Global challenges and industrial competitiveness are having an impact on the training and continuous education of skilled workers and students. In addition to theoretical principles, practical knowledge is also in demand, particularly with regard to digitized and networked manufacturing processes. Virtual learning factories based on 3D simulation platforms offer interesting possibilities when it comes to Industry 4.0: The Mechatronic Simulation Wall developed by MHJ Software GmbH & Co. KG is a mirror image of real mechatronic systems and can include up to four different stations, e.g. magazine, processing, quality assurance and sorting. This type of configuration makes it possible to program each station individually, or run the entire system, which opens up a wide range of learning scenarios with varying degrees of complexity.

Students at universities, training centers, and in other educational institutions work with control and automation technology either using real mechatronic models, large learning factories, or in 2D and 3D simulation environments. However, real learning factories with multiple stations are often very complex, making them not equally suitable for all students, who have different levels of knowledge. In addition, such a learning factory is beyond the budget of many educational institutions and training departments. Other factors that cannot be ignored are the maintenance requirements and the associated costs, as well as the risk of injuries. Unsupervised learning and testing of one's own programs is hardly possible here. Furthermore, in the worst case, the mechatronic models or components can be damaged if there is a programming error. The training is more practical and, above all, more cost-effective with the Mechatronic Simulation Wall developed by MHJ-Software. Real mechatronic learning factories, such as the LT system from K?ster Systemtechnik GmbH, are digitized and displayed on a scale of 1:1 or larger using several 3D simulations.

Four stations, countless possibilities

The MSW consists of four large-format wall-mounted screens, each connected to its own mini-PC. The PCs form a network, and each one runs an extended version of the software PLC-Lab 3D Player (also by MHJ). In addition, each PC is connected to a physical PLC or uses a software PLC such as PLCSIM Advanced. The four stations of the training factory simulate the production of cylindrical workpieces made of different materials, from the delivery of the blanks to processing and testing, and finally sorting.

Now, individual teams can start working on the various stations. Each team develops the control program for its own station, for example for the magazine, processing, testing and sorting, or storage. Different levels of difficulty enable teachers to assign teams based on their performance. Each station can be configured independently; for example, one can be linked to an S7 controller while another uses a CODESYS or Allen-Bradley controller. In computer science classes, MSW stations can also be controlled directly using the Python programming language.

Simulation of a continuous material flow

Once the control programs are ready, each team tests their station independently of the other stations with the help of the 3D simulation. Practice-oriented tools help to detect potential errors. For example, students can use the tags window to monitor all inputs and outputs. If necessary, an input or output can be set to a fixed value, a process known as “forcing”. This option for checking and manipulating the variables makes troubleshooting considerably easier and helps to quickly identify and rectify errors in the PLC program.

Once the individual stations are working, the learning factory can be simulated as a complete system. In this phase, the four 3D simulations exchange data to ensure a continuous flow of materials. For example, a workpiece arriving at the end of the conveyor belt from station 1 is automatically removed and inserted at the beginning of the conveyor belt from station 2. Together, the teams can now check to see if their factory is producing the workpieces correctly. Any problems that may occur, such as a material jam, can be discussed together to find solutions. All processes are displayed on the almost 6-meter-long monitor wall, and sometimes even better than in reality. For example, when processing in the real learning factory, a drilling process is only alluded to for security reasons; in the 3D simulation, on the other hand, a “real” virtual hole is drilled.

Diverse learning scenarios

As a digitized training factory is much more flexible than a real-life setting, it offers a whole range of extra possibilities. In addition to the four stations of the networked production line, the MSW also includes 25 smaller, self-contained simulation models with different levels of difficulty from simple to complex so that there is a suitable task for every level of training. From 2025, the new PLC-Lab 3D-Studio software will even make it possible to create your own 3D simulations from CAD data. This opens up interdisciplinary training opportunities: for example, future design engineers can create the CAD models while apprentices in mechatronics, electrical engineering or automation take over the programming. This opens up a wide range of possible learning scenarios.

The Mechatronic Simulation Wall is available now. MHJ-Software provides the licenses for PLC-Lab 3D Player including the MSW option. The hardware (screens, mini-PCs, PLC) can be set up by the customer or a third party. The manufacturer offers free support for selecting and setting up the components.