Logistics Connects

IFFOCUS 1/2009 Logistics Connects

Secure and Efficient Logistics

Secure Chains of Goods: More Than a Technical Solution Threat Detection with Pedestrian Motion Pattern Analysis VIERforES: Three-point Landing for More Security Curious about tomorrow? Are you majoring in mathematics, engineering or a natural science? Then start your career in applied research and help us develop technologies and products for the future. Apply now at: www.iff.fraunhofer.de. Editor’s Page

Dear Readers, Logistics providers on the other hand have entirely different worries. Prob - The issue of security accompanies lo- lems with distribution usually arise gistics on all its journeys. Goods ought wherever goods are handled. Goods to arrive undamaged at the right may be improperly transported or place at the right time. How can logi- stored, they may be at the wrong stics providers guarantee this to their location or not locatable at the right clients? People have to be safely time. In the worst case, they may even guided through zones with heavy traf- disappear. Logistics providers always fic. Sensitive areas must be securely bear full responsibility for their goods protected. Emergency plans have to in transit; claims for damages may be function when there is an emergency, lodged when they are lost or dama- response teams have to be coordi- ged. They are placing their hopes in nated quickly. How can airports, train the vision of completely secure chains stations and stadiums, i.e. facilities of goods. Researchers at the Fraun- with extremely high traffic density and hofer IFF in Magdeburg are also high numbers of visitors, best prepare working on this aspect of security. for this? This issue of IFFocus is devoted to Security concepts rely on clever system different topics related to secure, solutions, software and, naturally, reliable and efficient logistics. Peer technologies. The particular challenge through this window and catch a is to make systems reliable. This is glimpse of exciting research work easier said than done. Nearly every from the Fraunhofer IFF in Magde- technical device contains embedded burg. I wish you interesting reading. systems. Earlier, levers were activated; now, hidden processors activate the Your, desired function from inside the device. Newer and newer models with increasingly sophisticated technology are being launched on the market. So far, no manufacture has been able to Prof. Michael Schenk promise trouble-free operation. Small Prof. Michael Schenk Director of the Fraunhofer Institute for Factory Operation and Automation technical details may have devastating Photo: Dirk Mahler effects should they malfunction.

In the project VierforES, researchers from Magdeburg’s Fraunhofer Insti- tute for Factory Operation and Auto - mation IFF and their project partners at Otto von Guericke University Magdeburg, the Fraunhofer Institute IESE and the Technical University of Kaiserslautern are now jointly working on concepts intended to help manu- facturers perfect their products. Logistics experts are primarily working on material handling systems and researchers on pedestrian motion patterns as the basis for threat detection.

IFFOCUS 1/2009 3 In this issue ...

News Looking Back Fifteen Research and Deve- Years lopment 6 11 16 12th IFF Science Days: More than 500 An Intense Bond with the Technical Just where are you headed? Experts Convene in Magdeburg University Pedestrian Motion Patterns as the Basis for Threat Detection 6 Prof. Klaus Richter and Cathrin Plate Timber Logistics Experts Meet in In a Flash Hundisburg 20 12 Three-point Landing for More 7 12th IFF Science Days 2009 Security Discovering Logistics on Logistics Day Impressions Prof. Klaus Richter, Martin Kirch and Olaf Pönicke 8 Transport Exchanges: Enabling Com- Interview 24 panies to Reduce Logistics Costs Clever Combinations: 14 The “Secure Chain of Goods” Is 8 Optimizing Processes of the Trade: More than a Technical Solution New Cluster Supports Companies in Dentures Made in Germany Helmut Röben and Dr. Daniel Reh the Regional Energy Industry Mathias Baumgart, Managing Director of Baumgart Dental Lab in 28 9 Braunschweig The Latest from the LogMotionLab: State Supports Project for Professional Talking Systems, Transmitting Qualification with Virtual Reality Vehicles and a Thinking Assembly Table 10 Helmut Röben Web 2.0 for Companies

10 Center for Digital Engineering Opens Sharp Minds Gallery

32 44 48 Breaking the Mold: Research Marketing with an Athletic Impressions of Research and Radio Technologies from Magde- Spirit Technology burg Are Improving Internal Mate- rial Flows at a Foundry 45 Prof. Klaus Richter and Helmut Röben Always On the Move Upcoming Events 36 46 54 Intelligently Green: Innovative Lo- Researchers, Thinkers and Inventors: Meet up with researchers from the gistics Concepts for Converting Magdeburg Launches Its Research Fraunhofer Institute for Factory Energy from Residual Biomass Campaign Operation and Automation IFF at Prof. Michael Schenk, Sebastian these events. Trojahn and Dr. Ina Ehrhardt ... with doctorates 40 Editorial Notes Harz Power: 44 An Entire Region Is Pursuing One Marie Curie Program Facilitates Early 54 Goal: A Renewable Energy Supply Careers Editorial Notes Prof. Z. A. Styczynski, Dr. Przemyslaw Komarnicki and Dr. Gerhard Müller 45 Always Focused on His Goal News

12th IFF Science Days: Over 500 Experts Convene in Magdeburg

Science Days as a forum to present the state’s new logistics concept.

Automation experts also found topics right up their alley. One program topic, Safe Human-Robot Interaction, i.e. human- robot interaction without protective barriers, is a current preoccupation in the industry. New safety concepts and technologies are needed as the trend moves in this direction.

For more information, visit: www.wissenschaftstage.iff. fraunhofer.de

Saxony-Anhalt Minister of Transportation Karl-Heinz Daehre presented the state’s new logistics concept at the 12th IFF Science Days. Photo: Dirk Mahler

Even in these days of tight and process development, travel budgets, the Fraun- the digital factory and pro- hofer IFF knows how to fessional qualification and Timber Logistics Experts Meet in get large numbers of ex- thus in tune with the times: Hundisburg perts interested in current “You get much more out of research topics. Once virtual reality than pure 3-D again, more than 500 engineering. Every company This year’s timber logistics work- guests from business, aca- has to save time and shop was devoted to fundamental demia, research and gov- money. Doing better long issues of logistics, interfaces and ernment gathered in term with virtual technolo- efficient energy use. Jointly organ- Magdeburg on June 16 to gies is what the 12th IFF ized by the Fraunhofer IFF, the 18, 2009. The annual Science Days are about.” Forstbetrieb Sachsen-Anhalt and event’s program included the Niedersächsischen Landes- conferences on digital In addition to mobility and forsten, the March event drew engineering, logistics and transportation, the logistics forest owners, haulers and wood robotics. conference also focused on processing companies to Hundis- the trends and prospects of burg. Industry experts discussed The Fraunhofer’s digital green logistics. Contempo - potentials and opportunities for engineering specialists are rary logistics not only has to cooperation as well as fields of in great demand particularly plan, control and optimize action. A case study from a pilot in the machinery and plant global networks but also region in Lower Saxony highlighted manufacturing sector and manage complex networks, current issues in day-to-day busi- automotive industry. Hence, control risks and simulta- ness. Preparations are underway Director Michael Schenk is neously conserve existing for the popular industry meeting in emphasizing digital product resources better. Minister of 2010. Transportation Karl-Heinz Daehre used the 12th IFF

6 IFFOCUS 1/2009 Discovering Logistics on Logistics Day

Logistics Day was held throughout the country on April 16, 2009. Logis - tics services are highlighted on this day, an initiative of the German Logis - tics Association (BVL). The goal is to give the general public insight into logis - tics operations and jobs in logistics. Numerous companies and institutions including the Fraunhofer In- stitute for Factory Opera- tion and Automation IFF were involved in this campaign.

The Fraunhofer IFF opened its doors in the morning for a look behind the scenes. Visitors were able to learn about advanced logistics systems in the LogMotion- Lab, one Europe’s leading

Logistics Day: Experts at the Fraunhofer IFF easily explain the world of logistics in the LogMotionLab. Photo: Viktoria Kühne.

labs for the development, environmental conditions Nearly three hundred testing and certification of are having on their ship- events were already sched- RFID and telematic techno- ment. uled for Logistics Day logies. At the lab, Fraun- shortly before April 16, hofer experts develop In the afternoon, visitors to eight of them in Magde- customized solutions for the Fraunhofer IFF had the burg. Thus, the program their clients from industry opportunity to attend an offered even more than in and the service sector. For interesting presentation 2008 when more than instance, they employ RFID that was part of the 20,000 attendees explored transponders, small trans- Logistics Guest Lecture the diversity of logistical mitting labels that are al- Series. Winner of the solutions and services at ready found stuck to every German Logistics Award in 212 events. For detailed CD. These clever compan- 2007, logistics consultant information, visit ions are increasingly accom - Marc Schleyer discussed www.tag-der-logistik.de. panying logistical items on certain methods that their way to consumers and improve waiting and cycle have become indispensable times in logistics systems. in modern logistics systems. The Guest Lecture Series They make chains of goods was opened by its patron, more secure because they Saxony-Anhalt Minister for Popular forum for experts: The reveal the location of goods State Development and annual timber logistics work - to their owners at any Transportation Karl-Heinz shop at Hundisburg Castely. moment and any effects Daehre. Photo: Viktoria Kühne.

IFFOCUS 1/2009 7 News

Transport Exchanges: Enabling New Cluster Supports Companies in the Companies to Reduce Logistics Regional Energy Industry Costs The Saxony-Anhalt Renewable Energies cluster commenced its Small and medium-sized enterprises could work in Magdeburg in February. The cluster of regional operate much more efficiently and cost effec- companies and research organizations intends to strengthen tively. Considerable potential lies dormant in the renewable energy industry and consolidate the state’s procurement and distribution management and leadership in the sector. The Ministry of Economics and Labor is just waiting to be optimized. This is easier is supporting the project with 500,000 euros. said than done though. Since they ship and deliver relatively small quantities, these companies have hardly any options to optimize their Wind, water, sun and above all Operation and Automation IFF: European transportation on their own. The biomass – renewable energies “Saxony-Anhalt has the best consequence is poorly utilized transport and hold tremendous potential. prerequisites. We in Germany underutilization of intermodal transportation. A These natural treasures are are far ahead with renewable lot of air is driven here and there on European outstandingly suited for effi- energies, particularly wind roads. cient and environmentally power and photovoltaics. We compatible conversion into intend to fur ther consolidate Researchers are working on solving this energy. Saxony-Anhalt Minister this leader ship with the cluster problem in the Kassetts project. They are of Economics and Labor Reiner initiative to make regional pursuing the idea of implementing a European Haseloff emphasized this during companies even more competi- network of logistics brokers. Every broker is the opening event at the Fraun- tive. backed up by a logistics office that manufac- hofer Institute for Factory turing companies may use to electronically record and aggregate shipping orders and optimize them according to vehicle routes and the volume of traffic. When necessary, regional and transnational brokers working in the network are available to efficiently plan transnational supply chains by incorporating the different manufactur ing companies’ specific order and delivery data to be precise. Only then are the combined inquiries forwarded to logis - tics providers. Thus, rather than being a new logistics company or a fourth party logistics provider, the broker improves the supply and demand relationships of the companies involved. In addition, the broker opens opportunities for outsourcing and supports a logistics provider with organized demand. Consequently, this approach benefits both parties and helps save hard cash and protect the environment. The Istituto sui Trasporti e la Logistica in Bologna has already been tested the approach in Italy with convincing results. Over 20 percent of the costs were cut, 30 percent fewer kilometers were driven and the number of transport routes were reduced by 37 percent. Kassetts is being supported by the European Union. For more information on the Intending to collaborate closely in the CEESA cluster in the future: Prof. Zbigniew Styczynski, President of the Saxony-Anhalt Center for Renewable Energies (ZERE); project, its progress and the European logistics Cluster Manager Frank Busch from ATI GmbH Anhalt Dessau-Rosslau, Prof. Klaus- organizations involved, visit the official website: Erich Pollmann, President of Otto von Guericke University Magdeburg; Dr. Gerhard www.kassetts.eu. Müller, Deputy Director of the Fraunhofer IFF and Prof. Heribert Münch from Magdeburg-Stendal University of Applied Sciences. Photo: Viktoria Kühne.

8 IFFOCUS 1/2009 The Saxony-Anhalt Re- State Supports Project for Professional Qualification with newable Energies cluster Virtual Reality aims to combine the activities of companies, Haseloff: Everyday busi - research organizations ness will be hard to imag - and institutions in the ine without virtual tech- energy sector. The close nologies in the future. collaboration will particularly enable the part- Nothing changes faster ners to profit from tech- than modern technology. A nology transfer and number of things such as know-how exchange. technology and machinery They are intensively com- at the workplace or a job mitted to acquiring proj- itself are replaced over the ects and attracting in- course of one’s professional vestors and providing career. People who work them support when they with complex machinery locate in Saxony-Anhalt. and equipment in their job The cluster management must be able to handle it particularly concentrates particularly quickly and on energy recovery from confidently. RKW Sachsen- biomass and biowastes, Anhalt GmbH, education wind energy converter providers and companies construction and photo- intend to break new voltaics. “Ten percent of ground for professional the world’s energy requi- qualification with virtual rement will be coverable reality in the project A virtual interactive training sce nario with biomass alone in ViReKon. Virtual reality virtual reality. Everyday for professional qualification. Photo: Dirk Mahler the future. We absolute- imparts complicated techni- business will be hard to ly have to tap this po- cal knowledge much more imagine without virtual tential,” demands Prof. easily and cost effectively technologies in the future.” Zbigniew Styczynski than present instructional Thus, for example, future from the Center for Re- materials. Hence, virtual Supported with funds from machinist will learn how to newable Energies (ZERE). reality will become ordinary the European Union and prepare a job, correctly The center was author- equipment in Saxony- the State of Saxony-Anhalt, clamp a workpiece in a ized to manage the Anhalt’s small and medium- the ViReKon project will CNC lathe and correctly cluster jointly with the sized enterprises. enable the Technologie und program the machine for Agentur für Technolo- Berufsbildungszentrum machining. That’s not all. gie transfer and Innova- At the ViReKon business Magdeburg gGmbH and As an ambassador for tionsförderung GmbH day at the Fraunhofer Insti- Schweisstechnische Lehr- progress, the virtual lathe Anhalt. The initiators are tute for Factory Operation and Versuchsanstalt Halle comes directly from training inviting committed com- and Automation IFF’s GmbH to qualify engineers to the company where it panies and organizations Virtual Development and and machinists on virtual may be utilized versatilely. to actively collaborate. Training Centre VDTC, machinery in the future. To The virtual models are ide- The cluster opens prom- Minister of Economics and this end, trainers are devel- ally suited for training ising prospects for Labor Reiner Haseloff ex - oping special e-learning colleagues or as an interac- Saxony-Anhalt’s industry pressed his conviction that methods together with the tive maintenance manual. to successfully position “Saxony-Anhalt’s compa- experts at the Fraunhofer In other applications, the itself on the global ener- nies will only be able to IFF. Virtual models of the virtual models are used for gy market. keep up with global compe- same machinery on which quality inspection or as an tition when progress and operators and maintenance attractive marketing tool for innovation are lived. Earlier technicians will work later sales. this meant CAD programs, are being produced in today it means cyberspace.

IFFOCUS 1/2009 9 News

Web 2.0 for Companies hand, different Web 2.0 for Web 2.0 applications,” applications such as Wikis observes Stefan Voigt, Blogs, Wikis, portals such as developing new Web 2.0 and logs will be harmonized esearcher at the Fraunhofer YouTube and social net- communication portals and merged in a common IFF. “While large companies works such as Xing have adapted to corporate system where their func- have resources even to lastingly changed the Inter- needs. Three companies, tions complement one occasionally experiment net. Although companies Krautzberger GmbH, another as Bliki for exam- with the implementation of have also long since reco- Kristronics GmbH and ple. On the other hand, social software, gather gnized the potential of Stelco GmbH, are estab- applications will be inte- experiences and create rele- these Web 2.0 technolo- lishing the platform’s prac- grated in ERP and content vant expertise, many SMEs gies, many remain hesitant ticability. management systems to are faced by problems at to implement them. The support existing business times.” The experts intend concrete benefits are hard According to Dr. Fuchs- processes. to use the systematic ap- to assess, especially for Kittowski, a researcher at proach to particularly help small and medium-sized the Fraunhofer ISST, “The The experts from the SMEs also successfully enter enterprises. In the project key to the success of Web Fraunhofer Institutes and the Web 2.0 age, which are ICKE 2.0 (Integrated 2.0 in companies is integra- CosmoCode are relying on situated outside the infor- Collaboration & Knowledge tion. We intend to develop systematic economic feasi- mation economy where the Environment), specialists a complete system from bility studies and Web 2.0 barriers to entry are often from the Fraunhofer many isolated applications implementation strategies largest. Institute for Factory and integrate it in existing to identify and efficient Operation and Automation corporate infrastructures.” utilize concrete fields of The project is being suppor- IFF, the Fraunhofer Institute This necessitates merging application in companies. ted by the BMBF. For more for Software and Systems things as the technical “Many companies have information, visit www.icke- Engineering ISST and the foundation, which have not difficulty establishing the projekt.de. agency CosmoCode are yet fit together. On the one organizational conditions

Center for Digital Engineering Opens

Magdeburg is an established center of applied virtual technologies. Research and development of virtual and augmented reality is now going to be expanded. To this end, the Fraunhofer Institute for Factory Oper- ation and Automation IFF and Otto von Guericke University jointly founded the Center for Digital Engi- neering (CDE). In the future, the academic center will be based in the Experimental Factory in Magdeburg.

Embedded systems are increasingly controlling and monitoring devices that have become a given in everyday life. Researchers intend to take advantage of the benefits of virtual reality to develop more secure and reliable equipment. The performance of software integrated in machinery and devices can be demonstrated precisely in cyberspace. Photo: Viktoria Kühne.

10 IFFOCUS 1/2009 Looking Back Fifteen Years

Predominantly engineers Fraunhofer IFF and Otto An Intense Bond with the Technical and computer scientists, the von Guericke University University researchers will further are collaborating closely research and development on all these projects and of virtual technologies. The intend to use the new and Prof. Herrmann Kühnle Center for Digital Engineer - academic center to jointly assumed the man - ing aims to establish a node intensify their collabora- agement of the institute on where other projects can tion. July 1. Director until then, connect. In addition, the Prof. Eberhard Gottschalk partners intend to jointly Minsterialdirektor Wolf- transferred to the Fraun- support young researchers Dieter Lukas from the hofer-Gesellschaft’s head- in the field and significantly BMBF came to Magde- quarters in Munich. advance academic burg just to be at the programs. opening and declared, In particular, the institute’s “We are strongly relying new management worked The partners in the CDE are on strengths in the east to implement the coopera- combining their strengths. as part of our high-tech tion agreement between A symbiotic relationship is strategy. Our programs the Fraunhofer IFF and Otto being established between Cutting Edge Research von Guericke University the university’s basic rese- and Innovation in the Magdeburg. The Fraunhofer arch and the Fraunhofer New States and ICT IFF expanded its applied experts’ experience in 2020: Research for Inno- research with specializations applied research. The re- vation are promoting the in the research fields of the searchers simulate three- capabilities of the best. teaching disciplines repre- dimensional interactive Magdeburg is estab- sented by the Fraunhofer models of complex techni- lishing itself as an excel- Founder of the Fraunhofer IFF: directors at the university. cal systems in cyberspace lent link in the Virtual Prof. Eberhard Gottschalk. This model is characteristic Photo: Archive. for instance. In the future, Technology Innovation for institutes in the Fraun- this will make industrial Alliance.” Innovation alli- hofer-Gesellschaft. Institutes products and processes ances thematically In 1994, Fraunhofer had are closely connected with more reliable and assure combine projects from been in Magdeburg for two the system of higher educa- they are implemented different programs, thus years. The senate had tion and directors normally faster. The worldwide one- moving research and already named the institu- hold chairs. Diplom theses of-a-kind technical systems industry significantly tion an autonomous insti- and research papers may be at the Fraunhofer IFF Virtual closer together. This is tute one year after its completed directly at a Development and Training unique. Praising the founding. The staff at the Fraunhofer Institute. Centre VDTC open excel- commitment here, Fraunhofer IFF had grown Institutes serve to prepare lent opportunities for the Ministerialdirektor Lukas to fifty in the meantime. researchers and engineers experts to plan, test and continued, “The Center The offices on Elbstrasse for the working world in operate technical systems. for Digital Engineering were bursting at the seams. industry. Thus, by rigorously ideally unites Magde- Therefore, the institute promoting the transfer of In recent years, the Federal burg’s cutting edge opened a branch office at knowledge to practice, the Ministry of Education and expertise in academic the Innovations- and Fraunhofer-Gesellschaft Research (BMBF) has been and applied research. Gründerzentrum in plays a special role in the supporting a number of the The BMBF values this Barleben. innovative alliance of re - Fraunhofer IFF and its part- highly because the sus- search and industry. ners’ significant research tainable impact of our However, the year’s main projects with funding in the program is especially event was the change in double digit millions, important to us.” management at the Fraun- making Magdeburg one of hofer Institute for Factory Germany’s centers of virtual Operation and Automation reality research. The IFF. Prof. Michael Schenk

IFFOCUS 1/2009 11 In a Flash 12th IFF Science Days June 16 to 18, 2009

IMPRESSIONS Interview Photo: Anna-Kristina Wassilew

Optimizing Processes of the Trade some processes with a stopwatch. They uncovered a number of potentials for optimization. Bit by bit, we Dentures Made in modified some processes. After roughly two years, the lab has been Germany completely converted. Let us consider a typical process. What steps do you go through An interview with Master Dental Technician Mathias Baumgart, Managing when producing a crown or a Director of Baumgart Dental Lab in Braunschweig bridge for example?

Baumgart Dental Lab’s advertising promises dentures up to 50 percent A dentist makes an impression of a cheaper. How is master dental technician Mathias Baumgart able to keep patient’s teeth. We digitize the this ambitious promise? He optimized his processes and expanded his impression and develop a three- range of products together with experts from the Fraunhofer IFF in Mag- dimensional CAD model of a crown, deburg. The entrepreneur from Braunschweig talked with IFFocus editor a bridge or even an implant. Then, we Anna-Kristina Wassilew about his offensive against cheap Chinese manu- use a special machine to mill the facturing. frame for a patient’s individual dentures from zirconium oxide, a novel Anyone in need of dentures has to I quickly realized that this doesn’t material. Thus, it doesn’t necessarily be ready to make a larger invest- actually have to be. We ought to have to be gold anymore. The new ment in their health. Who has a recapture this market. After all, it’s far materials have outstanding properties. four digit sum on hand quickly better to manufacture here and create They are unbelievably durable. Brake though? Everyone is watching costs jobs here. The Chinese use the same disks for Porsches are made of zirco- – even patients. Therefore, dentists equipment. The quality of their pro- nium oxide. Then, the dental technici- are increasingly ordering implants, duct is good but China doesn’t have ans finish the dentures in the lab. bridges and crowns from China. to be cheaper than here. Finally, they are colored so that the What alternatives do you offer? crown also matches the natural color- How were you able to cut produc- ation of the other teeth well and Production in Germany. Foreign pro- tion costs? doesn’t stand out. The many work duction became interesting some time steps depend on real craftsmanship. ago because German denture pro- By optimizing the processes. The On the other hand, some work steps duction became too expensive. I en- process engineers from the Fraun- in the lab can already be completed countered boxes from China all over. hofer IFF scrutinized the operations in very well by apprentices after brief our lab. The researchers were ex- orientation. tremely precise. They even timed

14 IFFOCUS 1/2009 Where have you cut costs? Rapid prototyping particularly inter- Brief CV ested me. I could definitely imagine Some processes were automated. Else- picking up such a process and inte- Mathias Baumgart where, we were able to save material grating it in our work routine with the or assign differently qualified staff. Fraunhofer IFF. 1964 China is able to save labor costs Born in Hannover tremendously. We on the other hand Let us venture a look into the are saving the considerable logistics future. What plans do you have for 1981 - 1984 costs incurred when manufacturing in Baumgart Dental Lab? Training as a dental technician distant Asia. Our services right here are one significant advantage for patients. A while ago, I was still thinking about 1984 - 1994 We are much closer to them. So, you a franchise model. In the meantime, Dental technician in different dental see that Made in Germany has many I’ve decided on a system of satellite labs in Hannover and Braunschweig advantages. operations. I’ll be opening a kind of branch in different cities. One employ- 1992 - 1994 What’s the job situation? Are you ee in each city will be responsible for Establishment and organization of a cutting staff? sales. That colleague will also record training lab in Braunschweig while the 3-D models and send the data to working as an instructor on veneering No, quite the opposite. We precisely us at the lab in Braunschweig where with ceramic materials examined what skills and qualifica- we then make the dentures. When Organization of training courses for tions are demanded where. You don’t this model goes well, a branch can hearing impaired dental technicians need a master for every work step. I definitely become a permanent opera- hired three new employees just this tion. The staff there could hold a 49 1993 - 1996 year alone. By the way, we are one of percent share for instance. The opera- Freelance instructor for implant- the few labs in the region that offers tion would then carry the Divident supported suprastructures training at all. Three apprentices are product line. The first of this type will learning their trade at Baumgart be opening in Magdeburg this year. 1993 Dental Lab. That is comparatively Certification as master dental many. In the 1980s, for example, What do your colleagues actually technician in Hannover there were around 120 apprentices in say about your strategy? And what Braunschweig. There are just 20 are the views of the doctors you Seit 1994 today. The numbers clearly illustrate ultimately have to convince? Own dental lab in Braunschweig the shortage of skilled labor threaten- ing our industry. Unfortunately, my colleagues haven’t 2001 understood this strategy. I want to Swearing in as expert in the dental Talking about innovation is always wrest the market share away from the technician trade by the Braunschweig talking about money. With which Chinese not my colleagues in Chamber of Trades product innovations will you be Germany! The doctors are still skepti- able to earn money after collabo- cal. Apparently, nobody can imagine 2008 rating with the Fraunhofer IFF? that German top quality can keep up Founding of his own dental material with Chinese prices. I think we’ll have and training company Divident GmbH We even developed a new product to go through the patients who are line called Divident together with ultimately able to decide where their 2008 Fraunhofer researchers. Divident has dentures should be made. Development of the product Divident special properties defined by stand- as an extension of the dental lab’s ards, price and warrantee. One pressing question remains in range of products closing. If it’s all so easy, why hasn’t Will you also implement new anybody had this idea before? 2009 methods and technologies in the Start of the first satellite lab in future? What might they be? In all honesty? I have no idea! Magdeburg

I saw various technologies during my visits to the Fraunhofer IFF in Magde- burg. I was really taken by the impres- sive possibilities. It inspired me and I came home with many new ideas.

IFFOCUS 1/2009 15 Just where are you headed?

Pedestrian Motion Patterns as the Basis for Threat Detection

Prof. Klaus Richter and Cathrin Plate Photo: MEV-Verlag

16 IFFOCUS 1/2009 Airports and security are are steadi- and road systems are critical nodes for information systems. All carriers, ly converging in practice. Demands the German economy. Natural cata- installations and systems are highly on airport security have steadily in- strophes and technical breakdowns as interconnected, thus making them creased in recent years. Taking well as terrorism, criminality and sabo- vulnerable. Comparatively minor, indi- Frankfurt Airport as an example, tage can cause considerable damage vidual disturbances can snowball. The the joint airport security system in a world that is growing ever closer failure of just one transportation node project FluSs is investigating the po- together. can cause lasting consequential tential structure of an integrated damage in passenger and freight holistic security management con- Protection of Transportation transportation. Therefore, as an cept for airport infrastructures. The Infrastructures important European transit country, Fraunhofer IFF is one of the fifteen As part of its high-tech strategy,the Germany has a particular interest in partners in this project supported Federal Ministry for Education and the security of transportation infra- by the Federal Ministry of Educa- Research (BMBF) is investing around structures. tion and Research. The Magdeburg 123 million euros in its Research researchers are examining the be- Program for Civil Security until 2010. Customized Security Solutions havior of pedestrians and intend to The best ideas from science and Along with the impacts perceptible identify threat situations on the research are being sought in order to every day, area-wide failures of trans- basis of motion pattern analyses. advance innovative security solutions. portation systems caused by technical One emphasis is the protection of or natural catastrophes such as fire or The free transit of information, people transportation infrastructures. flood constitute risk factors for society and goods is the most important and the economy as much as terrorist factor for the success of an export- Roads, rails, air routes and waterways threats. These risks require customized oriented economy. One cannot be the are important cornerstones of the security solutions. This will improve global export leader without secure German economy and society. This both early warning systems and emer- energy and transportation networks, not only includes all transportation gency management strategies. internet and telecommunications, routes but also the related installati- food supply and health care. ons such as airports, train stations and For instance, complex operations must subway systems or bridges and be coordinated when an accident Germany has a dense transport infra- tunnels. It also includes nationally involving hazardous materials occurs. structure. More than 230,000 kilome- significant installations, e.g. air traffic Police and fire departments must be ters of roads, 44,000 kilometers of control centers, central rail control alerted, on site response teams and rails and 7,500 kilometers of water- centers or road traffic control and agencies must collaborate and resi- ways crisscross the country. According to the Federal Statistical Office, 150 million people are transported by air routes annually.

Vital Arteries are Vulnerable As significance increases, so does the risk. Given the high population density and the high-tech infrastructure, the global export leader Germany is being exposed to ever newer threats. Although technology is becoming more dependable, even little disturbances can produce great impacts. Transportation routes are so finely balanced that they are even vulnerable to minor disturbances. Global mobility enables dangers to spread more easily and makes them more difficult to combat. Airports, train stations and ports in particular and rail

Reliable security systems are now in demand wherever crowds gather. Photo: MEV-Verlag

IFFOCUS 1/2009 17 dents must be alerted and informed. attacks in New York and London are airport without making costly invest- At the same time, an emergency particularly interfering with airport ments may be more expedient from requires technical equipment, e.g. to processes. New challenges demand the perspective of cost and benefit. analyze chemicals or other unidenti- new responses. Airport operators are On the other hand, every security fied substances on site. Water, air, facing the challenge of adapting measure in a terminal has to be road or rail – although the challenges existing security management to new applied where there is bustling pedes - are all-encompassing, the protection threats and developing efficient, scala- trian traffic. Impacts must be mini - of transportation infrastructures is as ble and customer-oriented process mized, passive and active protective diverse as the infrastructures themsel- architectures. All this must be done in measures implemented and threats ves on which they are based: Mass the context of steadily rising numbers detected early. It is essential that panic can break out at train stations of passengers and commercial trans- specific investments assure maximum and airports. Different response teams port and it must remain affordable. security, while minimally interfering all over must be coordinated during with personal security and flight an emergency to assure operations Scenario: Threats at an Airport operations. run smoothly. Airport structures can fall prey to a number of attacks, e.g. by explosives What should the response to the There fore, fifteen partners from dif- or biological or chemical weapons. various threat scenarios in different ferent specialized fields, including Appropriate intelligence, monitoring critical areas be? The partners in the the Fraunhofer IFF in Magdeburg, and security measures are needed to joint project FluSs have selected the are investigating the potential struc- counter the various threats. While “onion principal” as their conceptual ture of an integrated holistic security minimizing the impact of a potential approach: They are analyzing and management concept for airport attack might suffice for less critical evaluating Frankfurt Airport and its infrastructures in the airport security areas, more critical areas require environs from the outside in as a system project FluSs. passive or additional active protective model site. They are performing a gap measures. Early threat detection is analysis of the current security infra- Airport Security imperative for highly critical areas. structure and processes and an event The issue of airport security is increas- and risk analysis to identify fields of ingly taking on greater and ubiquitous The implementation of measures to action, which will be the starting importance. Greatly increased security minimize the impact of an attack in points for further analyses. In the requirements following the terrorist the less sensitive outdoor area of an process, the partners are examining different subareas. They are looking into the latest fluoroscopic and sensor systems for hazardous material detection, ID technologies, localization and navigation technologies and object, motion and pattern recognition technologies. This is precisely where the Fraunhofer Institute for Factory Operation and Automation comes into action. It is responsible for the analysis of individuals and pedestrian flows.

Transparency Knowledge of such motion patterns will be an important contribution to increased security at airports because more people are increasingly spending time in non-security critical areas of airports (shops and restaurants), which are not under surveillance. The Fraunhofer researchers’ analyses will also include these people in its analy- Frankfurt Airport is serving as a model to test the practicability of security concepts sis, thus making the airport more in the FLUSs project. Photo: MEV-Verlag transparent.

18 IFFOCUS 1/2009 Every second counts in an emergency. Photo: Fraport

Situation Analysis The idea behind this is to automati- ture will constitute the basis of imple- The researchers from Magdeburg are cally identify threats by means of an mentation. Building upon this, a theo- analyzing people and pedestrian flows automatic trigger that goes off like a retically grounded security manage- in diverse airport areas on the basis of smoke detector when there is a fire. ment concept ready for implementa- video recordings (pixel data). This However, instead of plumes of smoke, tion will be developed. Airport em - enables then to answer certain questi- atypical movements are detected on ployees’ attitudes and concerns will ons. How many people are located in the basis of deviations from typical also be taken into account. one place at what time? Are they patterns. moving? If yes, in what direction? Allowing for varying basic conditions, How quickly? What is the makeup of When an emergency occurs, relevant the results will theoretically be appli- the group (mother with child or tour information can be extracted from the cable to any German airport. The group)? Is any individual leaving the captured data. This is a positive secon- transferability of the results to other group? Where is the individual dary effect of pedestrian flow analysis. carriers will also be analyzed. headed? Are there aberrations in the Anyone who knows where people are ordinary routine? located when a fire breaks out is able FLUSs is being supported by the BMBF to systematically reroute them. The by the project sponsor VDI (Project Approach: Automatic Threat airport’s data security supervisors and number: 13N10048). Detection employee representations are being Motion patterns identified as typical involved to increase acceptance of the form the basis for the identification of project. Contact: atypical movements and situations. As Prof. Klaus Richter many as five scenarios for diverse Optimized Catalog of Measures Material Handling Engineering airport areas will be developed in the The solution developed by the and Systems coming three years. Different move- Fraunhofer IFF as well as other appli- Telephone 0391 4090-420 ment patterns are considered typical cations developed in the joint project Fax 0391 4090-93-420 in different places, whether at the are being evaluated for their interac- [email protected] terminal or on the apron. Therefore, tions as well as cost effectiveness. The individual profiles will be compiled for goal is to derive a catalog of opti- each area. A comparison of actual mized measures that will define which movements and established patterns security measures must be initiated for will be piloted for a selected area at what threat at what time. The con- Frankfurt Airport. cept for integrated system architec-

IFFOCUS 1/2009 19 Three-point Landing for More Security

Prof. Klaus Richter, Martin Kirch and Olaf Pönicke

While operations and communication in international logistics are largely virtualized and automated, they do not always provide a complete overview of events. Under the umbrella of the research project ViERforES, researchers at the Fraunhofer Institute for Factory Operation and Automation IFF are working not only on monitoring situations in the logistics proc - ess by radio and but also visualizing them reliably. To do so, they are analyzing the movements of assets pixel by pixel and merged into motion patterns. Thus, in interaction with advanced identification technologies, information can be obtained more reliably.

20 IFFOCUS 1/2009 Photo: Woody Stein which canbe obtained byintelligently eries andincreasinglymore efficiency, tual supplies,perfectlypresorted de quires securetransportchains, punc- cost effectiveness.Competition re demands forreliability,quality and tic confronting Germanlogisticswithpar rope’s logisticshub.However,thisis and consolidateitspositionasEu merce andthushaspotentialtosecure moving tothecenterofglobalcom- center oflogistics.Ourcountryis enhancing Germany’spositionasa ing tradewithAsiancountriesare the EUexpandseastwardandincreas political andeconomicconditionsas to customers.Changesinbasic within companiesandfrom driven fromsupplierstocompanies, information holisticallyandmarket- trols everyflowofmaterial,goodsand The logisticsindustryplansandcon- thing movesforward. chains. Iftheycometoastandstill,no- out continualoptimizationofprocess ever, dynamicsisinconceivablewith- tion fornewjobsinthefuture.How high growthandpotentialforinnova- branch ofindustry,characterizedby itself hasevolvedintoanimportant In thiscontext,thelogisticsindustry Germany anexportworldleader. efficient logisticsstructures,making has furtheredthedevelopmentofvery steadily increasingexportorientation as anexportnation.Oureconomy’s cess asacenterofmanufacturingand nificantly determineGermany’ssuc- logistics processesandstructuressig value addedchain,highlyefficient management throughouttheentire Part ofcomprehensivesupplychain and thecompetitivenessoflogistics. formance ofthetransportationsys pects willlargelydependontheper- processes. Oureconomy’sfuturepros- pearance ofmodernmanufacturing tuality andprecisiondeterminetheap- globalization. Highdemandforpunc- the linchpinofbusinessinthisage “Just intime”–logisticshasbecome ular challenges,includingmounting - - tem liv - - - - - can eventsatalogisticsnode beob- step towardmoretransparency. How involved intheprocessisa substantial chain. Monitoringthedomains critical elementoftheglobalsupply freight anextraordinarilysecurity- legal regulationsmakeairandsea numerous nationalandinternational important. Itsinternationalityand national cargocentersisparticularly at sensitivesecurityareassuchasinter- curity. Continuoustrackingofgoods efforts formoretransparencyandse- vide logisticsproviderssupportintheir tion andAutomationIFFdevelopspro- Fraunhofer InstituteforFactoryOpera- Innovative technologiessuchasthe the prerequisiteforallofthis. transparent transportprocessesare structure andtrouble-free,maximally and storagecapacities.Areliableinfra- the utilizationofavailablecargospace combining transportsandimproving container atanytimesavesandmoney. right time.Thisrequireshavinganoverview. Goods mustarriveattherightplace Whoever knowstheexactlocationofhis Photo: WoodyStein IFFOCUS 1/2009 21 Ministry of Education and Research, experts from the Fraunhofer IFF in Magdeburg are investigating means to utilize scene understanding based on motion pattern analyses with reliable information for logistics. This research forms the foundation for more precise analysis of specific scenarios, e.g. events at a cargo hub. They want to describe the flow of goods precisely and thus detect security-critical situations and generate appropriate alerts. The researchers’ practical goal is to capture the overall situation at a logistics hub: What happens at the warehouse distribution center? When and where do trucks enter and exit? Are they unloading or loading pallets? Is everything happening according to the pattern typical for the situation or are misplaced containers or equipment obstructing the specified routes? While motion pattern analyses provide answers about correct conduct at the

A logistics hub is always busy. Goods are handled all day and night. Photo: MEV-Verlag

served though? Aviation security regu- sent to the control center – at least in lations prohibit the transport of active theory. In reality, the fields of applica- telematic units in the international car- tion for motion pattern analysis are go business. This limits the options to presently limited to sports and foren- localize cargo considerably and neces- sics. For instance, researchers from the sitates keeping an eye on cargo with University Bremen think they will be neutral systems unrelated to custo- able to recognize whether someone mers. intends to a steal a car or is just looking for his car based on his move- One method is video-based localiza- ments in a parking lot. tion. The movement flows of individual logistics assets in the surrounding of Recording and analyzing the move- such a logistics hubs are collected ments of logistics assets necessitates based on pixel data and assembled initially researching methods suitable into motion patterns. Critical system for processing localization data and states can be detected automatically identifying typical motion patterns. In based on the actual patterns’ deviati- the project VIERforEs (Virtual and Aug- ons from the motion patterns identi- mented Reality for Maximum Embed- fied as typical and an alarm message ded System Safety, Security and Reliability in the program Cutting Edge Research and Innovation in the New RFID has proven itself in the field. States) supported by the Federal Photo: Dirk Mahler

22 IFFOCUS 1/2009 hub, embedded radio-based systems on equipment and staff deliver additional information on cargo. An RFID FRAUNHOFER INSTITUTE FOR FACTORY glove developed by the Fraunhofer IFF OPERATION AND AUTOMATION IFF transmits data between cargo and equipment. It is worn by a worker and reliably scans – practically with one hand movement – all relevant infor- LOGISTICS AS A FIELD OF mation on vehicles, goods or carriers such as containers, thus supplying in- WORK OF THE FUTURE formation on every single container. This simplifies the loading of trucks, ships or even aircraft because every container must be placed in the spot designated for it in the cargo hold 12TH LOGISTICS GUEST LECTURE SERIES according to a specified sequence for APRIL 7 TO JUNE 9, 2009 security reasons. Knowledge of the precise position of every container makes loading easier to plan. That April 7, 2009, Cooperation for Connectivity – Integrierte Passagier- und saves time. Gepäcklogistik am Aviation Hub Frankfurt/Main (2008 German Logistics Award), Rolf-Dieter Gettert, Lufthansa; Jérôme Konn-Kruse, Fraport Thus, when many autonomous and dependable radio units are available on an airport apron, the combination April 16, 2009, Opening Remarks, Dr. Karl-Heinz Daehre, Saxony-Anhalt Minister of pixel-based situation analysis and of State Development and Transportation radio-based localization not only pro- duces more security but also more Discrete Time Analysis of Batch Processes in Material Flow Systems efficiency at a logistics hub. Since the (2007 German Science Award for Logistics), Dr. Marc Schleyer, 4flow requirements for both will continue increasing in international transporta- April 21, 2009, Fahrerlose Transportsysteme als zukunftssicheres tion, the experts in Magdeburg are Organisationsmittel der Intralogistik, Dr. Günter Ullrich, Unternehmensberatung pressing ahead with their research and Dr. Ullrich continuously testing other potential applications (e.g. in the project FLUSs on p. 16). April 28, 2009, Planerische Logistik in der Großserienfertigung, Steffen Lohmann, Bosch ViERforES is being supported by the BMBF through the project sponsor DLR May 5, 2009, Integrierte Produktions- und Logistiksysteme – Wie Logistik die (Project reference number: Wertschöpfung optimiert, Dr. Wolfram Süssenguth, Miebach Consulting 01IM08003). May 12, 2009, Risiken in der Lieferkette – Supply Chain Design als Beitrag zum Riskmanagement, Dr. Michael Höbig, Pleyma Contact: Prof. Klaus Richter Material Handling Engineering May 19, 2009, Dual-Tray-Poolservice – Ein durchgängiges System für and Systems Distribution, Präsentation und Leergutrückführung von Getränkeklein ge - Telephone 0391 4090-420 binden (2008 Logistics Service Award), Wolfgang Orgeldinger, IFCO Systems Fax 0391 4090-432 [email protected] June 2, 2009, Supply Chain Finanzierung (2008 German Science Award for Logistics), Dr. Moritz Gomm, Momax – Gesellschaft für Technologie und Mobilität; Joachim Getto, Camelot IDPro

June 9, 2009, Wettbewerbsvorteil durch agile globale Lieferketten, Robert Haastert, Accenture ADVERTISEMENT IFFOCUS 1/2009 23 Clever Combinations

The “Secure Chain of Goods” Is More than a Technical Solution

Helmut Röben and Dr. Daniel Reh

Like real life, logistics is complex everywhere. Obtaining secure chains of good from end to end requires clever interaction on different levels. Tactical and operative planning methods are just as much a part of this as suitable technical solutions. Only the combination of risk analysis and assessment and the systematic use of new technologies enable making supply chains more stable against external influences. Photo: NASA, JPL

24 IFFOCUS 1/2009 Circling the world – supply chains Risk Analysis saved individually for every asset. The reflect global interconnectedness that The implementation of a “secure integration of localization technolo- has become ubiquitous. Especially for chain of goods” necessitates making gies and sensor systems make it pos- networked companies, ongoing allowance for every adverse influence. sible to determine the condition and globalization is a risk driver, which First, risks in processes must be identi- location of individual assets. In ad- should not be underestimated. Novel fied. Discussions and workshops are dition, these technologies help inter- security concepts that meet these suited for this. connect individual assets. All this challenges are in demand. Researchers facilitates control in the supply chain. at the Fraunhofer Institute for Factory Once they have been systematically Systematic implementation of RF Operation and Automation IFF have identified, the risks must be evaluated technologies reduce and potentially developed innovative approaches and logistically, ideally so that the evalua- even eliminate weak points identified technologies to organize global chains tion results can be integrated in in the risk analysis. of goods securely. existing planning approaches of logistics systems. Software can help Simple and rugged solutions are Technical support of secure processes here. considered the means of choice. is only one aspect of the implementa- Ideally, these electronic aids are in tion of a secure chain of goods. In In recent years, the researchers at action from identification through fact, the interplay of tactical and oper- Magdeburg’s Fraunhofer Institute control. ative planning methods and suitable have developed various tools that technical solutions is necessary. evaluate and simulate risks. They help Classic Configuration systematically analyze risks and The entire technical process begins Despite current discussions about basically sensitize everyone involved in with identification by barcodes or rising energy prices, the trend is conti- a process to the vulnerability of in- simple RFID tags in enclosed areas. nuing toward creating value added by stalled operations. Thus, the influence Data storage on the asset is expedient means of widely branching inter- of risks to the certainty of supply of for complex capital goods or machi- national supply chains since supply individual companies in a manufactur- nery. chain optimization and organization, ing network can be simulated in the e.g. by means of outsourcing and lean medium term. It is always interesting whenever a management methods, are still prima- constant connection with a super- rily oriented toward cost. The conse- Analysis is focused on logistics plan- ordinate system cannot always be quences are obvious. Value added is ning parameters such as delivery assured and further information on shifted to the supplier structure, reliability for the purpose of logistical the asset is required. supplier and logistics processes are risk assessment. In addition, the increasingly becoming more inter- results of the simulation enable priori- Data storage on an asset also pro- national, inventories and safety stocks tizing risks to define actions. duces value added when different are decreasing. participants throughout the supply Not every risk is really critical and chain require data and a central data- Mounting Risks requires immediate action. The imple- base is unavailable or unfeasible. Reducing inventories and buffers mentation of measures to actively and Moreover, it can be combined with within processes increases risk. The passively control risks is important on additional modules such as localiza- disappearance of decoupling points the planning level to prevent, reduce tion and sensor systems. constitutes a mounting danger for or limit risks. This is precisely where companies. technical solutions come into play With the aid of GPS receivers, the again. assets in the supply chain outdoors Intense streamlining diminishes can be located and tracked to the processes’ impregnability – a leaner Electronic Aids exact meter. Even more precise results and leaner supply chain becomes Just-in-time! Identifying goods any- are possible inside buildings or extremely vulnerable to adverse events where at any time, monitoring them vehicles. A coordinate system may be and loses transparency. Long-distance and checking their intactness and defined in a warehouse so that assets delivery relationships and partners’ quality is becoming increasingly can be localized down to the centi- interconnectedness make it difficult important for international logistics meter. Thus, localization technologies for companies such as logistics plan- companies. RF technologies are ideal facilitate continuous monitoring ners to maintain an overview. All this for this. within a supply chain. bestows a particular risk potential on logistics as the connecting element in Contactless identification of assets in the supply chain, thus making appro- the supply chain is the basis for every priate action advisable. development with which data can be IFFOCUS 1/2009 25 Monitoring Condition is reached. The tag head sensor can Combined with RF technologies, be used, for example, to retrieve implemented sensor systems capture localization data by GSM or write it current conditions of assets, which are on an RFID transponder. The tag head made available to other systems. regularly transmits a status report to Fraunhofer experts in Magdeburg and the warehouse software or when it is Berlin have developed a special early retrieved by WLAN, GSM, ZigBee, etc. warning system, the so-called tag If the sensor values leave the defined head. This flexibly implementable unit security area, an alarm is automatically is outfitted with sensor, communica- transmitted and the relevant sensor tion, localization and RFID systems. values and the position are written on The sensors monitor temperature, the RFID transponder. humidity and vibrations. The tag head Communication technologies enable triggers an alarm when a preset limit interconnecting supply chain assets

autonomously rather than observing them singly. This establishes a connection between assets or to a central control station. The particular challenge is to expediently utilize the accumulating data for purpose of control.

Risk Management Creates Value Added The technologies behind the monitoring and control of goods and vehicles, secure transit of goods, direct monitoring and running inventories hold considerable potentials. This is not only an issue of security but also of cost. How long does transport take from unloading to receiving in the distribution center? What is the level of container utilization and can it be optimized? How can lost goods be relocated fastest? Does the driver even take the stipulated route? The tag head combines container condition monitoring and localization. RF solutions provide answers. Sensor systems provide an additional plus. For

26 IFFOCUS 1/2009 HOLD ONTO YOUR KNOW- LEDGE! WE’LL HELP YOU.

Finally, chains of goods can be fully secured Find out how others do it: with a clever combination of the latest RFID developments such as the RFID glove for docu- September 15, 2009 at MEVA in Haiterbach mented handling of goods and a delivery van October 22, 2009 at BMA AG in Braunschweig equipped with radio technologies. Photo: Dirk Mahler November 12, 2009 at Fraport AG in Frankfurt instance, critical components can be replaced by “intelligent components” or downtimes required by maintenance can be planned better.

The interplay of planning methods Learn how to implement knowledge management. and technology not only makes supply chains more secure but also more cost effective, reliable and transparent.

Contact: Helmut Röben Logistics and Factory Systems The free online portal with tips on implementation Telephone 0391 4090-485 including solution libraries, guidelines, checklists Fax 0391 4090-622 and case studies. [email protected] www.prowis.net ADVERTISEMENT Photo: MEV-Verlag The Latest from the LogMotionLab

Talking Systems, Transmitting Vehicles and a Thinking Assembly Table

Helmut Röben

The history of transportation is as old as humanity and a new chapter is added every year. A desire to observe transports from end-to-end has been driving the logistics industry worldwide for some time. The Fraunhofer IFF’s developments are making this reality. Innovative radio and video-based localization technologies facilitate continuously monitored routes, even when delivering replacement parts for industrial plants in remote regions.

28 IFFOCUS 1/2009 Waiting for the right moment entails replaced and, in particular, to gather the risk of missing it. Being able to information on a plant’s level of load foresee the right moment puts one on and wear. the safe side. Researchers at the Fraunhofer Institute for Factory The Plant Speaks Operation and Automation IFF know Providing a plant with localization best that this has nothing to do with technology and sensor systems makes magic. They employ the latest techno- it possible to localize faults and logies to predict specific scenarios that measure current conditions such as will take place in the future. temperature increases, pressure decreases or undesired vibrations. Help with Wear Radio modules transmit captured data Every system reaches its limit at some to a control station – the plant speaks. point. Plants succumb to wear. No The received information on the later than then, the moment has actual state must be utilized expedi- come to take action. What is to be ently. Logisticians are primarily aiming done though when a quick reaction is for one thing, i.e. to identify the ideal technically or logistically impossible or time to order and ship replacement when a replacement part is not in parts. stock or cannot be purchased and transported to the required location in When specific system components’ time? In such cases, operators may times of failure are known, the ware- wait, complain or hope, have good house system can be searched for luck or bad luck. The perfect solution replacement parts so they are avail- looks different though. Ideally, they able when needed. RF technologies intervene before damage occurs. This provide an overview and create a is where a new generation of mainte- transparent warehousing system. nance solutions comes into play, If the search is fruitless and a part is which interlinks identification and not in stock, an order process must be condition monitoring technologies. initiated. Everything here depends on the right moment too because the Technologies for Condition-based timing of the order normally deter- Maintenance mines the delivery date.

Foto: Dirk Mahler Medical checkups can save lives. The automotive industry also has good First Rate Lab reason for making recommendations Researchers in Magdeburg have been for maintenance. Components such as working in the field of condition-based spark plugs, engine oil, oil filters and maintenance managements for years. toothed belts wear out and must be They test the RFID, auto-ID and tele- replaced at regular intervals. Other matics applications they employ in components such as hoses and seals their LogMotionLab. One of Europe’s must be inspected regularly. leading development labs, Neglecting such important work and LogMotionLab houses most every components usually results in expen- identification technology that is sive major repairs. Therefore, regular commercially available or in develop- inspections assure safety, reliability ment – altogether more than forty and cost effectiveness not just in cars systems – on around 1,800 m2,. but also in complex industrial plants. Researchers in Magdeburg chiefly The technologies for condition-based work on new and special applications maintenance being developed at the of proven principles such as radio Fraunhofer IFF are a type of early frequency identification (RFID) and warning system. A combination of applied communication in distributed measured and empirical values networks. enables plant operators to infer when individual components must be

IFFOCUS 1/2009 29 Ultrasound localization can be used to excellently localize logistics assets in three dimensions, even outdoors. Photo: Dirk Mahler

Putting It to the Test conditions deliver sound information every package must be equipped with First and foremost, the researchers and data on the quality of a logistics a transponder. This enables the contai- have set themselves two goals this process supported by RFID. ner and its contents to “converse” and year. On the one hand, they intend to compare inventories. A telematic interconnect the sensor systems inte- Intelligent Container module with integrated GPS receiver grated in the LogMotionLab even fur- This has practical consequences. and wireless GSM simultaneously ther. On the other hand, they intend Model processes are set up in the monitors and localizes the box. Its to make them more utilizable for LogMotionLab to run as they would location can be retrieved in the mobile systems and vehicles in harsh under harsh conditions. Established Internet with the aid of map software environments, e.g. jeeps in the desert identification, localization and sensing or over the phone with a fully automa- or trucks in the Arctic. Extreme basic technologies are implemented. The tic language application. Sensors help climatic conditions confront the tech- “talking” system is the center of monitor the quality of the contents nologists with new challenges. Sand - attention. It reports a need for repair too. Thus, transported goods’ “state storms, searing heat or temperatures and initiates an order process, thus health” can be tracked. above 40 degrees Celsius demand activating the supply chain at the right quite a bit from sensors. Moreover, time. Transport chain monitoring helps Maintenance managers also know the heavy contamination, e.g. a vehicle’ goods reach their destination intact. location and condition of transported oily underbody, makes measurement This may be done by the IFF Smart replacement parts at any the time. difficult. The LogMotionLab’s test envi- Box, an intelligent transport container They know when they have reached ronment may be used to test different developed at the Fraunhofer IFF. their destination and whether they are RFID solutions under different physical intact. Naturally, they are also able to and organizational conditions. Integrated RFID antennas and a reader react to problems. Standardized and reproducible test based on HF radio waves enable the container to detect every loaded or The Wishing Table unloaded package and store the infor- For the first time, researchers from the mation in a database. To this end, Fraunhofer IFF are now able to also

30 IFFOCUS 1/2009 An RFID transponder was attached to a motor. Experimental setup of an order picking table. This intelligent solution could be applied The metallic environment is not a problem during in the mail order business for example. Photo: Dirk Mahler reading. Photo: Viktoria Kühne monitor the assembly of spare parts Better Safe than Sorry has limits though. Poor weather condi- once they have reached their destina- Precise radio localization is not neces- tions such as fog, rain and snow or tion intact. To do so, they have in- sarily precise enough. Whether simple objects that obstruct the view stalled a smart workbench – a high- because of unfavorable external condi- appear to constitute almost insur- tech assembly table that thinks for tions, unforeseen interfering factors or mountable obstacles. A combination itself – in the LogMotionLab. The the implementation of certain proce- of both localization systems provides a removal and installation of different dures, which deliver results that are remedy. Effective implementation of components may be documented by only precise to the centimeter, wishes such sensor data fusion is currently means of radio technologies. The table remain open, particularly outdoors. being field tested at Leipzig-Halle could also conceivably assume the role Magdeburg’s Fraunhofer researchers Airport. Researchers and practitioners of an assembly helper. Since it is able routinely advise anyone in need of intend to use it to more precisely to identify every individual component accurate results to combine radio and capture the situation at the DHL placed on its surface, the table is able video-based localization. Precisely this Logistics Hub. to recognize the overall situation. In mix of methods is being installed in other words, the table knows which the LogMotionLab as a prototype right www.logmotionlab.de work steps come next. It is able to now. support assemblers by starting the proper assembly video for instance. While radio technologies have primar - Contact: This requires equipping all components ily been used so far to localize and Helmut Röben with RFID transponders. The manage - identify assets in supply chains, images Logistics and Factory Systems able number of repair scenarios even integrate another dimension. Video Telephone 0391 4090-485 makes this attractive idea appear camera recordings are analyzed by Fax 0391 4090-622 financially feasible in maintenance differential image methods. The loca- [email protected] management. tion of assets can be determined with the results. They are identified by radio. Even video-based localization

IFFOCUS 1/2009 31 Breaking the Mold

Radio Technologies from Magdeburg Are Improving Internal Material Flows at a Foundry

Prof. Klaus Richter and Helmut Röben

When you say A, you must also say B. ALUNorf GmbH in Neuss has put this wisdom into practice. Actually, the foundry only wanted to implement a maintenance program with SAP R3/PM. Today, radio frequency identification (RFID) is transmitting from one end of production to another. The Westphalians are utilizing RFID technology to continuously track tools such as permanent molds. Since the data flows into the ERP system, maintenance managers know components’ condition and location at any time. Thus, searches on the plant premises are as much a thing of the past as undocumented permanent mold installation.

32 IFFOCUS 1/2009 Radio frequency identification (RFID) An Overview Thanks to ERP Soft- facilitates automatic identification of ware? individual items by radio waves at Companies rely on data processing short distance. More and more com- systems such as SAP for their produc- panies are implementing transponders tion planning and control. They map in manufacturing, warehousing and all the processes that occur in produc- logistics. The researchers at the Fraun- tion. Meticulous system maintenance hofer Institute in Magdeburg were is the prerequisite through. The themselves initially skeptical that structures mapped in SAP provide a transponders would even function in view of the current status of any such a raw environment as an alumi- process, piece of equipment or tool num remelt plant but their pilot and is thus the best foundation for project “RFID Technology for Perma- functioning and efficient maintenance nent Mold Tracking” dispelled any management. doubts. Manufacturing operations are too What do a commercial kitchen and a complex to always represent easily. foundry have in common? At first The situation becomes problematic glance, the differences couldn’t be whenever equipment or tools change greater. Yet, some parallels exist too: their location in a company. ERP soft- heat, grease, noise and production ware does not register this on its own. that is heavily dependent on a Employees in the shop or warehouse functioning flow of material and must enter the new locations goods. Whether flour or metal, both manually. must be at the right place at the right time so that the result is right. Forklifts, tractors and permanent molds are examples of such tools or Comparable Operations equipment that change location. The Intralogistics is an integral element of latter are foundry tools for melting reliable, continuous production in aluminum bars. Anything but delicate, every enterprise. Material flows in the they are nonetheless sensitive and foundry or metal processing industry therefore must be serviced routinely. do not fundamentally differ from SAP helps here. The traceable history those in manufacturing companies in in the system serves as a basis to keep other sectors. In every case, materials the schedule of and perform certain are delivered, processed and subse- maintenance and inspection work quently shipped as semi-finished or based on usage. For instance, perma- finished products. In turn, certain nent molds must be cleaned and tools are needed to process the recoated after a specified number of materials. The organization of the founding processes. Problems that optimal internal flow of materials and occur at a permanent mold can be Photo: Slamek/PIXELIO goods depends on this as well as on documented in the SAP system. The company size or the number of mold is barred from ongoing produc- facilities. If one intends to systemat- tion from this time onward and trans- ically control the flow – and that ferred to the shop for maintenance. ought to be the goal – one must fulfill several conditions. Minor Errors and Great Impacts The basis of every action is the plant First off, coordinators of intralogistics maintenance (PM) job order, which is and maintenance should be aware of used to enter or forecast maintenance every unit’s condition. They also ought work, requirements and maintenance to be able to externally update or and inspection job orders in the ERP control them. This is important in system. This is the basis for the main- critical situations in particular because knowledge is useless if one is unable to intervene in an emergency.

IFFOCUS 1/2009 33 tenance processes mapped in the ERP in the ERP system, erroneously plan- Maximum read ranges of three meters system. These processes are based ning inevitably results. Equipment and must be bridged. In addition, a solely on manual entries and this is the tools must be registered automatically permanent mold is routinely subject to critical point. After all, there are so that maintenance work is temperatures of up to 60 °C, dirt, situations in which the real world continuously monitored and thus water and oil and diverse impact loads departs from the virtual world, e.g. consistently performed. This is where when installed and removed. when a foundry job order with a parti- the automatic component tracking cular permanent mold is entered into solution developed at the Fraunhofer UHF RFID systems specially adjusted to the system but cannot be completed Institute in Magdeburg takes effect, the environment are able to meet the because the permanent mold is un- which ALUNorf implemented in a specific demands these conditions available at the appropriate time or a foundry for the first time. It is based place on the hardware. The passive permanent mold of the same type is on identification, localization and transponders installed on the perma- available faster. These changes must hybrid technologies. nent molds must have a housing that be added manually. Who should do resists water and oil. A strong metal this though? This necessitates training The ALUNorf GmbH Pilot Project frame provides protection against every employee in system entry, which Permanent molds are transported mechanical loads. All the reader entails considerable time. back and forth between permanent systems and antennas are integrated mold storage, the shop and the in the less vulnerable infrastructure. Locating a Permanent Mold remelt plant with the individual Since important updates such as pouring stations. Permanent mold Doors Can Read permanent mold exchanges are often shelves for temporary storage are The permanent mold flow begins in not entered, errors with serious conse- located between the pouring stations. permanent mold storage whence the quences slip into the system. Since the Continuous tracking of the permanent tool may only be transferred to the maintenance department plans its molds necessitates registering their shop or loaded onto a tractor with a processes on the basis of the entries transfer from one place to another. trailer for permanent molds. RFID reader systems at the doors capture and document their transit. The data enters the ERP system and the SAP system is informed.

An RFID system installed on a tractor and connected to the ERP system by WLAN registers when the trailer for permanent molds is loaded. Thus, a permanent mold can also be allocated to a tractor during its entire transport over the plant premises. Since a tractor with a trailer for permanent molds is mobile, the current location of the permanent mold-tractor aggregate is missing when said aggregate is allocated. A WLAN localization process allocates the aggregate in space. Thus, a permanent mold’s current location can be indirectly determined by the tractor’s location. This hybrid technology can be used in the ERP system to continuously track a permanent mold’s location. If the tractor-permanent mold aggregate is separated again, the last known location coordinate of the tractor is binding for the current Work meeting in permanent mold storage. location of the permanent mold. This Photo: Martin Kirch enables allocating permanent molds in space. Thus, even permanent molds

34 IFFOCUS 1/2009 temporarily placed in buffer zones are always locatable. If, on the other hand, a permanent mold is stored in a GUEST LECTURE SERIES rack for permanent molds or installed in a pouring station, then its new VIRTUAL REALITY: HUMAN AND location is registered by the UHF RFID systems installed in these stations and MACHINE IN INTERACTIVE transmitted to the ERP system. DIALOG Systematically Supplying the ERP System All data are transmitted to a central OCTOBER 28 - DECEMBER 2, 2009 localization server, processed, filtered, formatted and exported to the ERP system. This guarantees that only relevant information is exported through an interface to the ERP system and prevents a needless flood of data. In addition, the systems store only a very limited component tracking history. The last known location is guaranteed to always be available when a fault occurs.

Outlook ALUNorf GmbH has already been convinced by the use of RF supported component tracking. Standardized, online and always up-to-date component information has had positive effects, reduced cracking rates, ex- tended maintenance intervals, less maintenance and lower costs being but a few.

This system provides the basis for potential expansion to equipment such as tractors and coils as well as products such as aluminum bars. This is another challenge for the researchers at the Fraunhofer IFF. It represents all sorts of potential for foundries and other industrial companies.

Contact: Prof. Klaus Richter Material Handling Engineering and Systems Telephone 0391 4090-420 Fax 0391 4090-93-420 [email protected] ADVERTISEMENT tions tothisproblem rightnow. Its lo forestry would betoogreat.Theutilization ofresidualbiomass furnishesawayout. forests fromintensiveutilization aswellcompetitionwithagricultureand appear tobethemagicformula inresponsethough.Lastingdamageto Utilizing biomassforenergy conversiononagrandscaledoesnot oil ismakingnewapproaches toenergyrecoveryimperative. The depletionoffossilenergy sourcessuchascoalandcrude and Dr.InaEhrhardt Prof. MichaelSchenk,SebastianTrojahn Foto: Helmar Tepper Innovative LogisticsConceptsforConverting EnergyfromResidualBiomass Intelligently Green gistics isdifficult though.Magdeburg’s FraunhoferIFFisdeveloping innovativesolu- Biomass Protects the Climate tion of agricultural lands to produce and Material Handling Systems at Plant biomass is hotly dicussed as the biomass for energy recovery is just as Otto von Guericke University and the energy source of the future. The “old questionable. Max Planck Institute for Dynamics of fashioned” energy source wood has Complex Technical Systems has been been regaining its attractiveness since Residual Biomass as an Alternative at work in Magdeburg under the lead the world became aware that crude Therefore, a hunt for alternatives is management of the Fraunhofer IFF oil is actually a finite resource and fully underway. One alternative is the since the start of 2008. Their joint thus sets clearly discernible limits on utilization of residual biomass, i.e. a project is called NEWE, an acronym our current energy supply concept. multitude of hitherto largely ignored for “Netzwerke elektrochemischer The nearly omnipresent old great new plant residues and wastes from agri- Wandler in der Energieerzeugung” hope feeds energy suppliers’ fantasies culture, forestry and landscape (Electrochemical Converter Networks of a virtually unlimited raw material conservation and botanical material in Energy Conversion). Financed with that is constantly available, is renewa- that would otherwise be unutilized Excellence Funds from the state of ble and has a positive life cycle analy- and disposed of. The variety is Saxony-Anhalt, NEWE deals with lo- sis. When it is burned, plant material substantial and includes hay, straw, gistics processes that efficiently supply such as wood only releases as much bark, roadside vegetation cuttings and the energy source biomass. The CO2 as it has absorbed and stored private residual wood. The develop- common focus in this ambitious during its growth. Thus, unlike energy ment of new technologies to utilize project is the effort to make biomass recovery from crude oil or coal, ad- this material for energy conversion is available for hydrogen production. ditional CO2 does not enter the just about ready for implementation. Afterward, it will be supplied to atmosphere. sustainable utilization in fuel cells. The The researchers at Magdeburg’s goal of these efforts is a maximally According to the Federal Ministry for Fraunhofer Institute believe that a positive energy balance when they the Environment, Nature Conservation large part of the biomass for energy start utilizing biomass for conversion and Nuclear Safety, the percentage of recovery could be obtained from this into electrical power or heat. The renewable energies in Germany’s rich pool of residual material in the research organizations’ are pooling gross energy consumption nearly future. The energy recovered from the their different overlapping fields of tripled from 1992 to 2007 and is now quantities of available residual straw expertise in this promising collabo- above 14 percent. More than one alone could cover approximately six rative effort. quarter of this is recovered from percent of Saxony-Anhalt’s primary biomass. Among other things, easy energy requirement. If one projects The Fraunhofer IFF already has con - availability and rising energy and raw this on the total potential of all siderable know-how in the field of material prices are also responsible for residual biomass, one can imagine timber and biomass logistics. Its this positive development. They alone how many natural renewable energy logistics experts have been working have made biomass a cost effective resources still remain unutilized on the sustainable supply of raw energy supplier at present. In addition, material for several years. They have technologies that recover energy from Difficult Logistics already organized existing supply biomass have steadily advanced. Their The difficulty lies not only in the tech- processes more efficiently and further growing efficiency improves the nology needed for recovery but also in developed service provider models to chances of sustainably establishing the often widespread and partly very utilize raw wood. Together with biomass recovery to generate energy. small yield of such residual biomass. partners from the industry and forest Only its sum reveals its true potential. management agencies, they are Limited Potential Finding, structuring, collecting and working on innovative strategies to Despite all the advantages this tech- supplying it to maximally effective supply residual biomass in the future. nology brings, this valuable resource’s utilization constitute a profoundly Their experience in the field of timber potential is limited because it is not complex job, especially when one logistics is specialized knowledge, infinitely available. So far, it has been considers that the total work required which is sought after to provide obtained primarily from raw wood or for this effort may not devour more support when economically and eco- agricultural crops. Thus, it directly energy and money than may be gene- logically justifiable biomass supplies competes with material recovery from rated with it. are being operatively planned. timber and the food industry. However, intensified raw wood utiliza- Success-oriented Cooperation tion is inconsistent with ecologically Given this situation, a joint research sustainable forestry. Intensive utiliza- group from the Institute of Logistics

IFFOCUS 1/2009 37 Innovative Logistics Concepts collaboration based on the current recovered residual biomass are of One of the many problems is the market situation and the logistics particular interest. They determine the different ownership structures and work required. The goal is to organize type and quantity of raw material that microstructures confronted when the route from the site of origin up may ultimately be developed economi- dealing with residual biomass. Few through processing so efficiently, cost cally justifiably and supplied to contin- large and a multitude of smaller effectively and ecologically justifiably uously operate the plant. Above all, communal and private suppliers are as well as profitably for the stake- safeguarding sustainable, economic offset by a variable number of trans- holders involved as possible. and ecological factors such as the life port providers and potential end cycle analysis and the CO2 balance will buyers such as biomass cogeneration Life Cycle Analysis Counts be important for the construction of plants. Ultimately, it is essential to Together with partners such as the future power plants. “Nobody,” efficiently interconnect all of them so Deutsches Biomasseforschungs- according to Holger Seidel, Manager that the system of closed natural zentrum, Saxony-Anhalt’s Center for of the Logistics and Factory Systems resource utilization also functions. Renewable Energies and Otto von Business Unit Fraunhofer IFF, “is going Guericke University Magdeburg, the to be interested in a power plant at The Fraunhofer IFF considers one of Fraunhofer IFF is working on develop- the wrong site or in an incorrectly the main tasks for this to be the ing optimal biomass logistics sized power plant that is actually evaluation and specification of the concepts. Among other things, this much too large for the relatively small available base of data such as the includes optimally siting a biomass amount of biomass that can be justi- quantity, quality and geographic loca- cogeneration plant, while factoring in fiably drawn from the surrounding tion of the biomass yield. Afterward, the existing transportation infrastruc- region.” this is supplemented with logistically ture. The properties of the potentially relevant factors, e.g. infrastructure, equipment requirements and costs. On this basis, the researchers finally develop appropriate planning methods, i.e. models and processes for later organization of strategic and operative processes. This is intended to enable the relevant stakeholders to know in the future where and when what type of residual biomass is yielded, what its current value is, who is offering it, who potential buyers for it are and ultimately also which service providers will take over its transport. This is a tremendous challenge that also entails the development of suitable solutions that localize the smal- lest regis tered quantity of hay on an open field or timber residues in the middle of a forest for instance.

Such solutions require open systems for distributed partner networks in which all the stakeholders in the recovery processes engage or dis- engage depending on their interests. This is important because the entire process ultimately consists of sensitive interaction between providers and service providers. Everyone involved will be able to choose their form of

Fraunhofer expert Dr. Ina Ehrhardt develops smart technologies for biomass logistics. For instance, luminescent nanoparticles can be utilized to identify different residual timber. Photo: Viktoria Kühne

38 IFFOCUS 1/2009 Distributed Energy Supply Sustainable Biomass Utilization residues is difficult for the industry. The biomass’s relatively low energy Naturally, energy recovery from re - Immediate energy recovery is certainly density is the primary impetus for the newable raw materials is exceptionally profitable. Material recovery, e.g. construction of only small distributed environmentally compatible. Classic processing in the furniture industry, is energy conversion plants in the single biomass is growing scarce however. at significantly more sustainable. As digit megawatt range. Supplying best, it was composted in agriculture Business Unit Manager Holger Seidel larger power plants with biomass and forestry earlier; it will be quite reports, researchers at the Fraunhofer would require transporting large valuable in the future. Therefore, in a Institute for Factory Operation and quantities of it from ever greater joint research project, experts from Automation IFF and their international distances. Such effort would no Saxony-Anhalt and Valencia in Spain partners are jointly developing new longer be worthwhile because of the are analyzing methods to profitably processes and technologies for just higher costs. Therefore, the specialists recovery material from biomass this. Since industrial utilization neces- from the Fraunhofer IFF’s Process and residues. siatates sorting the different plant Plant Engineering Business Unit advo- residues and sorting requires identifi- cate distributed solutions for biomass Saxony-Anhalt primarily has residues cation, his researchers are working plants. Since they are operated with and waste from landscape conserva- interdisciplinary on smart concepts for renewable resources from the vicinity, tion. Valencia on the other hand has biomass logistics. A look at any they constitute an important step large quantities of biomass from the gardener’s compost heap and the toward a sustainable and nevertheless cultivation of olive and orange groves. unbelievable variety of different plant region-wide energy supply. The plant residues hold tremendous residues it contains are enough to potential. Unfortunately, standardized convince anyone that this is no easy and low cost recovery of these diverse task. In the Fraunhofer researchers’ vision for the future, residual timber could be equipped with RFID labels or green waste yielded during landscape conservation marked with luminescent nanoparticles. Once the precise biomass has been identified, a decision can be made about its intended use.

Limbs and branches can be processed into tons of woodchips or pressed into particle board for a furniture manufacturer. Even its use as insula- tion or as an additive in concrete parts is conceivable. The supply chain may be reorganized and monitored ac- cordingly from harvesting to storage and transport up to the final place of utilization.

Contact: Dr. Ina Ehrhardt Logistics and Factory Systems Telephone 0391 4090-811 Fax 0391 4090-93-811 [email protected]

Saxony-Anhalt Minister of Agriculture and the Environment Petra Wernicke and Deputy Director Dr. Gerhard Müller at the opening event at the Fraunhofer IFF. Photo: Viktoria Kühne

IFFOCUS 1/2009 39 Harz Power

An Entire Region Is Pursuing One Goal: A Renewable Energy Supply Photo: P. Kirchhoff/PIXELIO

Prof. Zbigniew Antoni Styczynski, Dr. Przemyslaw Komarnicki and Dr. Gerhard Müller

Until now, there have been few direct points of contact between energy efficiency and information and communication technologies (ICT). However, this is changing right now. The E-Energy support program launched by the federal government is aimed at intelligently uniting energy conversion, distribution, consumption and trade with ICT. Concrete structures are being tested by expert teams in six model regions throughout Germany, including the “Model Renewable Harz Region”, which intends to launch model solutions that link energy and communication networks by 2012. Attention is focused on the utilization of different renewable energy sources and controllable loads, which will be united in virtual power plants.

40 IFFOCUS 1/2009 On the one hand, our climate is system facilities and the millions of A Small Town with Big Goals changing, energy demand is mounting power-consuming terminals. The small town of Dardesheim is in and fossil fuels are running out. On the center of the model renewable the other hand, renewable energy This is where the E-Energy support Harz region. It is pursuing an ambi- sources have nearly inexhaustible program endowed with a total of 140 tious plan. In the medium term, it potential. Everything ought to be fine million euros comes into action. Six intends to supply more than 250,000 and the energy issue resolved, projects are developing model solu- residents with renewable energy. shouldn’t it? Deceivingly simple at first tions that will link energy and Roughly two thirds of the energy now glance, the situation demands more communication networks by 2012. consumed in the rural county is complex solutions. Ultimately, the A key point in all the projects is the already obtained renewably. The mix energy supply must be organized cost creation of market platforms for of wind power, solar energy, water effectively and environmentally residential and commercial customers power and biomass is considered compatibly in the future too. supported by ICT. Interdisciplinarily exemplary. Some forty wind energy assembled teams of experts are converters are in operation atop the Power plants always supply as much developing and testing ICT products, Druiberg on the outskirt of town. power as industry, households or methods and services intended to Biogas plants, solar cells on the roofs other consumers need at the moment. increase energy efficiency and supply of schools, preschools, businesses and Conventional power plants do this certainty and strengthen climate residences, a 5 MW cogeneration largely with nuclear power, lignite, protection. The Fraunhofer Institute plant operated with vegetable oil and water power, anthracite or natural for Factory Operation and Automation a renewable power charging station gas. Peaking power plants (e.g. and the Department of Electrical complete the picture of the model pumped-storage power plants) kick in Power Systems at Otto von Guericke energy town. The project “Model in an emergency. Renewable energies University Magdeburg are two of Renewable Harz Region” is intended are gaining momentum though. In nineteen consortium partners in the to further increase the share of re- 2007, they already accounted for 32 model project “Model Renewable newable energies while guaranteeing percent of the power generated in Harz Region RegModHarz”, the Harz cost effectiveness, supply certainty Saxony-Anhalt. According to the State region being the only model region in and environmental compatibility. Statistical Office, nearly every third eastern Germany. kilowatt hour is obtained from renew - able energies. However, precisely predicting sun, wind and heat is difficult. They supply power as a function of the weather. Does that mean every mill needs to be backed up by a power plant at the ready when they subside? Are renewable energies at all able to flexibly respond to fluctuating demand? Combined renewable power plants are considered the solution. When they are smartly interconnected, wind, sun and biogas mutually compensate each other’s fluctuations during production.

Energy Internet Assuring a green and stable supply of electrical power from its generation to distribution through its consumption is the crucial challenge for the future. Information and communication technologies (ICT) will play a key role. They will support a so-called “Energy Internet” in which many generation Dardesheim is 1500% renewable. In 2007, fifteen times the local demand for power, heat and plants communicate with power fuel was produced from indigenous renewable energies, partly in Druiberg wind park. Photo: Energiepark Druiberg GmbH.

IFFOCUS 1/2009 41 Perfect Interaction Quedlinburg, Halberstadt and together by means of online data The key element for the residents of Blankenburg are the partners. They acquisition. The combined renewable the Harz on their way to an energy are making the entire transmission power plant’s control center receives supply without fossil resources is a system of the 380 KV high voltage to near real-time information on the combined renewable power plant. low voltage grid available to the situation in the region. This complete Modern information and communica- project. The populace is also cooper- overview of generation, storage and tion technologies will collect informa- ating. Regional acceptance of the consumption facilitates forecasting. tion on all renewable power genera- project is very high. The benefit is the ability to utilize tors and consumption data. This will renewable energies optimally. allow adjusting consumption to the Virtual Combined Power Plant supply of renewable energies at any ICT are being implemented to Wash When the Wind Blows time and vice versa. In conjunction optimize the overall electricity supply The Harz virtual combined power with an innovative online network, it system from generation to transport plant intends to break new ground in will provide the generators, traders, and distribution up through consump- efficient energy use. Not only the power system operators and custo- tion. The heart is a virtual combined output of the energy generators but mers involved an ecologically and power plant that optimally combines also the energy consumption of volun- economically optimized energy supply the advantages of the different re- tarily cooperating consumers shall be up through full supply. Power system newable energies. The main challenge registered and coordinated. The goal operators Vattenfall Europe Trans- is how to intelligently bring renewable is to adjust variable power consump- mission and E.ON Avacon and energy generation, power con- tion to supply. In other words, con- municipal utility companies in sumption and storage technology sumers could turn on their washers or dishwashers manually or automatically when the wind is blowing or the sun is shining strongly.

A Giant Battery One important part of the project is the pumped-storage power plant at Rappbode dam in Wendefurth, which already provides considerable storage potential. It is able to inter mediately store excess renewable power practically like a giant battery – theoretically the entire output from twenty- four hours. The excess power can be used to pump water from the Bode River into the upper reservoir built in 1967. If the water is needed again, perhaps because the air is still at the moment, it can flow back into the valley and drive two 40 megawatt turbines. Thus, generated power returns to the network.

Cars as Energy Carriers Electric vehicles could be instrumental in further stabilizing the grid in the future. Since ICT facilitate data exchange, such vehicles will primarily The energy independent town of Dardesheim. The residents of the Harz region are pursuing their charge with excess wind or solar goal with all their power. They are breaking pioneering new ground in order to supply the roughly power. Since a car is normally driven 250,000 residents of the rural county exclusively with regionally produced renewable energies such no longer than forty minutes a day, as wind, biomass, water power, solar energy and geothermal. All the strands merge in the “Energy Internet”, which links supply and demand as well as generators and consumers. enough time remains to connect Photo: Energiepark Druiberg GmbH mobile batteries to the grid.

42 IFFOCUS 1/2009 The two pumped-storage power plant connecting pipelines/canals discharge in the power- house with two pumped storage/turbine sets apiece with 40 MW of power. For more information, visit www.energiepark-druiberg.de. Photo: Energiepark Druiberg GmbH.

If, for example, an excess of wind supply, cars may be used as energy power were produced and were carriers. Such concepts are also therefore particularly inexpensive, being researched in the project a car could charge green power. RegModHarz. In addition to a If there were a lull and not even vehicle’s function as a storage the sun were shining when demand system, the Fraunhofer researchers is high, the battery would simply are also studying load management feed its power back into and thus options. The approach behind this stabilize the grid. entails only charging vehicles at times that are ideal for the power The scenario described is also system. To this end, the e-mobility discussed as an “electromobility experts in Magdeburg will be devel- concept”, i.e. locomotion with oping and testing system services vehicles with powerful rechargeable that integrate electric vehicles in the batteries and operated with elec- power supply system. tricity from the power distribution network by means of so-called plug-ins, which treat the con - Contact: sumption and supply of electrical Dr. Przemyslaw Komarnicki power independently from one Process and Plant Engineering another. Thus, electricity from the Telephone 0391 4090-373 distribution network may be stored Fax 0391 4090-93-370 and utilized for driving at a later przemyslaw.komarnicki@ time or fed back into the distribu- iff.fraunhofer.de tion network. When such plug-ins are integrated in the electricity ADVERTISEMENT IFFOCUS 1/2009 43 Sharp Minds … with doctorates

Research Marketing with an Marie Curie paid the deposit for me. Athletic Spirit Program Facilitates That made me very happy because time was very tight Early Careers and I didn’t have to hunt Erik Dietzel earned his for a room first.” It was degree in industrial engi- He earned his undergrad- quite obviously a good neering from Magde- uate degree in Budapest choice; the young doctor is burg-Stendal University but his doctorate in Magde- still living there three years of Applied Sciences in burg. Dr. Tamás Juhász later. Evenings, he likes to 2001. When he was still traveled to his homeland of meet up with friends and an undergrad, he acqui- Hungary to defend his colleagues. They go to the red his first professional dissertation on “Object- movies together or hit the experience developing oriented Simulation in bars around Hasselbach- the regional sales area Mechatronics” where the platz. “It’s too bad that the for a major nursery. examination committee night life isn’t closer to Later, he freelanced at a awarded him the highest campus though. It’s rare law firm. His path first grade possible. Born in that something is going on led him to the Fraun- Miskolc in 1980, Tamás here in the evening,” says hofer IFF as a student Juhász’s undergraduate the computer scientist. assistant in 2000. After studies drew him to the graduation, the market- Hungarian capital. The Dr. Juhász is very happy ing expert took up a computer science major with his research work. In more responsible posi- wrote his Diplom thesis on the project ViERforES, he is tion. Dietzel managed the simulation of mobile primarily working on auto- the business of the robots in 2003. Afterward, motive engineering. “That’s Forschungs- und Ent- while already a doctoral really great. I always Erik Dietzel. Photo: Dirk Mahler wicklungszentrum candidate at the Technical wanted to do something in Magdeburg. Finally, he University of Budapest, a that field,” says the pleased The Fraunhofer IFF has had came to the Fraunhofer Marie Curie Fellowship twenty-nine year old. He a new marketing manager Institute in 2009 as its from the European Union would also like to remain since the beginning of the marketing manager. brought him to the Fraun- true to applied research in year. A native of Magde- Along with his volunteer hofer IFF in Magdeburg in the future too and work in burg, Erik Dietzel is enjoy- work for a Lutheran 2006 where he worked in Magdeburg for a while ing the wide ranging chal- congregation in Magde- the Virtual Engineering longer. He reveals his lenges. He provides burg where he looks Expert Group. Today he is dream: “I’m taken with Fraunhofer researchers after the finances as a working at the Center for Fraunhofer. Maybe there support when they show- member of the church Digital Engineering currently case their services at trade council, Erik Dietzel under development in the shows or when they visit teaches marketing at project VIERforES. The companies. The industrial Magdeburg-Stendal Fraunhofer IFF and Otto von engineer is increasingly University of Applied Guericke University in directing his energy toward Sciences. When he finds Magdeburg jointly opened conceiving and organizing time, Erik Dietzel has a the academic center on events that particularly great deal of athletic March 30, 2009. address potential clients. spirit. He has been a Erik Dietzel intends to meet passionate tennis player Dr. Tamás Juhász enjoys the special challenges of for thirty years and is being in Saxony-Anhalt’s research marketing at the training for the Magde- capital . He was impressed Fraunhofer IFF with custom- burg marathon. Erik when he arrived in Magde- ized marketing concepts. Dietzel is a family man. burg: “Everything had He lives with his wife already been prepared. My and two daughters in Fraunhofer colleagues had lovely Biederitz on the found a nice place for me outskirts of the capital. to live and had even already A fellow in the EU’s Marie Curie Program, Dr. Tamas Juhasz earned his doctorate. Photo: Viktoria Kühne

44 IFFOCUS 1/2009 will be a Fraunhofer Insti- Always On the Move tute in Budapest one day too. I’d like to be part of Prof. Klaus Richter has joined the that.” ranks of professors at Otto von Guericke University Magdeburg. The Always Focused Fraunhofer researcher was officially appointed supernumerary professor on His Goal at the meeting of the Advisory Board of the School of Mechanical Engi- Daniel Reh beams from ear neering in June. Prof. Richter will to ear. He just successfully now also take on work at the Insti- defended his doctoral tute of Logistics and Material Hand- dissertation. The likeable ling Systems (ILM). logistician can be proud of the outcome. He was The native of Dresden spent his awarded “magna cum youth in the chemical region of laude” for his dissertation. Merseburg and came to Magdeburg For nearly three years, Dr. to become a mechanical engineer. Reh wrote it alongside his Richter earned his doctorate from Dr. Daniel Reh on his way to the traditional doctoral daily project work at the ceremony at the monument to Otto von Guericke. the Department of Material Handling Fraunhofer IFF. Dr. Daniel Photo: Anna-Kristina Wassilew Systems at Magdeburg Technical Reh’s area of specialization College in 1985. After a brief stint is risk analysis in logistics where many members of his family worked in industry, Richter returned to re- processes. He also made influenced Daniel Reh. He completed several search in 1991 and came to the this the topic of his disser- internships there. He was drawn to Magde- Fraunhofer IFF in Magdeburg in tation, writing on the “De- burg for his undergraduate studies because 2000. Today, he manages the re- velopment of a Method- he could major in the industrial engineering searchers in the Material Handling ology of Logistical Risk program in logistics, which was new and Engineering and Systems Expert Analysis in Manufacturing unique in Germany in 1997. The student Group. The researcher with a and Supplier Networks.” belonged to the first class, was one of the mischievous grin manages projects Countless long nights and a first graduates and is now the first to earn a intended to make train stations and period of abstinence from doctorate. airports more secure. The tracking the pleasure of friends and of logistics assets is one of Richter’s family followed. Free time When he started at the Fraunhofer IFF in special topics. He researches tech- was a real luxury. When the 2002, the talented young researcher knew nologies that enable us to know examination committee from the start that the road to his goal would where a package is at any given allowed him the last word, be rocky. He was involved in industry projects moment day or night. he thanked his advisers in the Logistics and Factory Systems Business Prof. Schenk and Prof. Sihn, Unit from the beginning. Dr. Daniel Reh is an Whenever his extensive work occa- his colleagues, his family enthusiastic Fraunhofer employee: “Young sionally allows a little free time, Prof. and everyone who had staff members are given a great deal of Richter enjoys skiing but he’s still supported him. Above all, responsibility right from the very first day. The thinking about logistics even then. Daniel Reh thanked his girl- mix of research and practice provides great With his project partner Abatec, he friend “for her understan- variety.” Now the manager of seven research developed an RFID system that uses ding when I wanted to be associates and ten students, Dr. Reh can electromagnetic waves to analyze alone with my computer imagine working at Magdeburg’s Fraunhofer the direction and motion sequences more often than with her.” Institute a while longer. of skiers with absolute precision. This smart system is also now being A doctorate was always the First, Dr. Daniel Reh is looking forward to a bit employed in other sports. Prof. stated goal of the man more free time. Whether a kite surfing course Richter has also outfitted other from Lower Saxony. Dr. Reh or his planned tour of Canada next summer – professional athletes such as the was born in Gifhorn near he is drawn to the outdoors. He is also looking handball players on Magdeburg’s Wolfsburg in 1977. The forward to spending time with his family, his team SCM. proximity to Volkswagen friends and, naturally, his girlfriend.

IFFOCUS 1/2009 45 Sharp Minds

Researchers, Thinkers and Inventors: Magdeburg Launches Its Research Campaign

Magdeburg has evolved researchers’ research work Science eight years later. into an outstanding center and achievements. A Today, the institute is the of research and many out- brochure with the collected research hub for many standing researchers live researcher profiles will be programs in the federal and work in the city on the appearing soon, followed government’s high-tech Elbe. They are spreading by a large exhibit of photos, strategy. Magdeburg’s name throug- panel discussions and much hout the world with inter- more. Four researchers Prof. Klaus Richter was just national research studies from the Fraunhofer IFF are recently appointed profes- and global activities at part of this. sor at the university. conventions and conferen- Prof. Michael Schenk is “Precisely in light of the ces. The city marketing simultaneously the insti- urban development on the association ProMagdeburg tute’s Director and the Elbe, Magdeburg has deve- is working to make the Managing Director of the loped tremendously and people in Magdeburg Institute of Logistics and will increasingly be per- aware of this. Its new Material Handling Systems ceived as a successful and at Otto von Guericke future-oriented center of University. In his profile, research and business with Schenk related the stages an optimal infrastructure,” of the Fraunhofer IFF’s according to the researcher development from its start in his profile. Prof. Richter in a rundown building in then reported on the latest Prof. Klaus Richter manages the Material Handling Engineering and the Buckau neighborhood investments mad by the Systems Expert Group at the in 1991 to the move to the Ministries of Transportation, Fraunhofer IFF. new building on Sandtor - Economics and Education strasse in 1998 to the and Culture’s in Europe’s Dr. Norbert Elkmann is opening of the Virtual most important and most responsible for the biggest Development and Training innovative satellite naviga- industry project at the Centre in the Port of tion system Galileo. Fraunhofer IFF, the development of a sewer inspection Marco Schumann manages the system in the form of a Central Offices of ViVERA/ fleet of robots for the AVILUSplus and ViERforES at Emscher sewer system. Magdeburg‘s Fraunhofer Institute. “The robots take detailed campaign “Researchers for measurements in inacces- Magdeburg” is intended to sible areas and clean the introduce researchers who sewer. The systems are are very well known in the unique; the Fraunhofer IFF research community is years ahead of the global through their work. Few competition. The native of residents of Magdeburg are Wiesbaden has never re- aware of how many sharp gretted taking the step of minds are working on the coming to the state capital. de velopment of our future “Today, I’m proud to come world at their research from Magdeburg,” reports organizations. the researcher who has The campaign started in been instrumental in the June with a series of pro- Fraunhofer IFF’s develop- files in the Magdeburger ment, particularly the field Volksstimme. Every day, the of robotics, practically from daily newspaper published the start. a lengthy report on the Prof. Michael Schenk is the Director of the Fraunhofer IFF. Photos (4): Dirk Mahler

46 IFFOCUS 1/2009 Marco Schumann spent a major part of his academic career at the Fraunhofer IFF. He came to Magdeburg’s Fraunhofer Institute in 1995 as a student. Today, the native of Halberstadt manages three of the most important projects in the field of virtual and augmented reality. “I’m incredibly happy to have been able to support and be part of the development of the field of virtual reality from the start,” the researcher relates.

Pro Magdeburg carried out several domestic marketing campaigns in the past and promoted a sense of identity and identification with our city. The campaigns introduced residents of Magdeburg who exemplify Magdeburg’s positive development.

Dr. Norbert Elkmann manages the Robotic Systems Business Unit at the Fraunhofer IFF. ADVERTISEMENT Gallery

Field test at Leipzig/Halle Airport: Together with its project partners, the logistics experts at the Fraunhofer IFF are developing state-of-the-art systems that determine the position of logistics assets. This makes supply chains more secure and reliable. Logistics hubs with the latest localization technologies will have intelligent management systems in the future.

48 IFFOCUS 1/2009 Photo: Dirk Mahler

IFFOCUS 1/2009 49 Gallery

50 IFFOCUS 1/2009 Photo: MEV-Verlag

Every second counts in an emergency. Detailed security concepts and reliable emergency management are in demand precisely wherever many people are underway, in train stations or at airports for instance. Response teams must be coordinated in an emergency. However, dangerous situations can be assessed much better with prior knowledge of the development of pedestrian flows. This not only improves preparation for an emergency but also enables preventing certain dangerous situations entirely. Researchers from Magdeburg’s Fraunhofer IFF are working on concepts for increased security in the project VIERforEs.

IFFOCUS 1/2009 51 Gallery

52 IFFOCUS 1/2009 Photo: Dirk Mahler/Eon Avacon AG.

The Fraunhofer IFF hosts Jugend forscht: At the state competition in Magdeburg in April, sixty-one young researchers with thirty-seven exciting projects strove to win a ticket to the national competition. Elisabeth Hahn (14) and Anna Victoria Behr (17) from Halle were thrilled to take first place in the chemistry category. They developed a light pen that quickly checks the vitamin C content of food. Jugend forscht is clearly a source of inspiration. This was Elisabeth Hahn’s second win at a state competition.

IFFOCUS 1/2009 53 Upcoming Events

Meet up with researchers September 17-18, 2009 October 22, 2009 Editorial Notes from the Fraunhofer Insti- Virtual Technology ProWis-Connect North: tute for Factory Opera - Innovation Alliance Status Knowledge Management IFFOCUS 1/2009 tion and Automation IFF Conference with Corporate Presenta- This magazine appears biannually at these events: Magdeburg tions and is available free of charge to Braunschweig clients, partners, staff, members August 19, 2009 September 17-27, 2009 of the media and friends. Symposium on Dentistry 63rd International Motor October 28 – December 2, through the Ages Show IAA 2009 ISSN 1862-5320 Magdeburg Frankfurt am Main Virtual Reality Guest Lec- ISBN 978-3-8396-0042-9 ture Series: Interactive August 24-26, 2009 September 23, 2009 Human and Machine Publisher International Railway EMPASIA Best Practice Magdeburg Fraunhofer Institute for Factory Equipment Exhibition Conference on Sustain - Operation and Automation IFF IREE 2009 ability for SMEs November 2-3, 2009 Prof. Michael Schenk, Director New Delhi, India Bangkok, Thailand RFID in Maintenance (Conference) Sandtorstr. 22 August 25, 2009 23.-25. September 2009 Dortmund 39106 Magdeburg, Germany Opening of the Fraunho- 10 International Rail Telephone 0391 4090-0 Fax -596 fer IFF ASEAN Regional Vehicle Conference November 3, 2009 [email protected] Office Dresden 12th Cooperation in Plant www.iff.fraunhofer.de Bangkok, Thailand Engineering Working www.logmotionlab.de September 2009 Group August 26, 2009 Contactless Wheel Leverkusen Editorial Staff 1st Central German Measurement System Anna-Kristina Wassilew, Logistics Forum Workshop November 3-5, 2009 Stefanie Härtel, René Maresch Leipzig Magdeburg VISION International [email protected] Trade Fair for Machine September 8-10, 2009 October 6-7, 2009 Vision and Identification Photos, Images and Federal Armed Forces’ KnowTech 2009 Technologies Graphics Distance Learning Bad Homburg Stuttgart © Fraunhofer IFF unless other- Convention wise specified. Hamburg October 9-10, 2009 November 11-12, 2009 Image Processing North German Manu- Viktoria Kühne September 13-25, 2009 Technology Day facturing Days [email protected] Ergonomics and Kaiserslautern Dortmund Productivity: Selecting a Title Photo: Location October 13-15, 2009 November 15, 2009 Dirk Mahler Millstatt/Kärnten, Austria MAINTAIN – The Leading ProWis-Connect Central: [email protected] Trade Fair for Industrial Knowledge Management September 14-17, 2009 Maintenance with Corporate Presenta- Layout/Design Learning in the Digital München tions Bettina Rohrschneider Age Frankfurt am Main Berlin October 15, 2009 Translation In-Process Knowledge: November 19-20, 2009 Krister Johnson September 15, 2009 Knowledge Management Optical 3-D Metrology ProWis-Connect South: for SME for Quality Assurance in Printing Knowledge Management Magdeburg Manufacturing Harzdruckerei GmbH with Corporate Magdeburg Presentations October 21-23, 2009 We wish to thank our researchers Haiterbach 26th German Logistics December 9, 2009 and project partners for their Congress Identifying Potentials in support during the preparation of Berlin Dealing with Knowledge: this publication. Practical Solutions for October 21-23, 2009 Effective Knowledge © Fraunhofer IFF, Juli 2009 © by FRAUNHOFER VERLAG, 2009 eChallenges 2009 Management (Seminar) [email protected] Istanbul, Türkey Magdeburg http://verlag.fraunhofer.de 54 IFFOCUS 1/2009

FRAUNHOFER INSTITUTE FOR FACTORY OPERATION AND AUTOMATION IFF

PLANT ENGINEERING OF THE FUTURE

MARCH 4-5, 2010 IN MAGDEBURG

EFFICIENCY IN THE PLANT LIFE CYCLE is an issue that preoccupies every manufacturer and operator of industrial plants. Industry experts see clear potential for optimization. Concepts are being demanded for solutions that increase resource efficiency. Techni- cal innovations and new control tools for efficient manufacturing will enable you to secure a competitive edge in the future. Join the discussion with Germany’s experts. www.iff.fraunhofer.de