Digital twin and condition monitoring in the smart factory from HARTING

Digitalisation, miniaturisation, modular production, identification of all production resources, integration of the shop floor in ERP systems, and highly customised production for custom-made solutions: these are the key industry trends. HARTING unites these in a smart factory that incorporates all aspects of integrated industry. This factory will be presented live at the Hannover Messe (on 23 – 27 April, 2018). Co-exhibiting partner companies are also demonstrating how live manufacturing data and a digital twin of the facility can be used for condition monitoring, remote maintenance and predictive maintenance.


HARTING's Smart Factory "HARTING Integrated Industry 4 You" (HAII4YOU) provides a comprehensive implementation of solutions. This facility demonstrates total vertical integration – from the customer to the versatile production of a product – using the example of a modular Han® connector. Starting with configuring and ordering in a Web shop, the further processing within SAP and production take place fully automatically. So the customer can assign their own identification (e.g. item number) to a connector.

Distributing production in production cells

The HAII4You factory is special because it distributes production throughout three production cells. These have their own controllers and are controlled by special flowcharts which are assigned to the product as product memory. The activities in each production cell are carried out by one KUKA lightweight robot, which can also be used for human-robot collaboration (HRC).

An innovative circulating belt is used to transport materials between the cells. The product is identified within a production cell using HARTING RFID technology based on HARTING's MICA® Edge Computing System.

With the project 'FlexiMon' HARTING and the University of Bielefeld show what the future of manufacturing technology might look like. In our online configurator, you can experience the concept of flexible assembly playfully.

Discover the concept of flexible assembly (FlexiMon) in our online game.

Live data used for Industry 4.0 applications

In cooperation with our partner companies from the (the user organisation for the MICA mini computer), Industry 4.0 applications will be demonstrated on the HAII4You factory at the Hannover Messe. Assystem, for example, reads out the torques of the robot gripper to detect signs of wear. To accomplish this, the data is evaluated and compared with historical data in Microsoft Azure cloud. SDI Innovation also uses machine data and displays it in dashboards. The machine operator can then receive status notifications or even information about predicted events (predictive maintenance) on a mobile device at any time. HARTING is also demonstrating how power (current) measurements can be used for condition monitoring. Changes in the power consumption of drives, for example, indicate that there is wear.

PerFact has developed a digital twin for the HAII4You. Condition-based and proactive maintenance can be controlled centrally using the maintenance manager.

Remote service using the digital twin

Nowadays, anyone who designs a machine also creates a virtual image of the machine in parallel. PerFact, the newest member of the, has developed a digital twin of HAII4You which will be presented at the trade fair stand. When used together with the PerFact MPA (Meeting Point Architecture) solution, the MICA® is the core of the digital twin. Here, the MICA® provides the perfect foundation for safely constructing a remote connection to the machine. Machine data are recorded and displayed clearly. Condition-based and proactive maintenance can be controlled centrally using the maintenance manager. The digital twin enables an ideal maintenance situation. Thus, an on-site technician and a specialist (connected via the internet) can access this same data.