What is Industry 4.0?

Industry 4.0 and its synonym, the Fourth Industrial Revolution, are two concepts that refer to a new digital transformation of the industry driven by the emergence of new technologies.

These technologies are known as enabling technologies, and among them are Advanced and Collaborative Robotics, Augmented Reality, Virtual and Mixed Reality (XR), IoT (Internet of Things), Cloud Computing, Big Data, and 3D Printing.

Industry 4.0 involves a digitalization of all production processes, which allows for increased productivity, workplace safety, resource management efficiency, quality as a result of automated process control, and competitiveness of industrial companies. Extended Realities (XR) are essential to achieving the transition toward Industry 4.0.

This article will discuss the main industrial applications and use cases of VR, AR, and MR. But what exactly are Extended Realities and immersive technologies?

What are immersive technologies?

Extended Reality (Extended-Realities) is the concept used to encompass all immersive technologies (virtual, augmented, and mixed reality), and they are called this because what these three technologies have in common is their ability to hyper-realistically simulate the physical environment and add value to the known reality by overlaying digital elements on it. What differentiates these technologies is how and to what extent they add these new elements, as well as the devices used with each of them.

What is Augmented Reality?

On one hand, augmented reality (AR) is the technology that superimposes digital layers (such as text, graphics, or videos) over the real environment. To add these augmented objects, a smartphone or tablet is requiredWhat is Virtual Reality??

Virtual reality (VR), on the other hand, is the technology that uses glasses to replace the real world with a three-dimensional virtual space. It is the most immersive and invasive for the user, as once the VR headset is on, they feel as though they are physically in the recreated space. Being deprived of the real-world vision around them, the user becomes fully immersed in the environment or situation generated by a computer, with a sense of real presence. Additionally, they can interact in this virtual space through VR controllers, with which they can grab and move all kinds of objects.

And what is Mixed Reality?

Finally, mixed reality (MR) refers to the combination of virtual and augmented reality. This mix allows for the creation of new spaces where the user interacts with both real and virtual objects. Just like with VR, mixed reality requires the use of a headset, such as Microsoft HoloLens 2, but this time it allows the user to directly manipulate holograms in the same way they would interact with objects in the real world.

The introduction of immersive technologies into industrial plants is bringing about a true revolution in the sector, and their success is unstoppable. But what are the main applications of Extended Reality in Industry 4.0?

Virtual Reality in Industry 4.0

Let’s now look at the most in-demand uses of VR in the industrial sector.

3D industrial prototyping

There are certain sectors, such as the automotive industry, where until relatively recently, creating a prototype of products required a high investment, as the vehicle had to be physically manufactured to verify its proper functioning and design.

However, virtual reality presents a radical change in the design, manufacturing, and safety control processes of automobiles. VR provides automotive companies with a tool that accelerates the vehicle design phase. Engineers can visualize, in real-time and immersive form, different versions of a car, finishes, materials, colors, and functionality based on a virtual prototype, as if they were standing in front of the real product but without the need to physically manufacture it.

Additionally, during the vehicle manufacturing process, VR makes it possible to conduct automobile safety tests through simulations of specific situations, such as crashes. This technology allows design flaws to be detected in vehicles before the prototype is physically built. Seat is one of the manufacturers that has been using virtual reality in its production line for some time and states that VR allows them to “reduce prototype production time by 30%.”

In summary, virtual reality is an ideal tool for the design team, suppliers, and end customers to make prototype modifications in an agile manner, achieving the desired product while having the opportunity to test certain attributes (materials, colors, etc.) and see their effect on the future vehicle.

Operator training in Virtual Reality

Virtual reality brings new possibilities in training and occupational risk prevention. VR training programs allow employees to become familiar with and perfect certain tasks, even emergency situations, in their workplace, without exposing them to any risk.

VR technology makes it possible to hyper-realistically simulate environments that could occur in industrial processes (such as slips on wet surfaces, cuts, or fires). Through virtual training, an operator can practice emergency response protocols while experiencing a fully immersive environment. With VR controllers, the user has the freedom to actively respond to any accidents that occur in the production plant, practicing the necessary responses as many times as needed. This way, once the virtual reality training is complete, the operator will know exactly what to do and will act automatically if faced with that situation.

VR training is also beneficial for employees to familiarize themselves with maintenance or repair tasks before performing them in their actual work environment. The company Depuración de Aguas del Mediterráneo (DAM) relied on Innoarea Projects’ VR Training solution to train employees at their EDAR de Alzira-Carcaixent (Valencia) plant in maintenance and repair tasks for facilities.

Augmented Reality in Industry 4.0

More efficient and safer machinery maintenance

Augmented reality is another technology that is having a significant impact on the industrial sector. This technology makes it possible to visualize real-time information related to machines, their operation, and their processes.

Until a few years ago, when a machine had an issue, it had to be shut down, and once the technician identified the problem, they had to check the instruction manual to find a solution. The result was significant downtime, which led to production losses.

However, augmented reality optimizes this process and helps make machine maintenance more efficient and safer for operators. Innoarea Projects is developing AR solutions so that, through a tablet or mobile device, the machine can be identified and updated data about it is automatically displayed on the operator’s view, allowing them to access it at any time. With this, we aim to optimize maintenance and repair operations, reducing downtime in industrial companies.

Viewing parts in Augmented Reality

Another benefit that augmented reality offers us is the ability to view different objects or machinery parts that would otherwise be impossible. Through applications like JigSpace, launched on the new Apple Vision Pro, we can decompose an airplane turbine and see its different parts with simple gestures of our hands.

This technology can be extrapolated to any area of Industry 4.0, allowing us to apply it in processes such as training, design, manufacturing, etc.

Mixed Reality in Industry 4.0

Technical assistance or operator instruction guidance

Mixed Reality is a technology that represents a significant step in Industry 4.0 in terms of resolving technical issues in industrial machinery. Through Mixed Reality (MR), the factory worker has the ability to communicate directly with the technical service and be guided during the resolution process by that expert technician.

Stepview  is a tool that uses software and mixed reality devices to save waiting times caused by breakdowns and streamline the operator’s work when they need to resolve an issue.

The Stepview system enables the operator to maintain live communication and remotely with the person responsible for technical service, with the possibility of enhancing this connection with images and extra content that will be displayed in augmented reality on the operator’s real-world view, facilitating the required tasks. Seeing visual instructions from the technician on their field of vision improves not only their work but also their productivity and safety because the operator is guided step by step and knows exactly what to do to resolve the issue and repair the machine.

Smart factories are here to stay

Thanks to extended reality and the rest of the technologies linked to Industry 4.0, such as Advanced and Collaborative Robotics, the industrial sector is improving.

The path to the factory of the future is already underway, and we are getting closer, thanks to technology, to achieving more efficient, sustainable, innovative, and therefore, more competitive companies.