation IFF Magde burg.From 1994 on ward, hewas Director of theDivision of Planningand Logis tics andDeputy Direc tor of theDivision of Enter prisePlanning and Logisticsat the institute until2001 when he wasmade Deputy Director,which Dr. GerhardMüller continues to beto this day. Dr. Mülleris an elected represen-tative of the Fraun -hofer-Gesell schaft'sScien tific-TechnicalBoard, a juror for the

Dr. Willi Fuchs surprisedDeputy Director Dr.Gerhard Müller in the fest-ive setting of the eveningevent marking the fifteenthanniversary of the Fraun -hofer IFF Magdeburg. TheExecutive Director of theVDI awarded him the VDImedal of honor "for out -standing service and thecultivation of young engi -neers by involving them incollaboration betweenapplied research and indus -try in the pioneering fieldsof logistics and powerengineering."

Dr. Gerhard Müller majoredin mechanical engineeringat Otto von Guericke Tech -nical College in Magde -burg. From 1974 to 1992,he worked as assistantlecturer and chief engineerin the Technical College'sDepartment of Factory

annual major Fraunhoferresearch award and anactive Member of the Board

Dr. Gerhard Müller (left) receives his award from Dr. Willi Fuchs, Executive Director and Executive Member of the

VDI Executive Board (right). Photo: © Viktoria Kühne

of the Associ ation ofGerman Engineers.

VDI Medal of Honor for Deputy Director Dr. Gerhard Müller

March 6-7, 2008, Maritim Hotel Magdeburg

Plant Engineering of the Future

Virtual Engineering: Advantages for the Planning, Engineering, Quali fication and Reliable Operation of Plants

www.tagung-anlagenbau.de

IFF

FraunhoferInstitut Fabrikbetriebund -automatisierung

IFFOCUS 2/2007 55

There are people whobecome professors, taketheir annual vacation andfly to Riga where they teachstudents at a prestigiousprivate university. Prof. YuryToluyev from the Fraun -hofer Institute in Magde -burg is such a person

Born in the Soviet city ofYaroslavl on the Volga, hisfather's assignment to apost in Riga brought himthere at an early age wherehe had a classical academiccareer: He attended school,graduated from high schooland majored in automationengineering at the univer-sity. In 1977, he came as ayoung doctor to Dresdenwhere he estab lished hisfirst contact with Magde -burg through the technicaluniversity there. An inter -

national research projectultimately brought him tothe cathedral city's univer-sity to stay. The closecooperation makes thedistance to the Fraunhofernot so far and thus in addi-tion to his job at Otto vonGuericke University, he hasworked at the Fraun hoferInstitute in Magde burgsince 2001."I applied to the commis-sion responsible for the jobopening announced andreceived the professorship.Latvia still suffers a paucityof specialists. I can dosomething about that withmy work at the Universityof Riga," says Prof. Toluyev.Whenever many of hiscolleagues are taking vaca-tion, Prof. Toluyev flies tothe Latvian capital where heholds his seminar on

Toluyev 's eyes light upagain, which happensimmediately whenever hespeaks of his distant home-land, his wife who livesthere and life at the univer-sity. One day he'll returnthere for good but untilthen he'll remain true tothe Fraunhofer IFF for quitea while yet and continuehis research on real-timelogistics systems.

"Mathematical Modeling ofLogistics System" for thestudents.

It's hard to believe there'stime for other things. Apartfrom research, his greatpassion is music. He plays avariety of instruments suchas accordion and harmoni -ca. However he most lovesto play the tabla, a smalldrum held under one's arm.

Prof. Toluyev Follows Call to Riga

Pleased at his appointment: Prof. Yury Toluyev. Photo: Anna-Kristina Wassilew

Best Paper Award at CLAWAR inSingapore

They can't even begin to count how many papers they'vealready written and submitted. This time, their efforts werecrowned with particular success: Justus Hortig traveledfrom the Fraunhofer IFF as the representative of its RoboticSystems Business Unit to Singapore. At the 10th Inter -national Conference on Climbing and Walking RobotsCLAWAR 2007, Hortig, among some 120 other attendees,gave a presentation and presented the cleaning robotSIRIUSc. The years of research and experience paid off. Thepaper was so well received that the Fraunhofer researchersreceived not just one but two awards for their work.Representing his colleagues Dr. Norbert Elkmann, MarioLucke, Tino Krüger, Thomas Stürze and Dietmar Kunst,Justus Hortig accepted the Best Paper Award in the cate-gory of Climbing Robots sponsored by the professionaljournal Industrial Robot, which will publish an article aboutSIRIUSc. The robotic specialists have been designing andengineering facade cleaning systems for years, which are,for instance, in operation high atop the roofs of the NewLeipzig Exhibition Centre and Berlin Central Train Station.The Fraunhofer IFF's systems function outstandingly under-ground too: The researchers have engineered inspectionand cleaning systems for the Emschergenossenschaft'ssewer systems, the largest residential water managementproject in Europe.

"Even though our robots are excellent and quite wellknown too, I was still surprised and found myself at a lossfor words on my way to the stage," says Justus Hortig.The awards are mounted on finely tooled leather panelsthat now decorate the offices of the researchers at theFraunhofer Institute in Magdeburg.

S H A R P M I N D S

S H A R P M I N D S

56 IFFOCUS 2/2007

Dr. Matthias Gohla is thenew Manager of the Proc -ess and Plant EngineeringBusiness Unit at the Fraun -hofer IFF. The native ofHalle takes over the posi-tion from Dr. Lutz Hoyerwho is going into welldeserved retirement afterworking for ten years at theFraunhofer IFF.

Dr. Gohla majored inprocess engineering atMagdeburg TechnicalUniversity. After earning hisdoctorate with his disserta-tion on "Flow Mechanics ofCirculating Fluidized Beds"in 1994, he remained at theuniversity as an associateprofessor. The move toindustry came in 1998.

Dr. Matthias Gohla (left) and Dr. Lutz Hoyer (right). Photo: Viktoria Kühne

Dr. Matthias Gohla. Photo: Viktoria Kühne

Changing of the Guard in the Processand Plant Engineering Business Unit

Otto von Guericke Univer -sity Magdeburg PresidentPollmann was awardedthe Gruson Medal of Honorfor his dedication to theengineering profession inSaxony-Anhalt. The Saxony-Anhalt Chapter of theAssociation of GermanEngineers VDI thusly recog -nized the university presi-dent's particular achieve-ments at the thirteenthFestival of Engineering.Thanks to his active involve-ment, the School ofMechanical engineeringhas, after a longer lull,been receiving more newadmissions in the last twoyears. Registration forengineering programs hasrisen nearly twenty percentfrom 392 in the wintersemester of 2006-2007 to

473 in the winter semesterof 2007-2008, clearlydemonstrating that theSchool of MechanicalEngineering has regainedits attractiveness and repu-tation.

Prof. Pollmann was visiblydelighted as he acceptedthe medal and certificatepresented to him byMinister PresidentWolfgang Böhmer and VDIState Representative ofSaxony-Anhalt Prof. MichaelSchenk. This cermonialhighlight was followed bythe social part of theevening and the over 250guests enjoyed the partyuntil the wee hours of themorning. Representativesfrom busi ness, research andacademia and politics allgathered at the annual galaball of the Saxony-AnhaltChapter of the VDI.

VDI Honors President Pollmann

Prof. Klaus Erich Pollmann was honored with the VDI’s Gru son Medal ofHonor. L. to r: Dr. Jürgen Ude, Chairman of the VDI District Chapter

Magdeburg; Minister President Wolfgang Böhmer; award winner KlausErich Pollmann and VDI State Representative of Saxony-Anhalt Prof.

Michael Schenk. Photo: Andreas Lander/VDI

Elbstrom AG put the youngspecialist in charge of conver-ting the fuel supply for itscogeneration plant in Aschers -leben from the fossil fuel rawlignite to the renew able energysource residual and scrapwood. Dr. Matthias Gohlaremained a member of com -pany management until 2001when Dr. Lutz Hoyer broughthim to the Fraunhofer IFF inMagdeburg where first theDepartment and now BusinessUnit of Process and PlantEngineering was being estab -lished.

Two topics get the appliedresearcher Dr. Gohla excited:One is energy efficient manu-facturing. What has almostalready advanced to being an"in" phrase today, has been aguiding principle at the Fraun -hofer IFF for years. The other isrenewable energies for thegeneration of electricity in thebase load range on which Dr.Gohla works again and again.The particular challenge isachieving a steady and reliablepower supply with renewableenergies sources, which, likewind or sun, are not constantlyavailable.

The researcher's "burning"passion for his work doesn'tleave much time for otherthings. When it does, he findshis equilibrium spending timewith his two children, joggingor tuning young timers.Matthias Gohla naturally relieson renewable energy at hometoo. A wood-burning stoveprovides cozy heating. Theenergy expert even custom-assembled the components ofthe control system for the solarcollector on his roof himself.

Phot

o: A

nna-

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a W

assi

lew

Spotted at the 24th German Logistics Congress in Berlin: Dr. Vitali Klitschko, former world champion in boxing pagesthrough the IFFOCUS. His autograph on the cover wishes ourreaders “all the best”.

58 IFFOCUS 2/2007

G A L L E R YPh

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Dir

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ahle

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IFFOCUS 2/2007 59

The virtual model of a Dürr paint shop. Dürr clients can inspect a digitalfactory model on a virtual tour and discuss designs at the VDTC inMagdeburg. This is possible in the Elbe Dom, its 360 degree large projectionsystem – even on a scale of 1:1.

60 IFFOCUS 2/2007

G A L L E R Y

A virtual heavy machine tool controlled by a real controller. This modelapplication, a so-called demonstrator, was produced in collaboration withSchiess GmbH in Aschersleben and is the outcome of the just concluded projectViVERA. Funded by the BMBF, six Fraunhofer Institutes and their partneruniversities made it their goal to introduce research findings to corporatepractice faster.

Phot

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irk

Mah

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a-K

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Was

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Fiber reinforced composites areimpressive all-round talents. They areultralight but nonetheless withstandextreme weight loads. The widestvariety of shapes and properties canbe customized for various applicationsin lightweight construction, e.g. tomake windows.

Together with eighteen partners fromthe Growth Core Allianz Faserverbunde

(ALFA), the Fraunhofer researchers inMagdeburg are working on clever

development that showcasethese high-tech flyweights.

O U T L O O K

64 IFFOCUS 2/2007

Meet up with us:

January 22 - 23, 2008 KIBNET Darmstadt

January 29 - 31, 2008 Learntec Karlsruhe

February 19 - 21, 2008 LogiMATStuttgart

February 27, 2008 HLA Forum Fraunhofer IFF VDTCMagdeburg

February 26 - 29, 2008INTEC Subcontracting FairLeipzig

March 4 - 9, 2008CeBit Hannover

March 6 - 7, 2008 Plant Engineering of the FutureMaritim HotelMagdeburg

March 6 - 7, 2008 13th Magdeburg LogisticsConferenceMagdeburg

March 12 - 14, 2008 University Conference onVocational Education and TrainingNürnberg

April 1 - 2, 2008Jugend forscht State CompetitionFraunhofer IFFMagdeburg

April 4, 2008 Maintenance TechnologiesFraunhofer IFF Magdeburg

April 8 - June 10, 2008 Logistics Guest Lecture SeriesFraunhofer IFFMagdeburg

April 9, 2008Wood Logistics WorkshopHundisburg

April 17, 2008 Logistics DayMagdeburg (and throughoutGermany)

April 21 - 25, 2008 Hannover MesseFraunhofer Energy AllianceHannover

April 22 - 25, 2008Control Stuttgart

May 27 - 31, 2008 CeMat Hannover

May 31, 2008 Long Night of ScienceMagdeburg

June 10 - 11, 2008 29th VDI/VDEh Maintenance ForumRegensburg

June 10 - 13, 2008 Automatica Munich

June 11 - 12, 2008 BVL Scientific Symposium Munich

June 17 - 19, 2008transport logistic 2008Shanghai, China

June 25-26, 2008 11th IFF Science DaysFraunhofer IFF Magdeburg

Virtual Reality and AugmentedReality for Engineering, Testingand Operating Technical Systems

Logistics: Efficient and SecureChains of Goods in Industry andCommerce

September 23 - 26, 2008InnoTransFraunhofer Traffic and TransportationAllianceBerlin

September 25 - 26, 2008GI Special Interest Group’s5th Workshop on Virtual andAugmented RealityFraunhofer IFF VDTCMagdeburg

October 1 - 2, 200813th ASIM Conference onSimulation in Manufacturing andLogisticsBerlin

October 14 - 16, 2008MaintainMunich

October 22 - November 26, 2008VR Guest Lecture SeriesFraunhofer IFF VDTCMagdeburg

November 4 - 6, 2008VISIONStuttgart

Editorial Notes

IFFOCUS 2/2007This magazine appears biannually and is

available free of charge to clients part-

ners, staff, media and friends.

ISSN 1862-5320

ISBN 978-3-8167-7633-8

PublisherFraunhofer Institute for Factory Operation

and Automation IFF

Prof. Michael Schenk

Director

Sandtorstr. 22

39106 Magdeburg

Germany

Tel.: +49 391/40 90-0

Fax: +49 391/40 90-596

ideen@iff.fraunhofer.de

www.iff.fraunhofer.de

www.vdtc.de

Editorial StaffAnna-Kristina Wassilew

René Maresch

Thomas Zaschke

Photos, Images and Graphics© Fraunhofer IFF unless otherwise

indicated

Title photo: Dirk Mahler

Layout/DesignBettina Rohrschneider

TranslationKrister Johnson

Printing Harzdruckerei GmbH

We wish to thank our researchers and

project partners for their support during

the preparation of this publication.

© Fraunhofer IFF, December 2007.

IFF

FraunhoferInstitut Fabrikbetriebund -automatisierung

11th IFF Science Days June 24 - 26, 2008

www.iff.fraunhofer.de