Case Study of Using Virtual and Augmented Reality in Industrial System Monitoring
Case Study of Using Virtual and Augmented Reality in Industrial System Monitoring
Abstract—An equipment monitoring system is responsible In this study, we select several reference analytical ser-
for analytical services that assist the personnel in equipment vices that come from our pilot development with metalcutting
diagnostics, fault prediction, and post-analysis. In this work, we industry in Russia. The two service models are proposed:
consider a case study of using virtual and augmented reality
(VR/AR) for effective analytics delivery to the production equip- (a) Situational Center and (b) Virtual Assistant. We identify
ment personnel. The reference analytical services for our study the VR/AR advantages compared with the traditional style of
come from our pilot development with metalcutting industry in visualizing analytical services on computer screens. Our study
Russia. The two service models are proposed: (a) Situation Center is supported with prototype implementation of the VR/AR
and (b) Virtual Assistant. We identify the VR/AR advantages system for analytics delivery to the equipment personnel.
compared with the traditional style of visualizing analytical
services on computer screens. Our study is supported with The rest of the paper is organized as follows. Sec-
prototype implementation of the VR/AR system for analytics tion II provides an overview of analytical services useful in
delivery to the personnel. production equipment monitoring. Section III considers our
VR model for constructing analytical services for a situational
I. I NTRODUCTION center. Section IV considers our VR model for constructing
Modern enterprises use advanced information systems analytical services for a situational center. Section V describes
for equipment monitoring to optimize the production operation our prototype implementation of VR and AR based variants
and quickly respond to faults [1]. Multiple sensors are installed of analytical services.
on machines to collect data and to transfer the data to server
II. A NALYTICAL S ERVICES IN P RODUCTION E QUIPMENT
computers, where they are converted into a convenient form for
M ONITORING
the specialist to understand. The traditional method of check-
ing equipment is long, and searching for faulty equipment can A. Problem
lead to long downtime of the entire production line, while One of the tasks in maintenance is to analyze the
the equipment monitoring system in the enterprise has the condition of the equipment. Technical personnel need to detect
ability to check machine components in real-time and report problems related to equipment components in a timely manner
the failure of specific equipment. in order to eliminate them with minimal harm to production.
An equipment monitoring system collects big data to If the problem was not noticed, the situation may become
analyze the state of the entire production. Then a person critical, which may later stop the production line.
(equipment personnel) makes decisions depending on the An equipment monitoring system is installed in enter-
situation. In order to speed up understanding of the problem prises to help detect problems. A system capable of collecting
and finding a solution, the information from sensors and data from sensors on equipment for subsequent interpretation
services needs representing in a human-friendly form [2], [3]. in a form that is understandable to a person. It is also possible
which can help virtual and augmented reality—VR and AR, to perform a primary analysis, in which the monitoring system
respectively. is able to give advice to technical personnel on how to fix
The VR technology provides a new level of image the found vulnerability or notify them of the found fault in a
display through the use of a helmet [4]. The application of timely manner. Work [6] describes some representation of the
the stereoscopic effect, which gives a full immersion in the monitoring system shown in Fig. 1, which is divided into two
virtual world and allows you to feel the depth of the image, global worlds: physical and cyber. The physical world includes
with which you can determine the distance to the object and real objects involved in production (machines, equipment,
better perceive three-dimensional objects. people). Cyber world contains a software part consisting of
The AR technology is an auxiliary tool for assessing services, modules, and algorithms and is able to control the
(diagnosing) the equipment status situation [5]. By superim- physical world.
posing additional information on real objects, it is possible to The monitoring system uses large data collected from a
evaluate the machine condition based on sensor data. Technical variety of sensors installed on the equipment. For their analy-
personnel can easier check the equipment and determine the sis, it is necessary to process the received data for subsequent
cause of problems. analysis by a human [7]. The more clearly the information is
ISSN 2305-7254
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Depending on what type of presentation is required, the According to the description of services in Table III, one
technology can be used for several purposes [8]. can say that for displaying information from most services,
1) Doctors can use this technology to examine a patient visualization can be used in the form of graphs or color
from various points in real time. A live broadcast from indicators, as well as in the form of text data. For other
an x-ray machine can be used to superimpose an x-ray services, one can use data visualization in the form of 3D
image of a patient’s body part onto a real body part to models, checklists, or text and visual instructions.
better understand bone damage. The app can be made to
III. S ITUATION C ENTER : U SE OF V IRTUAL R EALITY
work with a head-up display or special glasses. In other
cases, the image may be shown on a screen where the The situation center uses an autonomous Oculus Quest
video is taken from a real camera and x-ray vision may virtual reality helmet to view data. Management in the virtual
be applied to it [8]. space is carried out using Oculus Touch controllers, which
2) In military applications, an AR-based overlay can pro- are presented inside the situation center in the form of virtual
vide multiple views of the target object without showing hands. The application requires a free space of more than 4
additional information in the text and blocking the square meters and an Internet connection via Wi-Fi.
soldier’s vision from other important objects around. If The situation center model is shown in Fig. 4. The
you were shooting at enemies with a computer mouse, concept model includes four levels:
you would already know what it would look like. 1) the target machine is located on the first level
Superimposing an infrared view or a radioactive view 2) at the second level, sensors capture data from the ma-
of an object or area can help save lives or win wars [8]. chine.
3) Overlaying ancient paintings on real objects can provide 3) at the third level, services process data from sensors.
interesting views of historical places. Broken monu- 4) at the fourth level, the situation center accepts data from
ments can come back to life in all their original glory. services and converts it into graphs and status indicators.
Perhaps different eras complete with landscapes can be it is also possible to change some parameters to change
re-lived with AR [8]. the request for data from services, for example, to output
4) Letting a tiger or snake get close to you can be an data for a certain period of time.
unpleasant experience with dangerous consequences, The situation center is a virtual room with a menu in
except when AR overlay is used. Placing a person in the form of a screen fixed in the air. Fig. 5 shows how the
a place or situation that is otherwise dangerous can be menu will look on the screen and its variations depending on
done safely using AR overlay [8]. the user’s choice. The screen shows the interface, which has
5) Overlaying a real object with its internal appearance can buttons with the corresponding text. The initial screen is used
also be useful in education, for example, for studying the
structure of bones [8].
According to the information provided in Table II, the
advantage of AR over desktop PCs and text documentation
is that in AR all data are presented in real time right in
front of the person’s eyes and, therefore, they do not have
to spend time accessing the PC or text documentation. Also,
in AR, the system itself can offer the necessary instructions
for setting up, performing diagnostics or Troubleshooting,
without being distracted by searching for information in the
text documentation. AR will help reduce the time spent on site
maintenance and reduce the likelihood of human error.
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5"#-&*VR ADVANTAGES
TABLE II"3"%7"/5"(&4
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# Service Application
1 ”Control of the swivel head installation” Service is used to determine the correct positioning of the swivel head
2 ”Fixing various errors that occur on the machine screen” the Service is designed to recognize errors that appear on the machine monitor in
order to determine the most complete description of new errors that appear (their
interpretation) and notify the working staff about their appearance
3 ”Creating tasks for technical personnel” the Function allows you to create maintenance or inspection points for technical
personnel, as well as to record the implementation of these points (fixing the passed
stage, adding photos, adding descriptions and comments)
4 ”Mobile element impact Detection” the Service records the occurrence of a mobile element impact event, records the
readings of all sensors, video sequences from surveillance cameras, and a set of
events preceding and following the impact for a certain period before and after the
event
5 ”Monitoring the current of the motor axes and spindle” when detecting abnormal consumption or current changes informs the user of sudden
increases in load or deviations from normal values, and also allows you to analyze
the readings from all current collectors
6 ”Help in hardware diagnostics” the System provides the ability to display data from various sensors and services on
a single screen, which allows the employee to track the status of the system as a
whole
7 ”Control of spindle bearings and motor” Service allows you to track the occurrence of vibrations and warn the user about it
8 ”Temperature control of auxiliary devices” Service allows you to monitor the temperature of pumps and inform users about
deviations from the norm, which will allow you to service or replace the unit in
time
9 ”Control of coolant supply during processing” the Service is used to display the current status of the coolant supply (present, absent)
and in case of atypical behavior of the feed notifies the responsible persons
10 ”Control of counterweight installation of the processing Service controls the installation of counterweights for the processing head
head”
11 ”Tracking the location of the operator” the Service allows you to track the presence of the machine operator and warn
interested parties in case of his absence from the workplace or when he performs
actions for which he does not have sufficient rights (for example: opening the
electrician’s Cabinet, entering the machine during operation)
12 ”Monitoring of machine load” Using data obtained from installed sensors, the service will allow you to de-
termine the level of machine load and generate reports indicating the time of
operation/downtime of the machine and the nodes involved
13 ”Diagnostics of linear guide axes X, Y, Z” the Service provides the user with an interface (”assistant”) for performing a
sequence of steps for diagnosing linear guide axes
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A. High-Level Architecture
The module system gathers data from the machine
Hardware and software components of implementation
sensors and save to the data base or notify about this server
are represented in Fig. 11. Each user uses AR/VR device
(API). The RabbitMQ message system is used for this purpose.
with application for interaction with UI. Application has
the following function: requesting the server for data and
B. Data Scaling
visualizing the data for the user.
The application uses specified API for getting data from Sensors of the module system generates huge values
server. API extracts data from database or getting those direct of data (for example, 200000 values in one second). In this
from the module system for visualization data in real time. case visualization of this data using some components (for
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Fig. 12. Example of calculating the detail levels with the max aggregation
function
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