The next generation of mobile broadband communication, 5G, is seen as a driver for the industrial Internet of things (IIoT). The expected 5G-increased performance spanning across different indicators, flexibility to tailor the network to the needs of specific use cases, and the inherent security that offers guarantees both in terms of performance and data isolation have triggered the emergence of the concept of public network integrated non-public network (PNI-NPN) 5G networks. These networks might be a flexible alternative for the well-known (albeit mostly proprietary) Ethernet wired connections and protocols commonly used in the industry setting. With that in mind, this paper presents a practical implementation of IIoT over 5G composed of different infrastructure and application components. From the infrastructure perspective, the implementation includes a 5G Internet of things (IoT) end device that collects sensing data from shop floor assets and the surrounding environment and makes these data available over an industrial 5G Network. Application-wise, the implementation includes an intelligent assistant that consumes such data to generate valuable insights that allow for the sustainable operation of assets. These components have been tested and validated in a real shop floor environment at Bosch Termotecnologia (Bosch TT). Results show the potential of 5G as an enhancer of IIoT towards smarter, more sustainable, green, and environmentally friendly factories.

To automate the quality control of painted surfaces of heating devices, an automatic defect detection and classification system was developed by combining deflectometry and bright light-based illumination on the image acquisition, deep learning models for the classification of non-defective (OK) and defective (NOK) surfaces that fused dual-modal information at the decision level, and an online network for information dispatching and visualization. Three decision-making algorithms were tested for implementation: a new model built and trained from scratch and transfer learning of pre-trained networks (ResNet-50 and Inception V3). The results revealed that the two illumination modes employed widened the type of defects that could be identified with this system, while maintaining its lower computational complexity by performing multi-modal fusion at the decision level. Furthermore, the pre-trained networks achieved higher accuracies on defect classification compared to the self-built network, with ResNet-50 displaying higher accuracy. The inspection system consistently obtained fast and accurate surface classifications because it imposed OK classification on models trained with images from both illumination modes. The obtained surface information was then successfully sent to a server to be forwarded to a graphical user interface for visualization. The developed system showed considerable robustness, demonstrating its potential as an efficient tool for industrial quality control.

This paper proposes an automated system integrating infrared thermography (IRT) and computer vision for air leak detection and localization in end-of-line (EOL) testing stations. This system consists of (1) a leak tester for detection and quantification of leaks, (2) an infrared camera for real-time thermal image acquisition; and (3) an algorithm for automatic leak localization. The python-based algorithm acquires thermal frames from the camera’s streaming video, identifies potential leak regions by selecting a region of interest, mitigates environmental interferences via image processing, and pinpoints leaks by employing pixel intensity thresholding. A closed circuit with an embedded leak system simulated relevant leakage scenarios, varying leak apertures (ranging from 0.25 to 3 mm), and camera–leak system distances (0.2 and 1 m). Results confirmed that (1) the leak tester effectively detected and quantified leaks, with larger apertures generating higher leak rates; (2) the IRT performance was highly dependent on leak aperture and camera–leak system distance, confirming that shorter distances improve localization accuracy; and (3) the algorithm localized all leaks in both lab and industrial environments, regardless of the camera–leak system distance, mostly achieving accuracies higher than 0.7. Overall, the combined system demonstrated great potential for long-term implementation in EOL leakage stations in the manufacturing sector, offering an effective and cost-effective alternative for manual inspections.