Industrial Solutions for Production

At Fraunhofer IPMS, we leverage edge computing and real-time data transmission to enable precise, on-site monitoring of industrial machinery. Our AI-supported sensor systems detect damage early, optimize maintenance schedules, and significantly reduce machine downtime.

AI-Driven Edge Computing for Smart Machine Monitoring

A live demonstrator featuring a miniaturized conveyor belt showcases the capabilities of our advanced monitoring toolbox for industrial environments. The system uses multimodal sensors to capture a range of physical signals, including acceleration, rotational speed, magnetic fields, as well as acoustic and ultrasonic waves. This allows it to accurately detect belt tension, blockages, and mechanical anomalies. AI models provide high-precision predictive maintenance, while real-time calibration ensures adaptability to dynamic operating conditions.

The system integrates proprietary sensors with a RISC-V-based edge computing platform, enabling complex AI processing directly at the point of measurement. This local processing power supports real-time decision-making, adapts to changing environments, and improves prediction accuracy, thus overcoming traditional limitations of embedded systems in time-critical applications.

Industry Partnerships

The expertise of Fraunhofer IPMS in the field of sensor technology and AI evaluation enables the continuous further development of the technology. Existing partnerships with companies such as Vetter Kleinförderbänder GmbH demonstrate the industry's interest in such solutions.

Human-robot collaboration (HRC) demands exceptional levels of safety, precision, and environmental awareness, especially in confined or dynamic workspaces. At Fraunhofer IPMS, we develop advanced multisensory systems that combine both optical and acoustic sensing technologies, including LiDAR, ultrasonic proximity sensors, acoustic cameras, and tactile sensors.

These systems enable the reliable detection of people and objects, as well as the analysis of textures and force distributions across ranges from several meters down to direct contact. The integration of multiple sensor types improves redundancy, robustness, and reliability for safety-critical applications.

Fraunhofer IPMS: Experts in miniaturized sensor modules

Fraunhofer IPMS specializes in miniaturized sensor modules that can be embedded in compact spaces and even directly onto surfaces. This allows for seamless integration into robotic systems and opens up new use cases in gripping, positioning, collision avoidance, and navigation. Our technology is ideal for sectors such as service robotics, professional service environments, and automated machine tending.

Emerging applications in Industry 4.0, Smart Health, Smart Security, and Automotive increasingly rely on intelligent, interactive systems. These technologies require reliable, real-time sensory data acquisition from objects and surfaces in the near-field and contact range. Key use cases include precision gripping, object handling, orientation, and positioning in robotics as well as augmented human perception (e.g. artificial skin, AR interfaces) and 3D environmental sensing such as depth-resolved gesture recognition and contactless control. These applications demand high information density, low latency, and AI-optimized, energy-efficient sensor networks.

Conventional optical and capacitive sensors often lack the ability to deliver spatially continuous, high-resolution detection or combine proximity and tactile sensing in one compact solution. To overcome these limitations, Fraunhofer IPMS is advancing a multimodal sensor platform based on ultrasound sensing for combined tactile and proximity monitoring.

Fraunhofer IPMS – Pioneering Ultrasound-Based Sensor Technology

For the first time, tactile and near-field sensing can be integrated on a single chip module, increasing data richness and enabling space-saving designs. Central to this innovation are CMOS-compatible capacitive micromachined ultrasonic transducers (CMUTs) combined with integrated electronics. This enables the development of cost-effective, miniaturized, and energy-efficient sensor solutions that offer high sensitivity and real-time processing, ideally suited for industrial and embedded AI applications.

Data transmission between rotating and stationary components remains one of the most complex challenges in industrial communication. Traditional slip rings are commonly used in applications such as wind turbines, helicopters, and industrial robots to facilitate this data exchange. However, contact-based slip rings often face limitations due to mechanical wear and material constraints, while contactless alternatives tend to be either expensive, prone to interference, or limited in data throughput.

Fraunhofer IPMS offers the innovative Li-Fi GigaDock® transceivers, delivering contactless, high-speed data transmission at rates up to 12.5 Gbit/s with full 360-degree rotational capability. Utilizing optical data transfer, these transceivers ensure interference-free, wear-resistant communication ideal for demanding rotary applications.

Our comprehensive services include:

• Custom optics and transceiver development
• Module integration tailored to customer systems
• Complete system setup and deployment
• Thorough characterization and testing
• Pilot manufacturing
• Dedicated customer support and maintenanceIPmaschine

Currently, classic connection technologies such as connectors and cable loops are primarily used to link machines and robots to data communication systems. Besides the lack of flexibility these solutions offer, the constant mechanical contact causes wear and tear on the components. Compared to hardwiring, connectors allow connections to be disconnected, a major advantage for repair, maintenance, and modernization. However, connectors are often limited in their number of mating cycles, and frequent plugging and unplugging can alter transmission properties.

Li-Fi as an alternative for wireless data transmission

Li-Fi, i.e., optical data transmission, provides a modern, contactless alternative as a connector or cable replacement, transmitting data at high gigabit speeds. This contactless connection technology is nearly wear-free, interference-resistant, and especially suitable for use in explosion-proof environments.

Our services:

• Technology consulting
  
• Concept development
• Hardware and module design
• Pilot manufacturing

Modern flexible production lines featuring mobile robots and tools, where every production cell and machine is connected to the cloud and networked with each other — these are typical Industry 4.0 and M2M scenarios that demand one thing above all: secure and wireless communication.

Li-Fi: Ideal for Industrial Real-Time Communication

Li-Fi hotspots use the light spectrum instead of radio waves to transmit data. Compared to radio technology, optical communication is fundamentally more resistant to electromagnetic interference. It is tap-proof and offers real-time capability in the microsecond range, with data rates of up to 1 Gbit/s. These factors make optical communication ideal for industrial applications.

Li-Fi is especially suitable for areas where even industrial Wi-Fi access points reach their limits. The local diversity of Li-Fi hotspots also simplifies network planning by eliminating the need for time-consuming antenna design and alignment.

Our services:

• Optics and transceiver development
• Module integration
• System setup
• Characterisation & test
• Pilot manufacturing
• Customer support

Quantum communication uses the principles of quantum physics to provide unprecedented security in data transmission. As quantum networks evolve, this next-generation security technology will become accessible to a wide range of users. Already today, quantum key distribution (QKD) enables the secure transmission of encryption keys over point-to-point connections.

Traditionally, quantum communication networks have been developed for long-distance links between remote buildings or infrastructure. However, just like classical networks, future quantum-secured networks will also need secure connections within local environments such as individual devices inside a building. This requires the development of Quantum Local Area Networks (Q-LANs) that allow secure, short-range exchange of quantum keys.

First Ever Li-Fi System for Wireless Quantum Communication

Fraunhofer IPMS is pioneering the first use of optical Li-Fi technology for wireless quantum key distribution. This novel approach enables secure, interference-free quantum communication within local networks. Various real-world use cases have already been identified and partially tested, demonstrating the practicality of the approach. This work lays critical groundwork for a multi-layered quantum internet, opening the door to flexible, scalable, and secure wireless communication via Q-LANs.

As intralogistics operations become increasingly automated, automated guided vehicles (AGVs) play a central role in ensuring continuous and flexible material flows. These vehicles typically rely on wireless connectivity, such as Wi-Fi or other radio-based technologies, for communication with central control systems, route management, or warehouse infrastructure.

However, as the number of connected devices grows, radio-based networks are prone to interference, resulting in unstable connections and reduced reliability, especially in dynamic environments with multiple moving systems.

Fraunhofer IPMS: Expertise in Industrial-Grade Li-Fi Communication

Li-Fi offers a robust alternative for interference-free and secure data transmission. By using light instead of radio waves, Li-Fi enables stable, high-speed communication between multiple AGVs, even in densely populated industrial networks. This allows for simultaneous, high-bandwidth connections without performance loss, ensuring that your intralogistics system remains efficient, scalable, and reliable at all times.

Our services:

• Optics and transceiver development
• Module integration
• System setup
• Characterisation & test
• Production support
• Customer Support

Fraunhofer IPMS is advancing the field of machine vision with its innovative "scanning eye" technology, enabling real-time, high-resolution 3D perception for industrial and mobile systems. The core of this solution lies in the institute’s MEMS scanning mirrors - miniaturized optical components that deflect light precisely and reliably. These robust and maintenance-free devices have been in development for years and are already used in industry, medicine, and smart devices.

Machine 3D Vision Powered by LiDAR

When mounted on a robot arm or vehicle, the MEMS-based scanner module functions as an intelligent optical eye, capturing the environment in all three spatial dimensions. By scanning a laser beam across the scene and measuring the time it takes for the light to return (time-of-flight), the system builds a detailed 3D map of its surroundings - a principle known as LiDAR (Light Detection and Ranging). This technology empowers robots and automated systems with situational awareness, enabling them to recognize objects, assess quality, and navigate autonomously with a high degree of precision.

Beyond 3D: Advanced 4D Machine Perception with Spectral Sensing

The next generation of Fraunhofer IPMS’ scanning systems integrates broadband light sources and spectral analysis. By applying an optical grating to the micromirror, the system can reflect different wavelengths selectively, enabling the chemical identification of solids, liquids, and gases. This 4D sensing approach combines time-of-flight data with material-specific spectral information, opening up new application fields:

•  Environmental monitoring and water quality control
•  Pharmaceutical process analysis
•  Leak detection in pipelines
•  Remote condition monitoring in production facilities
•  Enhanced safety in human-machine interfaces

This multi-modal sensing platform provides non-contact, high-resolution environmental analysis, reducing risk and enabling smarter, safer, and more efficient industrial processes.

Key Benefits of Fraunhofer IPMS' “Scanning Eye” Technology

• Non-contact 3D environmental analysis
• Ultra-high spatial and spectral resolution
• Compact, low-power and mobile-ready design
• Robust, durable, and maintenance-free
• Ideal for automation, robotics, and smart sensing

Smart glasses and wearable displays are transforming industrial manufacturing by enhancing productivity, precision, and safety. By projecting real-time data, instructions, and visual guidance directly into the user’s field of view, workers can operate hands-free, reducing errors and improving workflow efficiency, especially in complex or mobile environments.

To meet the demanding requirements of industrial and professional applications, Fraunhofer IPMS develops customized microdisplays that combine:

• Ultra-high resolution
• Flexible substrates
• Sunlight readability and high contrast
• Gesture and eye-tracking capabilities
• Robust surfaces with scratch resistance

Fraunhofer IPMS: Pioneering Wearable Display Technology

As the global wearables market grows, so does the need for miniaturized, energy-efficient display systems with enhanced functionality. Fraunhofer IPMS is developing next-generation technologies that go far beyond traditional displays.

One key innovation is the bidirectional microdisplay, which combines display and imaging functions on a single chip. This enables new interaction methods such as eye-controlled interfaces, where users can navigate and interact with content through natural gaze and movement without touching a screen.

By integrating optical sensing and low-power electronics into compact systems, Fraunhofer IPMS supports the development of next-gen AR glasses, smart headsets, and industrial HMI solutions that are robust, intelligent, and ready for real-world deployment. 

In the future, factories will produce individual products even more flexible than today and achieve greater profitability: in a short time, at low cost, with the highest quality. The employees are supported in the best possible way by modern AR assistance systems and integrated into the production and service processes. This enables to improve working conditions and production processes and also opens up completely new business models and services.

The aim of the secure AR joint project is to investigate innovative services in the industrial production environment. For this purpose, a cross-industry and open cloud-based service platform with open industry interfaces is implemented. This service platform collects data along the entire value chain, from planning to production processes to plant maintenance, and enables location- and situation-specific provision and visualization of the data via a new type of AR assistance system.