Mar 27, 2025

Software-Defined Automation: More Efficient, More Flexible, Future-Proof

• #AI
• #AsconQube
• #automation
• #digitaltwins
• #industry40
• #Processoptimiziation
• #SmartFactory

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Isabell M

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Rigid, hardware-based systems are reaching their limits in modern manufacturing. Software-defined automation provides a remedy: it combines IT and OT, enables real-time adjustments and improves decision-making through AI-supported analyses. But how can the transition from classic control systems to flexible, scalable automation solutions be achieved? And what role does Ascon Qube play in this? Our new blog article provides answers and shows how companies can make their production more efficient and future-proof.

How Ascon Qube is Rethinking the Industry

Industrial production is facing major challenges. Rigid, hardware-based systems reach their limits when it comes to efficiency, scalability, and adaptability. Software-defined automation offers a solution – and with Ascon Qube, there is a platform that enables this transformation.

What is Ascon Qube?

Ascon Qube is a software platform that unites IT and OT in the industry. It replaces rigid, pre-programmed controllers with flexible, software-based models. This enables real-time process adjustments, optimized connectivity, and improved decision-making through AI-driven analytics.

Why is a Rethink in Automation Necessary?

The need for more flexible and sustainable production processes is growing. Factors such as labor shortages, rising energy costs, and complex supply chains demand new automation concepts. At the same time, technological advances in Artificial Intelligence (AI), Edge Computing, and 5G/6G are opening up new opportunities for optimization.

The Benefits of Software-Defined Automation

Traditional automation solutions are often inflexible and expensive to adapt. Ascon Qube focuses on a strong connection between IT and OT and offers:

• Adaptive Process Control: Real-time adjustments through microservices and digital twins. 

• Universal Connectivity: Standardized interfaces such as EtherCAT, OPC UA, KAFKA, and REST. 

• Dynamic Flexibility: Continuous optimization and process adjustments. 

• Informed Analytics: AI-driven simulations for better decision-making. 

• Scalable Infrastructure: Operates on edge devices, in data centers, or in the cloud. 

Real-World Applications

Companies across various industries are already leveraging software-driven automation:

• Quality Control in the Automotive Industry: AI-based image processing reduces waste and improves precision. 

• Anomaly Detection in the Chemical Industry: Real-time sensor data analysis prevents production disruptions and enhances operational safety. 

• Predictive Maintenance in Mechanical Engineering: Predictive maintenance reduces unplanned downtimes and lowers costs. 

How to Successfully Transition?

The introduction of software-defined automation must be gradual. Ascon Qube provides a modular platform that does not replace existing production structures but intelligently expands them. The use of digital twins and AI helps optimize processes and unlock new opportunities.

Learn More: Webinar Recording Available

For further insights into the potential of software-defined automation, check out the recording of the webinar “Industrial Automation Simplified: Unlocking New Possibilities with Ascon Qube.” In this session, Dr. Steven Vettermann, R&D Manager and Thought Leader at Ascon Systems, explains how companies can leverage the benefits of this technology.

Watch the webinar recording here.

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Jun 13, 2024

Ascon Systems launches the Digital-Twin-Readiness-Check tool for digital twins in manufacturing

Press release June 13, 2024

Author

Isabell M

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Stuttgart, June 13, 2024 – Ascon Systems, a company that enables digital transformation towards a flexible, automated company through software-defined manufacturing, is expanding its consulting division. From now on, companies can use a Digital-Twin-Readiness-Check to find out what the requirements for end-to-end data transparency with digital twins and software-defined manufacturing are in their company’s  manufacturing processes. The result is an analysis of the current technical infrastructure and transformation needs , as well as a roadmap for the strategy and integration of digital twins as a foundation for software-defined manufacturing.

The digital transformation in manufacturing is still in full swing at many companies in Germany. A key component of this is the digital twin, a virtual model of physical processes and systems. It connects the real with the digital world and enables simulations. Using it leads to increased productivity and cost savings. Before digital twins can be integrated into existing systems, however, a careful analysis of the existing infrastructure of the shop floor systems is required, including the throughput of devices connected to the Internet of Things (IoT).

The Digital-Twin-Readiness Check

Ascon Systems now supports companies with a multi-stage Digital-Twin-Readiness Check, to quickly identify how their infrastructure is set up, how it should be optimized regarding the integration of digital twins, and which strategy should underlie a roadmap for implementation. These steps include:

• Analysis of the existing infrastructure
• Stakeholder analysis
• Risk analysis
• Maturity level determination
• Strategy for the roadmap
• Roadmap for implementation

Jens Mueller, CEO of Ascon Systems, comments: “We have always supported and advised companies with our expertise in key digital technologies on how they can produce more flexibly , cost-effectively, and with less dependency on resources. This digital transformation towards an orchestrated, automated manufacturing operation often fails right from the start if there is no clarity about the technical and procedural conditions and responsibilities. We have therefore developed the Digital-Twin-Readiness Check, a low-threshold tool that overcomes these hurdles, is user-friendly and, above all, leads to a quick, clear result. We aim to help companies to accelerate their digital development in Industry 4.0 more quickly and thus strengthen their competitive position. We also contribute to enabling companies to connect technologically to the Industrial Metaverse from NVIDIA, one of our partners.”

Transformation Services at Ascon Systems

Ascon Systems is a pioneer in the software development of digital twins and their implementation as a building block on the way to the Industrial Metaverse. With the consulting unit in the company, Ascon Systems also provides support through the transformation processes associated with adopting new technologies or transitioning to differ ones, advising on potentials for automation, flexibility and efficiency gains of technologies.

The Digital-Twin-Readiness-Check: Ascon AIM

Press contact Ascon Systems:
Susanne Weller
T: +49 172 308 41 36
E: s.weller@weller-media.com

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Apr 11, 2024

Threedy and Ascon Systems Demonstrate New Deep Tech Application: Digital Twin Data from a Smart Factory as 3D Visualizations in Near-Real-Time

Press release April 11, 2024

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Isabell M

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Darmstadt / Stuttgart, April 11, 2024 — Ascon Systems, a company paving the way to the industrial metaverse with digital twins and automation solutions for the manufacturing sector, and Threedy, a deep tech expert for spatial computing technology, will present a global first at the 2024 HANNOVER MESSE: Manufacturers can now transform their production facility into a 3D smart factory and access it from smartphones and tablets in real-time using standard collaboration software such as Microsoft Teams. This live 3D factory twin visualization relies on the interaction of digital twins from Ascon Systems and 3D visualization technology from Threedy. The two companies have been working together on implementing 3D solutions for working with large quantities of data generated in industrial settings since September 2023.

There has been a recent breakthrough in data visualization manufacturing control. Digital twins from Ascon Systems send data from multiple sources to a tablet or smartphone. Threedy takes real-time sensor information and automatically syncs it to engineering-grade 3D data and then visualizes the result using instant3Dhub, a microservice infrastructure for industrial 3D data. This allows users, no matter where they are, to go from machine to machine and, for instance, discuss running processes or the current status of specific hardware with their teams using collaboration software. The Threedy and Ascon Systems technologies operate on scalable infrastructure from cloud providers such as Microsoft Azure. This remote-ready, system-agnostic approach makes it possible to connect with additional data spaces while enabling integration with all kinds of applications. No specific preparation such as data consolidation, reduction, or simplification is necessary.

At HANNOVER MESSE, Threedy will reveal the results of its technology partnership with Ascon Systems and demonstrate on a real machine the interaction of contextualized data, software-defined production control with digital twins, and live 3D visualization.

You are welcome to attend a demonstration of the joint technology at Threedy’s booth at HANNOVER MESSE 2024. You can schedule a visit during the following times:

When: April 22-26, 2024, from 10am to 5pm.
Where: HANNOVER MESSE, Hall17, Booth G06
Who:

• Stefan Domdey, VP Sales, Threedy, Mobile: +49 151 525 798 62, Email: stefan.domdey@threedy.io
• Steven Vettermann, Thought Leader, Ascon Systems, Mobile: +49 170 772 42 43, Email: Steven.Vettermann@ascon-systems.de

Christian Stein, CEO of Threedy, said: “The way the Ascon Systems technologies interact with our instant3Dhub is an impressive demonstration of how even distributed data environments can be connected using a fully integrated digital twin without having to develop complex new systems and that brownfield applications can also profit from the benefits of a twin.”

Jens Mueller, CEO von Ascon Systems, said: “More and more machines and processes are now connected through the industrial internet of things and the quantity of data keeps increasing. Industrial enterprises often find it difficult to use all this data because it’s trapped in silos and they lack the necessary IT experts. Together with Threedy, we’ve found a solution to this problem. People are accustomed to communicating with each other over phones and tablets. Together, we’re making it possible for humans and machines to communicate in the same way. Our digital twins provide contextualized data from production operations for analysis, then Threedy creates a live, 3D visualization. The digital twin is then able to carry out additional control functions. We’re very pleased to be able to show how innovative and intuitive this approach is together with Threedy at this year’s HANNOVER MESSE.”

About Ascon Systems Holding GmbH:
Ascon Systems Holding connects the digital world with the real world. The company develops automation solutions based on digital twins that enable companies to achieve the digital transformation towards Industry 5.0 and industrial metaverse. The goal is to make the manufacturing industry more flexible and achieve this with IT/OT convergence und AI. Customers include BMW, Mercedes, Drees & Sommer and Läpple. Other customers are market-leading companies from the automotive, mechanical engineering, aviation, and logistics sectors. Ascon Systems Holding GmbH is the parent company of Ascon Systems GmbH, which was founded in 2017. The CEO is Jens Mueller. There are more than 130 employees working in the team. Ascon Systems is headquartered in Stuttgart, with additional locations in Berlin, Mainz, Munich, Heilbronn and Stade.
https://ascon-systems.de

About Threedy GmbH:
With its instant3Dhub, Threedy offers a unique infrastructure component that allows companies to meet the ever-growing demand for highly available 3D data in responsive and interactive 3D applications. Industrial 3D data is referenced directly, e.g., from an existing PLM system, without prior preparation and can be automatically linked with further business information. This results in new, scalable applications over the entire lifecycle, from engineering to after sales – web-based and with zero footprint on the client. Threedy GmbH was founded in 2020 as a spin-off of the Fraunhofer Institute for Computer Graphics Research. Threedy GmbH, headquartered in Darmstadt, with a current staff of 55 employees. https://www.threedy.io/

Press contact Ascon Systems:
Susanne Weller
T: +49 172 308 41 36
E: s.weller@weller-media.com

The post Threedy and Ascon Systems Demonstrate New Deep Tech Application: Digital Twin Data from a Smart Factory as 3D Visualizations in Near-Real-Time appeared first on Ascon Systems.

Nov 15, 2023

Destination Digital Factory: BMW i Ventures comes on board as an investor in Ascon Systems

Press release November 15, 2024

Author

Isabell M

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München / Stuttgart, November 15, 2023 – Ascon Systems, a company that enables the transformation to the industrial metaverse with digital twins and low-code software solutions, has welcomed BMW i Ventures, venture capital provider for innovative and high-performance start-ups in the automotive sector, as a new investor. With this commitment, BMW i Ventures supports the next stage of digital production and unlocks potential for the industrial metaverse and digital shopfloor management in the automotive and supplier industry. The common goal is to increase flexibility and efficiency in these important industries.

Ascon Systems paves the way for companies to achieve a data-driven digital factory and provides support by combining low-code software and high-tech in four steps: automate, simulate, model and flexibilize. The real shopfloor is connected to virtual digital twins. Decisions in the real company environment have an impact on the digital twins and vice versa. Ascon Systems thus enables the continuous optimization of industrial production processes, necessary maintenance work and training across different locations.

Marcus Behrendt, Managing Director at BMW i Ventures, comments: “Jens Müller and his team at Ascon Systems have impressed and convinced us with their forward-looking technologies. With its digital twin technology, Ascon Systems is opening up completely new and, above all, more efficient ways for shopfloor management in the industrial metaverse. As an Omniverse Partner of NVIDIA, Ascon is very well positioned. We at BMW i Ventures aim to actively support this development to ensure that the next stage of digitalization in production can be widely adopted.”

Jens Müller, CEO of Ascon Systems, adds: “We are delighted to have BMW i Ventures as a new partner. With our platform, we make it easy for companies to create a digital twin of their physical factory. This allows them to optimize processes, identify and correct errors – but above all, they can digitally simulate various scenarios for planning and determine the next steps for implementation based on this. We are currently expanding Ascon Systems and developing further high-tech solutions – also in cooperation with our partners – to pave the way for the factory of the future. With the support of BMW i Ventures, we are taking a big step towards these goals.”

Press contact Ascon Systems:
Susanne Weller
T: +49 172 308 41 36
E: s.weller@weller-media.com

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The requirements for the factory of the future are demanding. It needs to be highly flexible to foster resilience and prevent operation disruptions when facing resource shortages of any kind. This flexibility is crucial to ensure a seamless and uninterrupted production process. These factories need to be efficient, fast, scalable, and ideally controllable from anywhere. Predictive analytics, digital process documentation, and, notably, the management of sustainability, decarbonization, and circular practices are among the top priorities for numerous business leaders. The dawn of the future factory is upon us, with pioneering examples cropping up across diverse industries. What sets these future factories apart from their traditional counterparts is nothing short of transformative, and the journey towards this new frontier is equally distinctive and extensive. Enter the Industrial Metaverse, a visionary concept that has the potential to simplify this evolution by offering a tangible glimpse into what the factory of the future could become.

Could the Industrial Metaverse hold the key to unlocking the full potential of this evolution? Does it provide the necessary elements and parameters that will chart a course towards the factory of the future, outlining concrete steps along the way?

What distinguishes the factory of the future from the factory of today?

Manufacturing and control of production processes in many companies are based on the classic automation pyramid, outlining the data’s journey from its source to management. This pyramid maintains a hierarchical structure, ranging from sensors at the bottom, moving up to process signals, process control systems, and control levels, culminating at the plant management and company level. This framework, however, is rigid and fails to capture the full spectrum of activities within a factory.

The factory of the future, on the other hand, is based on intelligent networks that emerge through the interaction of cutting-edge technologies and services. It is through this intricate synergy that the factory gains its agility and efficiency, enabling it to adapt swiftly and inspire groundbreaking innovation. However, the new architecture not only transforms internal operational processes and procedures; it also redefines the roles and responsibilities of individuals within it. Shifting away from production, there’s a move towards planning, control, and design of specific components or modules. Product development takes on a more significant role within the value chain. The actual manufacturing work is then automated by the machines. Controls are organized in a decentralized manner, eliminating the need for experts to be physically present for adjustments.

What vision of the factory of the future does the Industrial Metaverse offer?

The Industrial Metaverse is emerging, not with a big bang or as a brand driven by one company. Instead, it is evolving continuously, through incremental changes and applications within an ever-expanding landscape of industrial and tech companies worldwide. While a uniform definition of the Industrial Metaverse remains elusive, there is agreement on the main characteristic: the Industrial Metaverse seamlessly combines reality and virtuality – and that has not existed until now. What one configures on their tablet or computer happens at the same time in the physical factory, forging connections between information and services that was previously not thought possible. This creates transparency and leads to the dismantling of silos. In the Industrial Metaverse, human expertise, machine capabilities, and a range of technologies converge harmoniously—a concept referred to as “hyperconvergence”. All these elements point to the disruptive potential of the Industrial Metaverse, a force capable of igniting profound and lasting transformation within the industry.

Designing the factory of the future

The inclusion of 3D elements in the Industrial Metaverse is possible, though not obligatory. What certainly forms an integral part of this digital landscape is the concept of digital twins, which you can read more about in this article. Digital twins mirror the real conditions of the factory in a digital version. This is what makes the Industrial Metaverse so future-proof: the digital twin of the factory can be used to predictively model one or more developments on the basis of historical data and assumptions about upcoming, possible events or desired changes. In this landscape, the “What if…” or “What happens if…” scenarios can be digitally simulated, enabling multifaceted testing of ideas before the physical implementation of machines and factory adjustments. This not only results in substantial efficiency gains but also translates into cost savings and resource conservation, further advancing the cause of sustainability and decarbonization. Another advantage for the factory of the future in the Industrial Metaverse: People can work collaboratively on the digital twin from different locations. Travel is no longer necessary, agility increases, and once again the outcome is a reduction in costs and a substantial contribution to sustainable practices.

Both SMEs and large corporations will benefit from the Industrial Metaverse, especially in situations where work is distributed across multiple locations. It particularly thrives in environments where innovation is a driving force, automation takes a front seat, and there’s a need to meet climate protection and sustainability criteria. It’s especially valuable in settings where complex, multi-stage production processes are the norm. In every context where the synergy of people, machinery, and technology holds significant importance, the environment is ripe for the Industrial Metaverse to thrive.

Author

Dr. Steven Vettermann, Ascon Systems

The post The Factory of the Future in the Industrial Metaverse: Utopia or Opportunity? appeared first on Ascon Systems.

In the industry of tomorrow, the boundaries between the physical and digital worlds will blur. People will interact with machines and sensors in new and innovative ways to shape and optimize processes on a global scale and in real time. These processes, which in the prevailing industrial paradigm still require time-consuming re-coding or re-designing, are at the heart of the emerging Industry 4.0.

To ensure the success of this transformative journey, a new infrastructure must be developed and adopted, which differs from the one we’re used to. The industrial metaverse is precisely this kind of infrastructure and will be instrumental in realizing the vision of an Industry 4.0 in which industrial processes are automated, interconnected, flexible, and modeled.

In the industrial metaverse, the digital and real worlds seamlessly merge for manufacturing, controlling, and planning. Where are we now, what do we know about the industrial metaverse? What are the key technologies? We’ll provide answers to the most important questions and shed light on what the future of industry could look like.

The Industrial Metaverse – 5 key takeaways

1. In the industrial metaverse, the real and digital worlds converge.
2. There is no standard, unified definition.
3. Industrial processes are becoming more flexible, automated, efficient, collaborative,and sustainable.
4. The industrial metaverse is emerging based on internet technologies and through acombination of foundational technologies (hyperconvergence).
5. Digital twins are the centerpiece, supported by sensors that facilitate connectivitywithin the Internet of Things, creating a platform for seamless data interaction.

Embracing the Future with the Industrial Metaverse

To run smoothly, industrial processes require stable framework conditions. These include a reliable supply of raw materials, skilled personnel, and dependable supply chains. In recent years, however, these critical conditions have experienced bottlenecks – presenting major challenges to industry. On top of this, there is tough global competition which calls for innovative solutions and efficiency improvements. Or at least, it should. The reality is that in Germany, technological change and the corresponding and necessary digitization have yet to reach the levels required for a future-proof, competitive, and resilient economy. Mounting pressure for sustainability, environmental protection, and decarbonization – all also statutory requirements – are triggering additional transformations which businesses should account for when designing production and manufacturing processes.

Industry 4.0 delivers solutions to these challenges, offering organizational signposts to guide businesses. Complementing Industry 4.0 is the industrial metaverse, and is where Industry 4.0 becomes tangible, where theoretical ideas of human-machine collaboration, cyber- physical network systems, and the Internet of Things become a reality.

• Continue reading in the ePaper: “7 essentials to unlock the industrial metaverse: Revolutionary automation for the factories of the future”

Unlocking the potential of the Industrial Metaverse

Defining the industrial metaverse is challenging as it is a concept still in its infancy. The novelty of the concept may be one factor in this, but the primary reason is its cross-sectoral and international applications compounded by the lack of standards. Current definitions, however, at least agree on key characteristics: With its convergence of technologies and information, the industrial metaverse promises unparalleled flexibility and automation. And for many in the business community, these are the cornerstones of future-readiness. With the industrial metaverse, business leaders recognize that the industrial metaverse is the key to achieving these goals.

Other characteristics: 

• Virtual Environments: These encompass digital twins, which serve as representationsof production facilities and processes, and can be used as training spaces
• Seamless Connectivity: The industrial metaverse fosters collaboration amongindividuals, sensors, and machines, as well as for product trainings
• Real-time Date: Data are generated in real-time, readily available and can be usedimmediately
• AI Integration: AI may play a role – but the industrial metaverse is capable offunctioning effectively without it
• Interoperable and Decentralized Systems: Systems are designed to work together seamlessly and are distributed for enhanced flexibility and reliability

In the industrial metaverse these facets converge, becoming tangible and immersive. It is a platform which people can log on to from anywhere in the world. They become part of a virtual environment where they can simultaneously access digital copies, i.e., digital twins, of manufacturing plants and production processes. Here they have the power to model, simulate, optimize, make changes, access specific parameters, and even perform repairs. Alternatively, they can conduct tests on new digital twins in this virtual environment to assess their feasibility and practicality in the real world.

• For more information, see „Digital Twin vs. Digital Shadow“

The Technologies of the Industrial Metaverse

One digital twin does not an industrial metaverse make – but it is the linchpin, without it, the very essence of the industrial metaverse would cease to exist. However, what truly distinguishes the industrial metaverse from conventional industrial production is the orchestration of various foundational technologies, particularly the hyper-convergent infrastructure. When combined with artificial intelligence (AI), it empowers devices, machines, and processes within the Internet of Things (IoT) with predictive capabilities. This combination of hardware, software, IT infrastructure, and connectivity technologies makes the synchronicity of real and virtual worlds possible and offers increased efficiency, automation, and flexibility.

At a glance: Key technologies and their interactive connections

Digital Twin

A digital twin can either be the virtual representation of a physical object, process, or system with identical properties, or it can be a simulation created before their real-world counterpart is built. Digital twins offer a unique advantage by enabling processes such as optimizations or planned interventions in the real world to either be initially carried out and tested in the digital realm or performed on the digital twin, which subsequently impacts the real-world counterpart.

Virtual Reality and Augmented Reality

Virtual environments in the industrial metaverse can either be copies of existing physical environments or serve as a simulation. No matter what: Teams can immerse themselves in this virtual environment, meeting regardless of their physical locations, simultaneously work on digital twins of machines, discuss processes, and conduct inspections or trainings. Augmented Reality (AR) seamlessly bridges the gap between the digital and physical worlds. Users of the device have information, data, or instructions from a tablet projected into their line of sight.

In the industrial metaverse, the virtual environment can either replicate an existing physical space or serve as a simulation. Whatever the case may be, teams can immerse themselves in this virtual realm, meeting regardless of their physical locations. Here, they can collaboratively and simultaneously work on digital twins of machinery, discuss processes, perform maintenance, or conduct training sessions. When an individual is using an AR device, information, data, or instructions are superimposed onto their field of view through a tablet or similar device.

Technology Platform 

The industrial metaverse’s control center is the technology platform. It is here that the data from various sources converge. The platform has to be upgradable, making it possible to connect additional technologies via plug-and-play during expansions. It is based on internet technology and is based in the cloud.

Sensors 

Sensors connected to machines and devices make it possible to transmit and receive data. A previously specified language – which may be a computer language – is used for communication.

Internet of Things (IoT)

The Internet of Things refers to a network of physical devices and machines that are embedded with sensors and connected with each other. Information from the Internet of Things is collected as data on the platform.

Artificial Intelligence (AI)

In the industrial metaverse, Artificial Intelligence is based on empirical values from the Internet of Things. Enabling advanced descriptive data analytics and predictive analytics, it delivers the information necessary for decision-making, taking into account a number of different parameters and scenarios. It will recognize if processes deviate from desired outcomes, can make suggestions for optimization and increased efficiency, and handle routine assignments.

Blockchain

Not all processes may be deleted immediately upon competition. Some data are important for the future and have to be preserved. Blockchain provides a straightforward, secure means of documentation.

Interoperability 

All components in the industrial metaverse have to be configured for interoperability, making it possible to expand or integrate other systems at a moment’s notice, without any restrictions.

From Vision to Business Model

At the moment, it may seem as if there were only very limited examples of industrial metaverse applications. This is deceiving. Transformation takes time – and compared to results, interim stages and processes are a rather less popular topic of conversation. In all sectors, but in particular in the manufacturing industries, businesses are currently exploring their own paths to and within the industrial metaverse. They discover the applications which offer the best fit, trial innovations by using digital twins rather than spending resources on building real machines and plants, run simulations, improve processes, and due to the advantages of automation, regain time for creative thinking and entrepreneurial planning. They compile their own customized technologies and gain experience. In a few years’ time, the term industrial metaverse will be the new normal and become part of what it is: a space for sustainable, data-based, forward-looking industrial production in the early 21st century.

*Good to know: Immersive virtual environment 
An immersive virtual environment is a simulated environment created with VR technologies. Users become a part of this environment and experience a real-world presence in the virtual world. They can interact with and cause events in the virtual environment.

Author
Susanne Weller, Weller Media

The post The Path to the Industrial Metaverse appeared first on Ascon Systems.

When it comes to industry 4.0, a number of new concepts – one could almost call them buzzwords – are frequently mentioned but often remain undefined. Big data, data mining, industrial metaverse, or the catchwords digital twin and digital shadow. In the following, we’ll explain the difference between the two latter terms, the ways in which they might be connected and, most importantly, why we say that our digital twin is ‘real’.

Digital Twin: a general definition

What exactly is a digital twin?

The idea of a technical twin was born at NASA during the Apollo program. In the late 1960s, an identical copy of the spacecraft was built to simulate and test the actual behavior of Apollo in space prior to its launch.

Fast forward to 2002, where the concept of a digital twin was first publicly introduced by Michael Grieves (Florida Institute of Technology and consultant to NASA) at a Society of Manufacturing Engineers conference in Troy, Michigan. In 2010, NASA’s John Vickers introduced a new use of the term digital twin for a technology roadmap. It was no longer confined to manufacturing industries, but applied across all sectors, including construction, engineering, transportation, and aerospace.

Today, we define a digital twin to be a digital replica of a real-world material or immaterial object. It is irrelevant whether the real-world counterpart already exists or will only come into existence in the future.

In view of the advances made in information technology over the past decade, the concept of digital twins appears to be a cogent logical extension: using the right IT infrastructure, it has become feasible to digitally capture and represent actual or notional objects so comprehensively that simulation, monitoring, analysis, and forecasts are possible in previously unavailable detail.

This description represents the overlap of the many existing definitions of the digital twin concept. For the digital twin to usher in industry 4.0 and even the industrial metaverse, however, we don’t feel that this is really innovative enough.

In our Ascon Systems Automation Platform, we define a digital twin as follows: Based on a logical model, the twin must act and interact autonomously while a factory is in operation. The Ascon Systems Automation Platform makes it possible to see both past and future of a production and to

adjust devices, processes, or settings rapidly, flexibly, and autonomously in the present. Control your production here and now, with only a few clicks. All decisions are based on data and modelling, validated and controlled.

The way we talk about digital twins will need to keep up with software makers that are clearly pursuing widely diverging concepts.

Either way, it should be noted that the current hype concerning the digital twin and its almost unfathomable potential will become the digitalized industry’s new paradigm. Without the digital twin, industry 4.0 will never materialize. And what’s more, digital twins are the ticket for the journey to the industrial metaverse.

Not a digital shadow

A digital twin is not a shadow, because shadows – even though a wide range of data is available – do not provide interoperability between the real and physical world. The digital shadow is limited to collecting and presenting data, while a real digital twin is able to interact with a real-world object.

Not a simulation

A digital twin is not a simulation, since a simulation is the emulation of a system and its dynamic processes in an experimental model to gain insights that can be transferred to the real-world situation. A simulation is created to answer a predefined question, while the aim of a digital twin is to have a constant, positive feedback loop between real-world object and digital copy. A digital twin is, especially focused on capturing measurement data and information during operations, utilizing them across multiple layers and within various systems and objects. A simulation is not digitally connected to a real-world object.

Not Computer-Aided Design (CAD)

Computer-Aided Design is a precursor of the digital twin, but the digital twin is much more than CAD.

CAD creates preliminary designs of real machines and their features prior to production. A CAD model describes reality but has no links to it.

Digital Shadow: Why it is not a digital twin.

‘Digital shadow’ refers to the process data generated by machines during operation. These raw data are passive by-products of the actual production in a factory. Users can access and aggregate this data through the IT infrastructure. However, this represents an incomplete data pool which may be further processed and interpreted to answer specific questions. For more in-depth analysis, the digital shadow’s data can be augmented by dynamic data and in this way provide more detailed insights. When recognized as data traces which completely lack connectivity, it becomes evident why they are unable to influence the real-world system they refer to. Only systems which react to the digital shadow (e.g., sensor-actuator systems) can autonomously take action, fully or partially automated, to influence production.

Who profits from a digital twin?

Primarily manufacturing companies with complex and comprehensive processes and products will benefit from digital twins. In particular, production processes which have an intense and regular flow of sensor data may profit from digital twins. Should this not be the case, cost and complexity will likely make the use of a digital twin unattractive or unprofitable.

Types of projects which specifically benefit from the use of digital twins are, e.g.:

Physically large projects: buildings, bridges and other complex structures

Mechanically complex projects: jet turbines, automobiles and aircraft

Power equipment: mechanisms for generating and transmitting power 

Manufacturing projects in industrial environments with co-functioning machine systems

Therefore, the industries that achieve the greatest success with digital twins are those involved with large-scale products or projects:

• engineering (systems)
• automobile manufacturing
• aircraft production
• railcar design
• construction
• manufacturing • power utilities

A new dimension: Ascon Systems digital twin

Ascon System’s digital twin encompasses everything you understand about digital twins, plus the capability to enable real-world objects and their twins to interact in near real-time, automated, and as a self-learning system. Using the Ascon Systems Automation Platform, you create a digital inventory of your facility, your overall production or entire factory and control all your real-world objects and their digital twins in near real-time from a single dashboard. Production data can be continually monitored, while sensors, actuators, status and faults reporting, process and behavior modelling, twin templates and validations do their work automatically. Whether on the shop floor or remote, you can react to events immediately and with only a few clicks, take anticipatory action, access the data history, and directly implement altered requirements. Boundaries which were considered insurmountable in the automation pyramid disappear, and you take full digital control of your entire production facility, if not your whole factory.

In addition, Ascon System’s digital twin is naturally also fully matured when it comes to IT security, access rights, handling of certificates, and version control.

Because there can be no one-size-fits-all approach to digital twins, Ascon Systems develops a fully customized concept for the introduction of the Ascon Digital Twin in collaboration with its customers. Ascon Systems plans your company’s digital future with you and will also ensure that your existing staff will master the digital twin and use it to its full potential.

With Ascon System’s digital twin, you safeguard your long-term future viability and competitive edge, and simultaneously improve your climate footprint thanks to reduced resource and energy inputs.

Conclusion:

For those highly specialized industries which benefit from the use of digital twins, the twin concept ushers in a new age and blazes a trail to the industrial metaverse. Without digital twins and artificial intelligence, industry 4.0 will not come to pass. For most companies, maintaining their digital competitiveness will mean, at a minimum, an in-depth exploration of digital shadows. In addition, industry 4.0 will face the issues of the ethics of globalization, the climate crisis, and the skills shortage, and here, too, the digital twin is the best possible answer.

Ascon Systems is your partner for digital strategies, unearthing your digital treasure, and introducing the real digital twin to your company. Experience the digital production of the future – with Ascon Systems!

Author

Claudia Schulz, Technical Writer, ASCon Systems Holding GmbH

The post Digital Twin: Real or often only a shadow? appeared first on Ascon Systems.

Sep 5, 2023

Ascon Systems and Threedy collaborate in 3D visualization of industrial processes

Press release September 5, 2023

Author

Isabell M

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Stuttgart / Berlin, September 5, 2023 – Ascon Systems, a company enabling the transformation towards industrial metaverse with digital twins and low-code software solutions, and Threedy, a spin-off of the Fraunhofer Institute for Computer Graphics Research and a technology specialist in industrial 3D applications, now collaborate in the field of 3D visualization and networking.

This joint endeavor offers manufacturing companies an opportunity to access 3D data of objects and processes on a cloud-based platform, and use it for modeling, simulations, and maintenance, or even direct transferring into mixed-reality applications. This will boost efficiency and lower costs, automate processes and increase process flexibility, and make operations hardware and software independent. The results are lower data volumes, a decrease in server loads, and smaller carbon footprints.

Having a flexible IT architecture based on low-code software which offers access to 3D data will be pivotal for the factory of the future. To make this possible, Ascon Systems offers a platform on which digital twins virtually represent machines and their interactions either for simulation and testing, or – in the case of actual real-world machines – for modelling, controlling, and automation in general. To these applications, Threedy contributes its technology for 3D visualization. Maneuvering, turning and rotating offers a way to experience the machines intuitively. Through a shared platform, Ascon System’s and Threedy’s collaboration lets businesses benefit from the entire spectrum of these forward-looking technologies and enables them to link digital twins, real-world shop floors, and other corporate data with 3D visualizations.

To guarantee interoperability, bulk data are provided in the cloud, which compared to storage on servers also increases the speed at which visualizations can be handled. Use scenarios include monitoring machines and processes, maintenance and servicing support, (spatially) distributed collaboration and real-time display of status data.

Hello machine, what’s your problem: a sample application
On a factory’s work floor, an engineer wants to look at the current status of a machine or check an error message. After calling up the machine’s live data via a tablet’s browser, she or he has the location displayed, walks over and looks at the process data on the tablet as well as the fault’s localization. Additional information is displayed in a window: the current status, maintenance history, and any notes or recommendations made by technicians. The engineer is able to live share with others all data and information and may work on or operate the machine together. This scenario applies to all workshop machines and processes. They are recorded and displayed via the automation platform and Ascon System’s digital twins and, using Threedy’s 3D visualizations, can be tablet-operated without any need in-depth knowledge about the machines. Monitoring is carried out via sensors which transmit their data to the common platform, making it possible to check large numbers of individual components and processes simultaneously. Troubleshooting and maintenance are carried out precisely, rapidly, and easily without extended workflow interruptions.

Jens Mueller, CEO of Ascon Systems, comments: “We are delighted about our collaboration with Threedy. The synergy between our two technologies allows us to address problems that many industrial companies still face today. On the one hand, they need various hardware and software solutions to monitor their shop floor. And on the other, that they often have to outsource cost-intensive maintenance processes and run them separately to business operations. Now, the people working the machinery and processes are supported by the intelligence of our platform’s digital twins and the real-time visualization in 3D provided by Threedy, enabling them to significantly increase efficiency across the board and massively drive down costs. This is industrial metaverse in action: it thrives on high-tech collaboration and brings the future right into the workshop.”

Christian Stein, CEO of Threedy, adds: “We’re highly impressed by our joint partnership with Ascon Systems. Our technology lives on strong partnerships, because the added value for our customers grows the more networked the 3D data are. We are very happy to be able to offer together with Ascon Systems a one-stop solution for the manufacturing industry.”

Press contact Ascon Systems:
Susanne Weller
T: +49 172 308 41 36
E: s.weller@weller-media.com

The post Ascon Systems and Threedy collaborate in 3D visualization of industrial processes appeared first on Ascon Systems.

Aug 22, 2023

NVIDIA brings Ascon Systems for Digital Twins on board as a new member of NVIDIA inception funding program

Press release August 22, 2023

Author

Isabell M

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Stuttgart / Berlin, August 22, 2023 – Ascon Systems, a company enabling the transformation towards industrial metaverse with Digital Twins and no-code software solutions, is now a new member of NVIDIA Inception. The Program was set up by NVIDIA, a leading global chip manufacturer and AI computing provider based in Santa Clara, USA. The aim is to support the rapid development of high-tech start-ups that make industry companies future-proof with digital technologies.

NVIDIA Inception goes beyond traditional accelerator programs to support startups and innovative companies at all stages of the lifecycle, from product development and prototyping to product launch. Members in the program benefit from close collaboration with NVIDIA experts, rapid access to cutting-edge technology, short paths to venture capitalists and co-marketing.

As part of the cooperation, Ascon Systems is developing an interface that connects its automation platform with NVIDIA’s Omniverse, a cloud-based platform that enables users, regardless of their location, to create and operate metaverse applications simultaneously and in real time. By combining its automation platform and interface with Omniverse, Ascon Systems enables the seamless flow of relevant data from the shop floor into Omniverse in near real time. Users are provided with innovative means to de-silo manufacturing planning and operations, allowing them to holistically simulate processes.

Since 2017, Ascon Systems has been supporting companies from industries such as automotive, mechanical engineering and aviation in automating process planning and controlling, as well as optimizing industrial processes via digital twins. These technologies thus enable the connection to the industrial metaverse with real-world assets on the shop floor. In this interconnected environment, decisions made in the real business environment impact the digital twins, and vice versa.

Jens Mueller, CEO of Ascon Systems, comments: “The industrial metaverse is developing in leaps and bounds – and we are contributing to this. This transformation requires cooperation. Therefore, it was a natural step for us to become a member of NVIDIAs Inception. With our software and platform, we eliminate complicated transitions between the digital and real worlds and enable co-existence. These dual spaces offer companies enormous opportunities but are currently still new to many users. We can nowdrive the transfer of knowledge on industrial automation even faster and better by participating in Inception Program with other industry-leading experts and AI-driven companies.”

Press contact Ascon Systems:
Susanne Weller
T: +49 172 308 41 36
E: s.weller@weller-media.com

The post NVIDIA brings Ascon Systems for Digital Twins on board as a new member of NVIDIA inception funding program appeared first on Ascon Systems.