Kautex Maschinenbau GmbH developed Virtual Trainer, a new simulator tool that allows machine operators to train on a "virtual machine" while the "real machine" is in production.
The initial idea was to create a software tool for Kautex' process personnel to test new machine processes and to see how improvements to the machines and operation software could be made, says Chuck Flammer, vice president of sales North America for Kautex. Kautex was able to successfully simulate machine movements and verify that the results represented the real world on its production equipment.
Virtual Trainer is a standalone compact workstation comprising a computer, two monitors, a projector and a real machine control panel with I/O hardware. Virtual Trainer simulates the same controls hardware and programs on the production machine, and displays a 3-D projection of the machine which a user can manipulate. Users can simulate a range of functions including tool setup and machine startup, and can simulate fault conditions that occur in the machine — such as a bad parison — or external issues — such as a resin problem. Commercial production programs can be brought into the Virtual Trainer system to optimize the process, or simulated trials of a new project can be run.
The standalone equipment allows operators and setup personnel to train without fear of damaging the equipment or incurring a loss of production time, resin or energy. Traditionally, users had to have the training in conjunction with the start-up of a production unit, and that instruction would interfere with the final assembly and testing of the machine. Now training can take place whenever the customer needs it, at any time, for many new Kautex machines, or in a classroom, says Flammer.
Virtual Trainer is currently available with simulation programs for Kautex' KBB line and its KBS fuel-tank machines. Simulation for its KCC line is being developed. Certain pieces of downstream equipment can be included in the simulation. Certificates are awarded following successful training, however, there are no credits that can be applied to higher-learning facilities.
Mikell Knights, senior correspondent
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