Industrial competitiveness is directly linked to the education and training of skilled workers and students. In addition to theoretical principles, practical knowledge of digitalized and networked manufacturing processes is particularly in demand. Virtual learning factories based on 3D simulation platforms offer new opportunities in the field of Industry 4.0. The Mechatronic Simulation Wall (MSW) from MHJ Software is no exception. It is a mirror image of real mechatronic systems and can include up to four different stations: Magazine, Processing, Quality Assurance and Sorting. Such a configuration allows each station to be programmed individually or the entire system to be put into operation, enabling a variety of learning scenarios of varying complexity.

Four stations simulate production

The MSW consists of four screens, each of which is connected to a mini PC. The PCs are networked together; each runs an extended version of the PLC-Lab 3D Player software. 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 of different materials, from the delivery of the blanks to processing, testing and sorting.

The individual stations can be operated by different teams. Each team develops the control program for its own station, for example for the magazine, processing, checking and sorting or storage. As the levels of difficulty vary, instructors can deploy the teams according to their level of ability. Each station can be configured independently, for example one can be linked to an S7 controller, while another uses a Codesys or Bradley controller. If the MSW is used in computer science lessons, stations can also be controlled directly using the Python programming language.

In addition to the four stations of the networked production line, the MSW also contains smaller, self-sufficient simulation models with different levels of difficulty.

© MHJ-Software GmbH & Co. KG

Once the control programs are ready, each team tests its station independently of the other stations using the 3D simulation. If the individual stations work, the learning factory can be simulated as an overall system. In this phase, the four 3D simulations exchange data to ensure a continuous material flow.

From 2025, it will be possible to create your own 3D simulations from CAD data using the new PLC-Lab 3D-Studio software. For example, budding design engineers will then be able to create the CAD models, while trainees in the fields of mechatronics, electrical engineering or automation will be able to do the programming.