An augmented reality-based training system with a natural user interface for manual milling operations
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ORIGINAL ARTICLE
An augmented reality‑based training system with a natural user interface for manual milling operations Chih‑Kai Yang1 · Yu‑Hsi Chen1 · Tung‑Jui Chuang1 · Kalpana Shankhwar1 · Shana Smith1 Received: 27 July 2019 / Accepted: 27 November 2019 © Springer-Verlag London Ltd., part of Springer Nature 2019
Abstract This study developed an augmented reality (AR)-based training system for conventional manual milling operations. An Intel RealSense R200 depth camera and a Leap Motion controller were mounted on an HTC Vive head-mounted display to allow users freely walk around in a room-size AR environment to operate a full-size virtual milling machine with their barehands, using their natural operation behaviors, as if they were operating a real milling machine in the real world, without additional worn or handheld devices. GPU parallel computing was used to handle dynamic occlusions and accelerate the machining simulation to achieve a real-time simulation. Using the developed AR-based training system, novices can receive a hands-on training in a safe environment, without any injury or damage. User test results showed that using the developed AR-based training resulted in lower failure rates and inquiry times than using video training. Users also commented that the AR-based training was interesting and helpful for novices to learn the basic manual milling operation techniques. Keywords Augmented reality · Natural operation behavior · Manual milling operation · Occlusion
1 Introduction Machining operations are often complicated and dangerous. Because of safety issues and the lack of one-to-one training resources, many machine tool trainings are not effective. Some researchers started to apply virtual reality (VR) or augmented reality (AR) to assist machining trainings to avoid potential injury or damage. For example, Zhang et al. (2008) developed an AR-assisted computer numerical control (CNC) machining simulation system. The system allowed operators to analyze machining processes on real machines. Neugebauer et al. (2010) created a VR-based numerical control (NC) milling machine system by combining a virtual environment with an actual control panel. The system enabled novices to quickly comprehend complex operation processes and recognize potential errors without any extra cost or danger. Kiswanto and Ariansyah (2013) developed an AR-based 3-axis CNC machining simulation system to machine a virtual workpiece on a real milling machine. Users can validate their machining processes to * Shana Smith [email protected] 1
Department of Mechanical Engineering, National Taiwan University, Taipei, Taiwan
avoid collisions. Chardonnet et al. (2017) used a handheld device to display AR images to assist CNC machining. Realtime operation conditions and cutting tool motions were displayed on the handheld device. Although NC machines have many advantages over conventional machine tools, most small-quantity and low-cost projects are still carried out by conventional machine tools. Conventional machining training is an
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