! " # $&%' ( Robotics Institute University of Valencia
!#"$&% '(*) +%,!-)./ Training of heavy machinery operators involves several problems both from the safety and economical point of view. The operation of a harbor crane by an inexpert operator implies a high risk, and some of the exercises that benefit the learning process are not possible in real machinery, as they imply danger for the driver and the equipment. On the other hand, dedication of equipment units to training tasks implies a high cost for the company. A training simulator allows repetition of maneuvers and exercises under a very wide range of conditions, and the exposition of the trainee to many extraordinary events that are not possible when using real machinery (weather conditions, operation under machinery fault, stressed operation, etc.). Benefits obtained from the use of simulators for training: The main goal of a training simulator is that users learn how to use different machines without the need of using a real one, avoiding risks and saving money. Moreover, a training simulator includes a sophisticated Instructional Design that maximizes the performance obtained from the systems guiding both the instructor and the operator through a complete course. Finally, the simulator also provides tools for an objective evaluation of the progress and the acquired skills of each operator.
"!-) '.)!!- ) & % % &% & '+) +% ' % ) A Simulation System is a complex system made of a set of subsystems that perform different tasks. Every system developed at the Robotics Institute comprises an specific mathematical model that computes the state of the simulated crane and a visual subsystem that generates high quality images in real time to represent the scene computed by the mathematical model. The simulators use a full-size cabin with real instruments giving a high degree of realism and immersion. A six-degree-of-freedom (DOF) inertia simulation system provides the cabin and the user with the necessary movements to avoid sickness and fatigue. The simulators use the newest techniques of inertia simulation, computer graphics and dynamic modeling. A full instructional design and a complete set of tools for evaluation and control of the training process are provided with every simulator. Every simulator has been designed in cooperation with a team of experienced crane operators and instructors from the Port of Valencia. In this way, the simulators provide a realistic simulation of the tasks performed with every crane. The virtual environment percibed by the user reproduces the working environment of real cranes, with real scenarios and textures and digital sounds that gives the user a full sensation of immersion. Architecture: the simulation systems developed at Robotics Institute are based on the use of off-the-shelf components and a cluster of standard PC, reducing considerably the cost of the equipment and enhancing the upgradability and scalability of the system. Every simulator can be presented in a wide range of hardware architectures; from the complete simulator with a cabin and 6-DOF motion platforms to an affordable training equipments based on a single PC and a desktop console.
& % +)! - Flexibility: The simulation system provides the most complete tool for training operators of the main models of harbour cranes using a single common platform. Currently available cranes are: Quayside crane Rubber Tyred Gantry crane Mobile bulk crane Reach-Stacker crane Ro-Ro Tractor unit Scalability: A simulation system can be purchased for the desired number of crane simulators. The system will be easily upgraded in the future with the remaining/new simulators if required by the customer System Support: The Robotics Institute offers full support during the lifetime of the simulators Every simulator is equipped with an specific Instructional design that allows top performance in the skills acquired Specific mathematical models for each simulated machinery, including complex interaction with the environment: Vessel behavior Machine response to load, collisions, etc. Realistic behavior of collisions, coal and grain piles, etc. Simulation of special working conditions such as: A variety of weather conditions and reduced visibility Day and night work Work under machine failure Visual System: Virtual scenarios with digitalized pictures from real harbors and real crane sound playing during the simulation Reproduction of real cabin of every simulated crane Motion system: The inertia simulation system provides the trainee with the feel of operating the actual equipment. The system feeds back the user with feels due to impacts and movements. Instructor's console to control the simulation environment and to introduce faults as mechanical failures. The console provides with information about previous simulation sessions and the progress made by the trainee. Instructor's console manual and operation manual Operator database system, both for trainee and for advanced users Visualization of the simulation at the instructor's console Adaptability to customer needs: although the simulator is sold as a finished product, it is possible to customize them to best fit the customer needs. The simulators can be adapted to fit specific harbour characteristics and even to fit the different machinery to be used.
%*-) ) % & -' % &% - A Training Simulation System is a tool designed for the instruction of new operators and advanced training of experienced ones. Within this premise, all the simulators include, as an integrating part, a set of tools that help both the instructor and the user of the simulator to obtain the maximum performance of the equipment, and allow an optimum use of the instruction time. The Instructional Design provided with the simulators includes a large set of exercises, guiding the instruction process with visual messages and indications on screen, and with a complete illustrated manual. A set of tools help the instructor to evaluate and follow the progress of each individual trainee. Reports are generated including information of a wide variety of parameters and aspects of the simulation. Reports are generated in a per-exercise basis or for the complete formation process. Evaluation and formation programas features: Guided exercises with visual instructions on screen Course manual with accurate description of the exercises and of the different skills to be acquired through every one. Database system to store all the information of each trainee and of advanced users Record system to monitor the evolution of every user along the training program. Individual performance reports and stadistical comparison with historical data. Exercise and overall reports, summaries, etc. with graphical plots and general information for each trainee Possibility of introducing new parameters and data in the reports upon demand Full control of the different tools from the instructor's console Video recording of an exercise Pause in the simulation that can be invoked from the instructor's console to give indications to the trainee at any moment during the simulation!#"%$&(')!* +$ '),')-.%'/10 Date, time and duration information per exercise Overall course information with finished exercises, average performance of the trainee, evolution along time, skills acquired, etc. Velocity log, and graphical plots of velocities. Maximum velocities record Collision log, with track of collision velocities and of strong collisions Graphical representation of trajectories of spreader, hook, vehicle, etc. Acceleration log, with record of dangerous accelerations, overload of the machinery, etc. and graphical plots Record of dangerous or prohibited maneuvers during the simulation. Statistical analysis of data to better plan future training programs
Contact Information: Instituto de Robótica Edificio de Institutos de Investigación 46980 Paterna (Valencia) SPAIN Telf: +34 96 354 3564 e-mail: rafael.martinez@uv.es http://robotica.uv.es/lsym