An innovative system

To provide an interactive 3D tool for an industrial site, allowing the operators to be trained on tyre manufacture To reduce the training period To train operators on the adjustments and malfunctions To free the real machine during the training period using a virtual environment

This system will increase the level of skills the operators training, and will bring up the plant productivity to get a higher rank with respect to other plants in the group.

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The simulator description

The RVPI simulator is a virtual reality training tool including five training modules:

• The virtual visit: In the guided mode or free mode, users can discover their future work space, learn the terminology and familiarise themselves with the basics of quality and safety.
• The operation mode: This presents the manufacturing cycle on the machine in a detailed way.
• The adjustments :Virtual workshops allow the user to adjust the machine interactively from a real control panel.
• The self-control (check): the operator learns preparing his machine for production and tests his knowledge on safety and quality requirements.
• The Malfunctions: In this module, the operator learns how to reduce machine down time dealing with breakdowns and frequent occurring incidents.

A system follows up the training allowing operators as well as trainers to monitor individual progress all along the training.

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Simulator architecture

The system is based on a local website linking different modules. This interface includes two kinds of elements: the 3D elements and the training follow up. The web site is based on the web server and a data base.

The 3D modules, developed with the Virtools software, communicate with a real control panel. The link between the control panel and the 3D environment is ensured by a plug-in (developed by our team) using the OPC protocol and allows the reading and writing of the state of the automated machinery installed on the control panel.

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Which skills are necessary to design and realize this tool

Engineers in mechanical systems, graphics software, real-time 3D computer graphics, an automation technician, an ergonomist and virtual reality researchers (in the field of interaction, training and cognition) have worked together to develop a user centred application integrating all the aspects of tyre manufacturing.