This article has been written by Volina Aneja pursuing a Remote freelancing and profile building program from Skill Arbitrage.

This article has been edited and published by Shashwat Kaushik.

Introduction

Industrial automation has undergone a significant transformation in the last few decades. Industrial processes, which were once controlled manually with the advent of integrated circuits and digitalization, started getting controlled using computers and other electronic devices, making them more accurate, safe, and highly efficient.

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In recent years, the next era of augmented reality (AR) and virtual reality (VR) technologies has brought powerful tools that have further enhanced the way industrial automation is done. They have enormous potential to change how we interact with our environment using information, visualisation, and interaction. AR & VR have evolved beyond gaming and entertainment and have become critical tools in various industries like healthcare, education, and industrial automation.

Understanding AR and VR

AR integrates and adds value to the user’s interface with the real world, whereas VR gives the simulation experience outside the real world—virtually. AR uses real-time information that could be in the form of text, graphics, audio, or video and integrates it with real-world elements using holographic technology. VR isolates the user from the real world and takes the user to a virtual world, allowing users to interact with the computer-generated 3D spaces using computer modelling and simulation. These technologies have revolutionised industrial automation.

The role of AR and VR in industrial automation

In recent years, the integration of AR (augmented reality) and VR (virtual reality) with industrial automation has emerged as a game changer in revolutionising the way tasks are performed, empowering industries to automate processes, optimising operational efficiencies, providing a safe and secure environment, improving productivity and enhancing the overall user experience. There are various ways in which AR and VR are used in industrial automation.

As per Statista, the AR & VR market is projected to generate revenue of US$40.4 billion in 2024. This market is expected to grow at an annual rate of 8.97% (CAGR 2024-2029), resulting in a projected market volume of US$62.0 billion by 2029. 

Applications of AR in industrial automation

There are many ways in which AR (augmented reality) is being used these days in industrial automation for maintenance and repair, quality control, remote assistance, workflow visualisation, fleet management and skill development.

Maintenance and repair

Earlier, it was quite a time-consuming exercise involving intricate manuals, procedures, and finding faults with the help of expert technicians. AR provides real-time diagnosis and guidance to the maintenance and repair team, hence making it more streamlined, accessible and reducing MTTR (Mean Time to repair). Even if the expert technician is not able to travel to the site, he can guide the junior technicians to go step by step using AR technology without compromising on the quality of work. Technicians can either use AR headsets or mobile devices to access step-by-step instructions overlaid on the equipment they are working on, resulting in faster and more accurate troubleshooting. They can wear AR glasses and can even view the internal components of the machine without disassembling it. This reduces downtime, enhances operational uptime, and minimises errors.

Training and skill development

With the help of AR, real-world scenarios can be simulated, and a trainee can be trained or skilled in an interactive way, thereby ensuring an efficient learning experience. Using AR-enabled devices, trainers can provide real-time hands-on training to their trainees, where the trainees can view step-by-step instructions and digital overlays on actual machinery and equipment. Not only this, they get immediate feedback on their actions, which will help them understand what went wrong and why. This method of training allows trainees to practice their tasks in a real environment with digital guidance, without getting scared of making any tangible loss to the company. This enhances their learning efficiency and effectiveness. This also helps multiple trainees to participate in a shared augmented environment, where a trainer can be in a remote location but can guide them through digital annotations and instructions while trainees can share their views through AR glasses or any other mobile device in real-time.

Quality Control and Inspection

AR (augmented reality) is making the lives of quality and inspection teams much easier. It allows the inspectors to view digital overlays like defect markers and measurement tolerances on the physical products themselves, making it easier for them to identify defects or issues. They can even compare the products with the desired CAD models. Any discrepancy calls for immediate action and hence reduces the inspection and action time to fix the fault. This is possible because the AR provides real-time information to the inspectors. Example – The automotive industry uses AR to ensure that each vehicle meets stringent quality standards, leading to a significant reduction in inspection times.

Applications of VR in industrial automation

Applications of VR (virtual reality) in industrial automation are manifold, ranging from product and process design to remote and virtual demonstrations to employees, customers and potential partners.   

Virtual prototyping and design

VR, besides optimising the design process, makes them impressive and holistic. It allows engineers to prototype the completed design virtually and show it to their clients for approval.  Even engineers sitting at different locations can collaborate and work together on a design as Avatars. They can not only create but they can even test their virtual prototypes in the virtual environment and resolve any design issues before production begins. They can test various variations in the design and note down the cause-and-effect relationship of the same, which otherwise would have been very difficult and expensive. VR provides them with a platform to experiment and explore unconventional ideas that the traditional system doesn’t allow. This freedom of creativity leads to innovation and breakthroughs. Many CAD software providers these days offer inherent integration with virtual reality environments.

Training and simulation

This is a lifesaver when it comes to training employees for hazardous tasks. VR technology allows workers to get trained in a controlled, risk-free virtual environment. This helps them gain confidence before actually performing risky tasks in a real environment. For instance, in the oil and gas industry, they train their workers on VR before actually boarding them for the real tasks in the real world. Besides this, the frontline workers get access to interactive training material anytime and anywhere. Crisis readiness training in situations like explosions, fires, floods, toxic releases, and earthquakes is also given using VR technology. Research shows that VR can help reduce the odds of work-associated injuries by 43%, which translates to substantial financial savings for companies regarding workers’ compensation claims, legal fees, and lost productivity. 39% of big organisations leverage VR/AR technology to facilitate training in simulated environments.

Remote collaboration

Traditionally, for sophisticated machines, experts were called on-site for installation, training, maintenance, or repair. With VR, all this is possible virtually with the help of self-guided step-by-step VR tutorials. With VR headsets, on-site workers can also use AI and connect with technicians remotely. VR technology helps remote teams connect. VR became very useful in the time of COVID. With the rise of remote work, VR technology appeared as a game changer in those difficult times. It helped industries communicate and collaborate across distances. VR technology enables virtual meetings in 3D spaces. It creates an environment where the participants and the digital objects interact with each other as if they were in the same room. Hence, it enhances the sense of engagement, effective collaboration, and team building. VR technology also gives the customer a virtual experience of the product and service, enabling sales professionals to connect with their customers remotely on a virtual platform. Customers get the option to interact with virtual products, understand their features, and even explore different configurations, leading to more informed purchase decisions.

Case study and live examples

Boeing’s efficiency improvement with AR

Boeing uses AR technology to assist its workers in assembling aircraft. AR glasses provide step-by-step instructions and overlays that indicate the exact locations for component placement, reducing assembly time and errors. Boeing reduced wiring time in some aircraft by an impressive 30%.

Porsche turns to AR to grade up its service

Porsche is using CAD data from its new Taycan for the world’s first workshop solution using augmented reality (AR). The goal is to make the service and maintenance of the company easier and faster and give convenience to its workshop employees, who no longer need to search through page after page of repair manuals.

Siemens utilises virtual reality to enhance the employee experience

Since Siemens employees work with heavy machinery in factories, they provide EHS training to their staff with valuable insights about their workplace, underlying processes, and safety measures. To enhance that learning, Siemens, in collaboration with VRdirect, created a virtual tour and an escape game using VR technology for its workers to improve their understanding of their workplace in a fun and interactive manner.

Ford uses AR & VR to design cars, reduce costs, and train employees

Ford uses the digital manufacturing concept to reduce injuries, lower tooling costs and improve quality. Ford uses VR to design new cars and AR to train its salespeople on new vehicle models. The company has developed an AR app that allows salespeople to see a 3D model of a new vehicle overlaid in the real world.

Benefits of AR and VR in industrial automation

The benefits of AR and VR in industrial automation are immense-

  • They improve efficiency and productivity by reducing human errors.
  • Significantly reduces workplace accidents by allowing workers to practice handling dangerous situations in a virtual or simulated environment.
  • Leads to substantial cost savings by reducing errors, downtime, material and labour costs, operational costs, and associated costs by creating virtual prototypes.
  • Reduces product time to market (TTM). All this is possible because these technologies provide real-time information and allow users to experiment with new ideas and scenarios, even if the teams are dispersed geographically.
  • It increases user engagement and motivation because of its interactive nature and capability to enhance visualisation.

Limitations of AR & VR in industrial automation

Though AR and VR technologies have shown significant potential in industrial automation, there are still certain concerns that need to be addressed for their widespread adoption. High initial cost of hardware, software and associated infrastructure. Developing customised content is not easy. User comfort and safety where they have to wear the headsets for a longer time, causing discomfort to the eyes and motion sickness. Ensuring a safe environment for users so that users don’t get hurt because of a lack of awareness of their surroundings while wearing R/VR headsets. As these technologies are developing, Data Privacy remains a foremost concern. Other limitations include:

  • Cost: AR and VR hardware and software can be expensive, making it challenging for small and medium-sized enterprises to invest in these technologies. The cost of VR headsets alone ranges from a few hundred to several thousand dollars, while AR glasses can cost even more. Additionally, businesses may need to invest in additional infrastructure, such as powerful computers and tracking systems, to support these technologies.
  • Complexity of implementation: Implementing AR and VR solutions in an industrial setting can be complex and time-consuming. Companies need to develop or purchase specialised software, integrate it with existing systems, and train employees on how to use the technology effectively. This process can be disruptive to operations and may require downtime for installation and configuration.
  • User experience: While AR and VR can provide immersive and engaging experiences, there are still challenges related to user experience. Some users may experience discomfort, dizziness, or nausea when using VR headsets for extended periods. AR glasses can also be bulky and uncomfortable to wear, especially during long work shifts. Additionally, the field of view of AR and VR devices may be limited, which can impact the user’s ability to perform tasks effectively.
  • Safety concerns: AR and VR technologies can introduce new safety risks in industrial environments. For example, workers wearing VR headsets may not be fully aware of their surroundings, which could lead to accidents or injuries. AR glasses may also create visual distractions, making it difficult for workers to focus on their tasks. To address these concerns, companies need to develop and implement comprehensive safety protocols for the use of AR and VR in industrial settings.
  • Data privacy and security: Industrial automation often involves sensitive data, such as production plans, customer information, and financial records. The use of AR and VR devices can raise concerns about data privacy and security. Companies need to ensure that these technologies are equipped with robust security measures to protect sensitive data from unauthorised access and breaches.

Overcoming these limitations will be critical for the widespread adoption of AR and VR in industrial automation. As these technologies continue to evolve, it is likely that many of these challenges will be addressed, making AR and VR even more valuable tools for businesses in the future.

Future trends and developments

Augmented reality (AR) and virtual reality (VR) technologies continue to make significant strides, although their mainstream adoption is still in its early stages. Statista, a leading provider of market and consumer data, suggests that the growth of AR and VR is poised for exponential growth in the coming years.

As hardware components become more advanced, comfortable headsets are developed, and artificial intelligence (AI) makes greater inroads into industrial automation, the user experience of AR and VR is anticipated to improve dramatically. These enhancements will likely lead to increased adoption rates of these technologies.

According to Statista’s projections, the global AR and VR market is expected to exceed 100 million users by 2027, signalling a significant milestone in the industry’s growth. This remarkable expansion is expected to be driven by a compound annual growth rate (CAGR) of 8.97% between 2024 and 2029, resulting in a projected market valuation of approximately US$62.0 billion by 2029.

Several factors are contributing to the anticipated surge in AR and VR adoption. The rising popularity of immersive gaming experiences, the increasing demand for virtual training and education platforms, and the growing utilisation of AR and VR in healthcare, manufacturing, and retail sectors are among the key drivers of this expansion.

As the lines between the physical and digital worlds continue to blur, AR and VR technologies have the potential to transform various industries. From revolutionising product design and prototyping to enhancing workforce training and collaboration, the applications of these technologies are limitless.

However, challenges such as motion sickness, latency issues, and the need for specialised hardware may hinder the widespread adoption of AR and VR. Additionally, privacy and security concerns surrounding the collection and use of personal data in these immersive environments need to be addressed.

Despite these obstacles, the future of AR and VR technology appears exceptionally promising. As technology continues to improve and the cost of headsets decreases, the integration of AR and VR into our daily lives is likely to become more prevalent. These technologies have the potential to reshape entertainment, education, healthcare, and communication, offering users new and immersive ways to interact with the world around them.

There is a growing demand for standalone devices that do not require a connection to a PC or a console to offer greater convenience and mobility to their users. The focus is on improving the audio and visual quality for a better AR and VR experience. Higher-resolution displays, enhanced graphics processing, and spatial audio technologies are being developed to provide a more realistic and immersive experience.

Over the next decade, AR and VR are expected to become vital components of smart factories, driving further productivity and efficiency. Their applications are immense, from product design to employee training to maintenance to remote collaboration.

Conclusion

Augmented reality (AR) and virtual reality (VR) are undoubtedly the cutting edge technologies revolutionising industrial automation by giving an immersive user experience to enhance productivity, efficiency and cost reduction. With advancements in AI and machine learning, these technologies will further evolve in blending the digital and physical elements in the real world in AR and the virtual world in VR. Ensuring data privacy, robust security and establishing industry standards will lead to wider user acceptance. Development in the hardware of AR and VR devices and fast internet connections will lead to better high quality user experience and hence these technologies will become an integral part of industry automation. 

References

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