Virtual Reality Machines to improve training in Control and Automation

Transcripción

ETD 351
Virtual Reality Machines to improve training in Control and Automation
Alfredo R. Izaguirre, Manuel E. Macías
Electrical Engineering Department
Tecnológico de Monterrey
Monterrey N.L., México
Abstract.
Current market requirements in industrial sector have motivated the development and adoption
of digital manufacturing software tools for control systems design, training, and process
optimization to validate and ensure the production system´s programming control and
automation equipment. This practice, known as Virtual Commissioning, emulates the real
process behavior in a computer software environment. This technology represents an opportunity
for education where the virtual emulation of real processes can be used to equip Control and
Automation laboratories where students can test, validate, and debug their control and
automation strategies, contributing to student formation and solving the need of having costly,
real industrial machinery to reinforce the understanding of classroom theory, with practice. This
is an excellent option for universities without enough resources, mainly in developing countries,
where laboratories are commonly equipped with improvised homemade systems that don´t
represent what students will face in an industrial environment. However, the integration of this
technology in education cannot be transparent, as a majority of present market applications are
not designed for education and others, don´t cover the actual education needs. Because of this a
set of features, that intends to enhance the advantage of this type commercial applications is
proposed its principal objective is to integrate and motivate the spreading of these tools in
education and make them affordable for low-resource universities. In this paper, an application
called Virtual Reality Machine (VRM), that covers the set of features needed in education, is
introduced. A methodology for VRM creation is also proposed, supported by a set of LabVIEW
applications consisting of CAD solid creation, conversion process, assembly process, animation
process, and connection process, followed by the automation validation process. Finally, an
example of VRM capabilities, scope, usage, and impact in student formation is presented.
Introduction.
The consumption world market constantly is increasing and changing its requirements. Day by
day more and better quality products are asked for customers what shrink the market product life
cycle, encourage a more extensive product variety and reduce product launch times. Moreover
this is happening while market price erode, global sourcing increases and quality product must to
be keep high1. This represents challenges that manufacturers have to face in a high competition
environment what forces companies to implement technologies, processes, and practices that
enhance their competiveness and differentiate from the others. Product improvement, constant
product offer changing, process standardization and optimization, price and cost reduction,
quality, etc. are some of the practice that companies implement daily oriented to accomplish new
market requirements. However some of these practices appear to be opposed, by one side having
a fresh product offering requires constantly production lines changing what opposes to cost
© Conference for Industry and Education Collaboration
American Society for Engineering Education
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reduction and process standardization. Then to remain successfully in market and in some cases
even to survive, companies must be able to keep a constant innovation. This targeted to look for
necessary practices and tools that support them to face actual challenges and assurance them that
changes in any production aspect, will impact in the planned way all related company sectors.
Market globalization has forced that companies increases production quotes motivating that
these open plants in other countries, increase production lines, change or totally replace their
process and the way of fabricate goods, etc. This growing has brought a bigger organization
structure inside companies, more process and equipment to control and manage. In addition at
the same time, practices like lean manufacturing, six sigma, QFD, ISO quality certifications and
other production quality activities are being implemented. This is translated in more product´s
specifications, processes and procedures information to handle. For solving this, many software
tools focused to different sectors and with different scope have arisen as support for
manufacturing companies CAD/CAM (Computer Aided Design/Computer Aided
Manufacturing), CAE(Computer Aided Engineering), CAPP (Computer Aided Process
Planning), PPC (Production Planning and Control).Some of these can be implemented
individually, however in the highest level these are integrated in a software manufacturing suite
known as PLM (Product Lean Manufacturing) whose principal objective is to enable companies
to achieve the business imperative of timely and cost effective product launches. This software
tools oriented to improve and enhance manufacturing’s resources and production are known as
Digital Manufacturing tools (DM) as merge the virtual and physical manufacturing world.
Digital Manufacturing (DM).
DM is an integrated suite of software solutions that supports manufacturing process, tool design,
and visualization through 3D virtual simulation tools. The factory environment and the
production process can be modeled including buildings, production lines, transportation,
workflow, and other facilities that represent the complete physical production environment1. On
these environments, manufacturing engineers can validate and optimize the processes, designing,
synchronizing, and validating production lines, robotic workcells, machine centers, production
equipment, control systems functionality and requirements completely prior to the purchase,
installation, and commissioning of physical equipment. In essence, DM facilitates the complete
view of product and process design as integral components of the overall product life cycle. This
virtual validation and commission have turn more important lately as the looking for major
production and trusty processes have causes that totally automated complex manufacturing
systems be used more frequently in industry. Because of this there is a section of DM that allows
manufacturing engineers to merge virtual models of production equipment with automation and
controls what enables the complete validation of controls logic, automation strategies and HMI
functionality in a process called Automation Simulation2. This extended level of manufacturing
process design let executing “perfect” launches and production changes by validating totally all
aspect related with the process from the tool and machine design to the final automation strategy.
Automation Simulation.
Automation simulation involves the entire process of modeling, animation, evaluation,
optimization, and validation of controls systems for automation equipment and systems in a
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virtual environment. Which represent manufacturing workcell with 2D image or 3D solids
elaborated in CAD that may represent from single process with primitive graphics to elaborated
production systems, including multiple robots, complex tooling and fixtures, clamp automation
and PLCs. Automation Simulation intends mimic and simulate the real process to be automated
by animation sequences, with the objective of commissioning and debugging total or partial
control logic changes of the manufacturing workcell2. This can be done even weeks or months
before the real machinery be present in shop floor, as control logic strategy is simulated in virtual
cell where interaction and control sequences of tooling, robots, clamps, safety devices, electrical,
hydraulics and pneumatics, etc. can be tested. Inside automation simulation this practice is
known as virtual commissioning and helps to assurance that any change in automation system
will cause the desired impact in production, providing to manufacturing and controls engineers
an opportunity to ensure controls design before production starts.
Virtual Commissioning.
Virtual commissioning principal objective is assurances optimizes and validates control and
automation implementation and changes in virtual automated production systems prior to real
commissioning. This is on state-of-the-art digital manufacturing simulation technology; such
depends on advanced simulation methods that truly represent the merging of 3D virtual
simulation environment, to accomplish the level of automation and synchronization required,
with the physical automation world of control logic and control platforms that perform the
production processes3. Virtual commissioning is carried out on virtual prototypes of production
systems and equipment which are based on direct real model capabilities and appearance.
Originally was intended for allowing the debugging of the control code on an actual
Programmable Logic Controller (PLC)3. However its scope goes further as allows the user
efficiently and cost effectively optimizes and validates any implementation or change in
manufacturing processes control strategies, testing different control scenarios, accelerate learning
curve and enables control engineers with the ability to reduce costly errors occurrences, and
mitigate risks in a virtual environment well before using real equipment to accomplish
commissioning. This Virtual Commissioning features have caused that also be used in industry
with training purposes, as learning process can be carry out on this.
Virtual commissioning is intended to validate control strategies in virtual production system
environment and then move these to real production system. However moving is not necessary
as if virtual commissioning stops in virtual environment the control strategy validation can be
done anyway what makes it useful for validating control engineers programming skills, as the
knowledge necessary for controlling virtual production system is exactly the same for controlling
the real one. Then automation simulation can be used with didactic objectives as a teaching tool
in automation and control curses as offers a process to control where students can observe the
correct or incorrect functionality of their control program. This way, automation simulation
supported by virtual commissioning is used for industry and for education. In the first one it has
two orientations; production systems optimization and validation, and control engineers and
laborer training. In the second one it is used in control and automation courses where final
applications are used for supporting engineering student’s formation with practice.
Optimization and Validation.
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The virtual 3D world created by automation simulation technologies of solid model product,
digital mockup, and manufacturing process simulation goes further that only simulate production
systems behavior. As its objective is to assurance a control and automation strategy that can be
loaded to real automation hardware and controls a real production systems; making the final link
to the actual production work environment by the connection to machine control systems. In
addition to model and simulate the machine tool, conveyor line, robotic workcell, PLC, etc;
automation simulation generates accurate information capable of driving correctly control
systems, shorts the ramp-up of production lines during commissioning and product launch,
reduces cost, time, design changes, and risk of errors2. These advantages represent critical factors
in product delivery and ultimately company profit or loss; as production lines, workcells, and
control systems must be designed, installed, and deployed in the shortest possible time, working
correctly with the least amount of test and validation what has become automation simulation in
a key piece for manufacturing industry.
Automation simulation gives to production engineers the capability of building virtual
production systems based on real automation events. What enable them to virtually model, the
most correct physical and logical interface and material handling operations that can occur
between the components of workcells and production lines. Because it permits control strategies
or production scenario construction for experimentation, that would otherwise be expensive
and/or time-consuming. This empowers engineers to try ideas in a dynamic, synthetic
environment while collecting virtual response data to determine the physical responses of the
control system. During virtual commissioning engineers are typically finding over 100
mechanical and electrical errors in logic, HMI, and drawings per cell1. Problems are normally
found and fixed with minimal disruption to operation as are solved more quickly since engineers
can narrow them down to items such as physical connections, confident that the validated control
code works. With automation simulation consequences two to three man weeks are saved during
startup, saving thousands of dollars in engineering and production labor costs.
Training.
There are two training orientations. For engineers that carry out added value activities in
production systems and for laborer who are final machines users. According to orientation
automation simulation objective, scope, and usage are different. In training for engineers usually
control or manufacturing ones, automation simulation is used for building virtual environments
which can emulates real production systems that are already present on shop floor or that will be
in a future. The objective of these training simulations is to serves as a virtual commissioning
tool where engineers gain a proper understanding of the process testing control strategies;
observe production systems limitations and scopes; known production times and response to
process changing. These aspects are principally important for beginner engineers or for new ones
in a specific area2. Once that the virtual environment is built engineers training consist in
consecutive virtual commissioning on the same simulation. With the objective of acquire the
necessary knowledge for understanding and control the production system. Laborers in
manufacturing companies receive training when are hired, when are moved from production
process, when new machinery is going to be used or a product change is planned, actual
manufacturers constantly draw on to some of these situations what means that laborer needs to
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be trained frequently. Training for laborers uses virtual environments created by automation
simulations tools, but these emulations are not intended for a constant virtual commissioning, the
objective is to train machine operators that will use real production systems. With virtual
automation simulation is available for operators the virtual model of the real production system
connected to a human machine interface (HMI) or a control panel similar to what is used in the
real machine2. Then operators can observe how the machine emulation reacts to control device
that is the same that will use in the real machine. With emulation, possible human errors during
real machine operation can be illustrated, avoiding the risk of costly machinery damage and
above all is assurance that the laborer will known what happens when a human mistake occurs.
This is achieves without endanger laborer´s health or machine hardware. Training simulators
play a significant role in reducing the time for plant to go operation and reduces learning curve
time and risks, as empowers the plant operators, to perform the needed tasks needed, with a
deeply understanding of the machine that is going to be operated.
Education.
Automation simulation software tools are used with two orientations in education. The first one
is their usage principally in Universities focused in control, automation, mechanical,
manufacturing and electrical careers. In universities automation simulation tools are taught
principally in advanced engineering courses where students learn about the automation tool
itself, its features, limitations, scope, etc. What means that students work with the development
environment not with final emulations, as the teaching is oriented to the automation simulation
tool. The second one automation simulation orientation consists in using final emulation
applications for teaching engineering students and supporting automation and control theory
taught in classrooms with practice. This is done in laboratories where students´ control and
automation strategies can be tested on emulation of production systems that are really used in
industry, without risk to damage costly equipment. This is done taking advantage of the fact that
is also possible carry out all the virtual commissioning process, and never deploys the
automation in a real model, just like is done for engineers training in industry. Having this
emulation enables students to deploy different control strategies in each one of these, makes
possible that they relate with different sensors, actuators, machinery functionality, etc.
From this point of view, automation simulation well used in education opens the opportunity of
solving the problem that faces many universities in what refers to control and automation
laboratories equipping. That is the fact of having a process where students practice the
knowledge acquired in classrooms. As usually real workcell used in industry are very expensive
and universities cannot paid for some of these. For this reason, the possibility of having a variety
of virtual emulations process where students increment, reaffirm or practice automation and
control skills is an opportunity for educational institutions for complementing and supporting
their automation and control courses, and increase the knowledge, abilities and formation of their
students. However in market there isn’t a big offer of final virtual application. There are only a
reduce number of companies like Festo by Ciros Mechatronics, SIEMENS by SIMIT SCE and
EasyPLC that offer 3D final application for carry out virtual commissioning and learning
automation. Prologix an independent tool offers 2D final virtual applications, others like Delmia
Automation by Dassault Systemes, Tecnomatix by SIEMENS, RsTestStand by Rockweel, Unity
Pro by Schneider are oriented to give the software tool for building virtual applications and not
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offer final virtual environments where students can testing and validate their programs. Then
from the reduced vendors’ group in market, there is a more reduce group that offers final
applications for training oriented to Educational Institutions whose scope varies. Application
particularities cause advantages and disadvantage between final virtual applications what impact
directly in the students’ learning level. Although the strong impact that can cause these final
application in education, these have not been broadly used, as these are not as popular in
education as could be. Considering their scope in training the lack of popularity has been
motivated principally for particular tool disadvantages and the small number of option in market.
Automation Simulation software tools in market.
Automation Simulation is practically new and has been exploded and developed only for a
reduced group of software vendors. The software solutions present in market are very different,
everyone with its own particularities and scope. Differences are found principally in aspects like
origin, target sector orientation, cost, origin country, visualization capabilities, connectivity
supported, licensing, usage complexity, integration level, programming environment,
performance, flexibility, graphics quality, etc.4 The origin of the tools present in market varies as
different companies whose orientation are sectors some way related to manufacturing and
automation have created these tools, or some others have been developed for a small group of
individual programmers with specific purpose. Origin seems to be closely related with tool
particularities and scope. Some aspects of the software tool developer company as expertise,
know-how, objective, availability of means as previous software developments, products
portfolio, etc. dictate some of the principal features of the tool and therefore its scope. Origin of
the tools refers to orientation of the company that created or commercializes the software tool.
Principally there are three origins of the tools present in market. 1) PLM software tools. 2)
Automation hardware and/or software vendors. 3) Software tool from Third Party.
PLM software tools.
Companies that develop this kind of tools are the beginners in this field and who more are
developed and exploded the automation simulation and virtual commissioning concept; the scope
of these tools is extended. These are the most broadly used in industry by big companies like
GM, Ford, Airbus, etc. as are supported by a renowned company. There are principally two PLM
software vendors that offer automation simulation tools inside their product portfolio. These are
Delmia from Dassault Systems powered by IBM and Tecnomatix powered by SIEMENS. From
these with previous experience in CAD/CAM and CAP software Delmia is the beginner of this
technology and who establishes and defines the automation simulation and virtual
commissioning concepts, Delmia Automation is the tool offered for this vendor2. Tecnomatix is
more recent and arises from the integration of Unigraphics with SIEMENS; it offers a tool called
eM-PLC oriented to virtual commissioning with SIEMENS´s PLCs5.
Automation Hardware or Software Vendors.
Automation tools that have been developed and are offered in market for automation hardware
manufacturers are part of this classification. In automation technology software is closely related
and necessary for using automation hardware. Companies that are automation hardware vendors
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like SIEMENS, Rockwell, Schneider, ABB, etc. offers in their product portfolio different
software application oriented principally to own PLC programming and PLC emulation, some of
these also offers automation simulation software that is intended for being virtual emulations
developing software. The resulting applications vary in visualization, scope and complexity
depending of the vendor. Visualization of these tools goes from primitive 2D objects to
importation of 3D solids created in CAD; the scope of these tools is principally oriented to
validate PLC programming. Despite these tools don´t offer the features and capabilities that offer
PLM tools and is scope is more reduced, as its principal objective is to validate automation and
control PLC programming, these are considered as automation simulation tools. The principal
feature of this kind is that are compatible only with developer automation hardware. SIMIT by
SIEMENS, RS TestStand by Allen Bradley and Unity Pro by Schneider are examples of these.
Software tools from third party.
The origin of tools in this classification is very heterogeneous some of these are developed by
software companies with orientation to automation. Despite that aren´t part of PLM solutions
some of these are supported for renowned software companies with brand positioning and
expertise in automation. These are robust and have a high level of integration with proprietary
and external applications. Some examples are EasyVeep, Cosimir PLC & Ciros Mechatronics by
Festo, InControl and InTouh from Wonderware suite by InvenSys. Tools developed by software
companies without automation orientation but with expertise in software developing are also in
this classification, either in independent way or by joining with automation hardware
manufacturers, taraVRcontrol by Tarakos is an example of these. A third division what is
principally intended for own training and is the most varied group is integrated for automation
simulations tools created for individuals or little groups of programmers principally automations
professor or PLC fans, oriented to helping to understanding PLC programming some of these
tools have an extended scope and offer other possibilities. However because their origin these
aren’t so robust and their capabilities are poor compared with tools in others two classifications,
EasyPLC, SPS-VISU, Prologix are examples of these. In table 1 in appendix A in the end of the
paper is shown a brief resume of the principal features and capabilities of these 12 automation
simulation tools in market. These, are the most common used, and cover almost all the tools
present in market. In case of some omission, tools mentioned describe well the status and
capabilities of simulation tools in market.
From table 1 eM-PLC and Delmia Automation are the most used in industry principally in big
companies as have a high integration level and capabilities, however the licensing cost of the
tools is high. InControl and InTouch are used for automation companies, who develop final
application for industry these are oriented to developing and are based in 2D visualization,
licensing is required. RS TestStand Unity Pro, SIMIT in industry version are oriented to middle
size companies where are used for manufacturers and for external automation companies for
validating PLC programs, these only work with hardware from Allen Bradley, Schneider
Electric, and SIEMENS respectively licensing is required for it use. SPS-VISU has achieved
integration with SIEMENS10 however visualization capabilities is poor as only uses 2D graphics.
taraVRControl is also a developing tool final applications this use OPC server what makes
possible communicate final application developed on this with any PLC6 however licensing and
somebody that develop applications are necessary. The rest aren´t intended for being used in
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industry as are created for small developing companies, EasyPLC, offers powerful visual process
emulations, PLC and HMI programming environment and a suite called machine simulator for
building virtual applications. The principal objective of these tools is to be used as virtual
environment developing software and don´t offer final applications for practicing only
EasyVeep, CIROS for Mechatronics and ProLogix are final applications EasyPLC and SIMIT
SCE offer some examples, but the rest are developing tools what makes necessary buying the
software or hiring a company that develop final applications. All these tools require licensing
whose price varies according with the tool.
Features for Virtual Commissioning in Education.
Despite that automation simulation is practically new and that there aren´t and extended offer of
these tools in market this technology is being adopted more frequently for manufacturers. In this
sector it has had the desired impact principally in the reduction of starting up and learning curve
as for laborer as engineers. The impact in learning that automation simulation has in engineers
can be moved to educational sector where can impact in the same way to engineering students as
these seem to fit in the scenario presented for many educational institutions whose needs in
automation and control field are an opportunity for integrating them.
Automation Simulation tools in market are principally focused to industry and the context and
needs for education are different as there isn´t need of adding developing tools but final
applications for equipping laboratories with processes to control. Then the contribution that
automation simulation software platforms can do to education lies in final application developed
in these, not in the developing software. Where students can prove, test and validate their control
program, in a process closely to a real industrial one. As can be observed in table 1 From the
tools in market only a reduced group of software companies have launched to market final
applications with the objective of engineers and students training. However features as,
licensing, price, connectivity, quality, etc of each one of these have caused that aren´t broadly
used in universities.
The need to create a virtual final application whose features, be oriented to education arises. In
addition application´s features must complement students formation with practice, represent
closely real processes, accomplish equipping universities needs with a high performance, let the
spreading of virtual final applications, enhance their impact in educational sector and at the same
time let that these kind of application can be implemented in universities with low resources with
the objective of making them available also for universities in developing countries. A set of
desired features according to the presented educational context needs are proposed next. In
addition an automation simulation final application called Virtual Reality Machine (VRM) that
tries to fulfill these features, its developing procedure, and application are described.
Set of Features.
(1) The student must be capable of analyses and understands the sense of automated process
systems their time and space relations and limits, how sensors and actuator mechanically work,
how mechanism are formed and impact the process, identify the function and mode of operation
of the individual components. For these 3D graphics applications are needed. As there is more
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visual information transmitted with 3D graphics than with 2D. (2) Applications must be
representations of processes found in industry to familiarize students with the operation of the
system and to understand the product and the processing method. The ability to experiment with
real process models creates an environment close to a real manufacturing system, which is the
real objective of training. (3) Interconnection with principal commercial automation software
vendors is optimums as with programming as with softPLC software. While more relation have
students with industry controllers´ software easier would be their adaptation in industry.
Compatibility with softPLC or PLC simulators helps for testing programs without a real PLC. (4)
Connection with real control devices as PLC, touch panels, etc. As this gives more reality to the
process, provides to student industrial hardware familiarization and interaction. The feature of
proving and debugging the programming in a real controller takes the students from the process
virtuallity to the real PLC controller interconnecting the simulated world with the real world. (5)
The final virtual automation application must to add the less possible cost to the solution as the
application is software the prices is principally in licensing for this reason licensing for running
applications has to be the cheapest possible. (6)The hardware necessary for running the
applications, with a high performance, has to be the most common and commercial possible for
avoiding high costs. (7) The simulation must to have short response times; high performance and
speed when 3D visualizations, simulation and virtual commissioning is being carry out. (8) Easy
installation of final applications for avoiding complicated configuration or many and specific
installation steps.
Virtual Reality Machine (VRM) Concept.
There isn´t a single term for calling final automation simulation. In market every vendor gives a
different name, trying to cover the particularities of everyone. The features of the virtual final
application that is going to be presented, explained and developed turn it different from those
mentioned in table 1. For this reason the concept of Virtual Reality Machine (VRM) is
introduced and defined next.
A VRM is a computational application that models and emulates appearance and behavior of a
real machine, process or production system. It is based in a set of 3D solids that mimic as close
to a real machine as possible, visual, audible and functional aspects of the machine elements,
(mechanism and sensors).The VRM dynamic and behavior is controlled by virtual sensors and
virtual mechanism defined and programmed during VRM creation process. These are ready for
connecting with external devices and sending and receiving control signals from/to either real
PLC or SoftPLC. Communication of control signals is done by addressing virtual mechanism
and sensors in a VRM´s pin out table. By itself a VRM is not capable of carry out controlled
sequences as this needs the implementation of a control strategy previously programmed in
external automation hardware. This makes that dynamic and functionality of the VRM depends
only of the control logic sequences programmed by the user.
General Procedure for VRM developing.
For every process that is going to be emulated a VRM has to be created. Despite that every VRM
has a specific final functionality when these are created share certain general developing aspects
that repeat every time that a new VRM is developed. These aspects can be summarized;
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organized and separated in a set of steps according to their developing objective. In every one of
these steps a developing method is followed. Conjunction of all steps integrate a general VRM
developing procedure that can be clearly separated in 6 steps: 3D CAD creation, Conversion
process, Assembly process, Animation process and Validation process, every one of VRM
developing method´ stages and its procedures are described next. In figure 1 is shown the
organization of stages, order and their interaction inside general procedure, the VRM´s part that
is created in every one of these and some application tools used for helping in the VRM
developing.
Figure 1. General procedure for VRM developing.
3D CAD Creation.
The first step for creating the VRM is the Virtual Machine Elements (VME) modeling in CAD
software, the only requirement from the CAD software to use is that it has the capability for
saving the solid created in VRML 2.0 (97)12 format. Requirement that must be accomplished for
future conversion in LabVIEW. Two consideration must to be taking in care when modeling in
CAD software that later are reflected in the VME due to VRML structure features. The first one
is solid number. When the VRML file is converted in a VME this turns in a LabVIEW Virtual
Instrument (VI) turning the solid information in LabVIEW code part. This make more efficient
the final application, extends manipulation capabilities, and enhance the features that can be
represented, accessed or gotten from it before or during simulation running. This is deeper
detailed in Solid Conversion Section. The second is solid functionality for defining if a part or an
assembly is going to be created is necessary consider the dynamic that will have the solid to
model in the final VRM. Similar to real machine in VRM there are two classes of VMEs,
dynamic VMEs, that move as result of a PLC input signal and static VMEs that are part of the
VRM structure, this has to be considered when the decision of what solid include in an specific
VRML that is going to be converted is taken.
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Conversion Process.
Once that the VRML file is created it is processed in an application that has been developed
called VRML-VME Converter. The VRML file structure contains in ASCII code the complete
information that defines the solid, this is separated in object nodes, where each one of this
contains information about the triangle´s coordinates vertex, normal, color values and index of
each solid part that forms the solid12. The application recognizes this structure and processes the
VRML files, gets and organizes the important data required for render the new file in LabVIEW.
Then the VRML file is processed only once by LabVIEW. As result a VME (Virtual Machine
Element) is created. This is a LabVIEW Virtual Instrument (VI), which represents exactly the
solid models as the VRML file, since nothing of information is lost during the conversion. Once
that the process finishes the new VME in saved in a library. Then the VME now is a LabVIEW
native file and has all the information necessary for representing and rendered the 3D solid
without need of VRML or any CAD software or file. Having the 3D solid as VME represents
some advantages as: faster execution time, deeper control of the 3D solid, integration of VME
code to other LabVIEW applications, makes available the usage of some special properties
because all solid data are available during execution. There are two classes of VME for Virtual
Mechanisms and VME for Environment.
VME for Virtual Mechanism: A Virtual Machine Mechanism (VMM) is integrated by two or
more VMEs which are related by at least one dynamic action one over another and at least one of
them is affected by a change of signal received from the external controller. Inside VME for
Mechanism classification there are two VME types: VME part this is gotten when a VRML that
contains information of individual part is converter. VME assembly this is gotten when a VRML
that contains information from solids set is converter. Both can be affected with translational and
rotational movement or color and shape change animation.
VME for Environment: This VME type objective is to serve as VRM decoration exclusively this
represents for example floor, walls or any other solid in the scene that has not connection with
the real controller. This can have movement or be static during VRM functionality.
Assembly Process.
A set of virtual machine mechanisms (VMM) is used for creating a VRM. These VMMs are
integrated by a set of animated VMEs which first have to be placed spatially in their
corresponding position inside the VRM in a previous VRM assembly process, for this, a process
similar to the assembly that is carried out in CAD software, where assemblies or parts have to be
placed in certain (X,Y,Z) coordinates has to be done. However as LabVIEW is not intended for
being a CAD Software this process is not easy and friendly to realize. This assembled has to be
done because when a set of VME´s are called and rendered in the same LabVIEW scene by
default are placed in the position where were saved in CAD software during the Solid Creation
stage, usually this position is the origin (0,0,0) however this can be any point in the space and not
precisely the correct place inside the VRM final assembly, for this reason a set of VMEs when
are rendered are placed normally overlapped in origin and is necessary to place them in their
correct spatial position.
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Inheritance.
Inheritance is defined as parent and child relations among VMEs that command how rotational
and translational transformations applied on one VME affect others VMEs in a VRM.
Inheritance must be specified for a correct VMM functionality. Whether this is defined, when a
movement transformation is applied to one parent VME this affects also its children VME but
when is applied to a child VME this affect only itself. VMEs inheritance structures can vary
from one single branch to a set of branches complexly related in the VRM. Complexity of
relations depends directly of the VMM dynamic relations and functionality inside the VRM.
Subassembly concept.
To fulfill the requirements of the VRM functionality and defined inheritance, a subassembly
must be specified. A subassembly is a set of VMEs or others subassemblies which are affected
dynamically by the same transformation. In addition it contains an internal inheritance structure
which relates all the subassembly components. Subassemblies are generally used for VMM
definition as the elements inside a subassembly can be affected individually by transformations,
defining their dynamic relations inside the VMM and the subassembly as a whole can also be
affected by a different transformations, defining its dynamic relations inside the VRM. Then as
these two transformations need to be handled in the VRM subassemblies must to be used and
defined considering the VRM’s functionality and its VMM.
Assembler.
The VME assembly process carry out in LabVIEW is time consuming, is complex and requires a
complicated programming structure. This motivated the developing of a LabVIEW native
application called Assembler, whose principal objectives are: Optimizing VRM assembly
process, reducing programming time, organizing VME´s data and turning friendly VME
transformations addition. The Assembly process has two principal objectives; placing VMEs in
their correct spatial position and establishes inheritance relations. The first one is repetitive for
every VME that is assembled and the second one differs only a little depending of the
complexity of the mechanism. The Assembler takes advantage of this repetitively letting that the
user set only some parameters as X, Y, Z position, angle and axis for spin and inheritance
definition, these data are processed, organized and structured only once every time that the VRM
is executed this way of assembly the VMEs reduces the programming time as avoids that the
user generates all the programming structure optimizing the assembly process. The file gotten
from this process is a Virtual Machine Assembly (VMA).
In figure 2 is shown the Assembly process in a VRM this is composed in total for 8 VME which
are organized in one static VME that is the principal assembly parent and 7 dynamic VMEs.
Three of the dynamic VME are parents in subassembly 1, 2 and 3 and four of them are individual
VME subassembly 3. In a) is shown the VME origin position when they are rendered, in b)
subassembly 1 which contains 1 VME and to the subassembly 2, in its principal branch, is
moved and only the principal assembly parent keeps in its positions. In c) subassembly 2 which
contains 1 VME and to the subassembly 3, in its principal branch, is moved. In d) the
subassembly 3 which contains 4 VME, in its principal branch, is moved. In e) the 4 individual
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VME inside subassembly 3 are moved. In f) a top view of all VMEs in the VRM is shown in g)
and h) the assembly process is illustrated when one VME is placed in its correct position. In i)
the final correct assembly is shown. As was mentioned a subassembly can contains VMEs or
other subassemblies for example subassembly 1 contains 1 VME and subassembly 2, but as
subassembly 2 contains also 1 VME and to subassembly 3 and subassembly 3 contains 4 VMEs
subassembly 1 could be referred as a subassembly that have 7 VME in all its branch structure or
that contains 1 VME and to subassembly 2 in its principal branch just like in CAD.
Figure 2. Process of placing VMEs in their correct position.
Animation Process.
In this process is defined the internal programming of the VRM. It includes all aspect related to
VRM functionality as VME movements inside the virtual machine mechanism (VMM), sensors
programming, conditions validations, signal generations, is necessary to specify that this
procedure doesn´t refer to VRM programming control but animation sequences required for
VMR acts dynamically according to control sequences received from external controller. This
process is done in LabVIEW using the necessary operations, conditions, structures, subVIs,
validation and instructions that the VRM needs for having a behavior the closest to the real
process as possible. For achieving this objective many aspects have to be considered as a VRM
not only involves VMM functionality but all aspects related with the process emulated and its
environment. Then Animation depends of every VRM functionality and the way that
programming is done vary according to VRM´s logic programmer. Despite every VRM has a
particular internal programming according to its functionality some important and general
aspects independent of the VRM can be underlined in animation programming. These are VMM
programming, virtual sensors programming and extra animations programming.
VMM Programming.
During the animation programming VME are grouped and turned in a Virtual Machine
Mechanism (VMM) using inheritance defined in the Assembly process. A VMM is integrated by
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two or more VMEs which are related by at least one dynamic action one over another and at least
one of them is affected by a change of signal received from the external controller. In VMM
VMEs behave as actuator. This means that when a change in an external signal is received VME
are affected during VRM execution usually with transformation operations like rotation,
escalation, translation, color change, etc. until other change in the signal is received for achieving
this behavior. In VMM four tasks must be carried out, these are: validating the reception of an
external signal, recognizing of the signal, deciding what action to take and execute the action.
Virtual sensors programming.
The reception and processing of signals from the external controller is closely related with VMM
functionality as these are validated and processed inside the VRM. However the response of
VMM according to these signals has to feedback it somehow to the external controller as in the
control programming running in it the effects of these signals have to be validated for achieving
a correct control of the process. In a real process, signals are sent from the process through many
types of sensors that are placed in a specific position. As VRM emulates totally a real process,
this sending of signals must also be done, for this, virtual sensors are used. These are individual
VME or part of VMM; that in addition include programming oriented to emulate the behavior of
the real sensor and generates the signals that a real one would generate. When certain conditions
inside sensor programming accomplished a change in virtual sensor’s state occurs; this is
reflected in the same indicator that communicates with the external controller which is
established in connection process, this means that the output of a virtual sensor gotten after
validations must affect the same variable in the programming that serves as input to the external
controller something similar to real sensor.
Extra-Animation Programming.
In addition of VMM and virtual sensors programming other animations sequences are also
required in VRM, these don´t relate directly with VMM or virtual sensors functionality and their
objective is making more real the VRM functionality. For example VME color change, VME or
a VME part appearing or disappearing, movement of some VME that aren´t VMM´s part inside
the scene, change of inheritance, addition of the real sounds to VMM movements, and any other
animation required for the correct process´s visualization that the VRM emulates and doesn´t
receive or send signals from/to external controller In addition sometimes controlled extraanimations have to be used because some sequences are difficult to program in LabVIEW as this
is not intended for being an emulation process program then the use of extra-animations helps to
solve these difficulties.
Connection Process.
After animation process the application gotten still cannot be considered as a VRM as this still
has not connection to external control devices. This means that a control strategy cannot be carry
out on this as a VRM has not internal control sequences saved. At this stage it can be considered
only as a VM (Virtual Machine). Then for accomplishing the control and automation
functionality, is necessary the connection of the external controller outputs with VM´s VMM
inputs and external controller inputs with VM´s virtual sensors. Similar to real automated control
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systems where control device´s I/O are interconnected for communication with manufacturing
process´s sensors and actuators by voltage signals that are carry usually over electrical wires.
This is done in VM through a connection procedure whose objective is turning VM into VRM
addressing, organizing and describing in a Pin Out table the VRM´s VMM and virtual sensors
for being available for the external controller. However the VRM is a software application that
emulates mechanism and sensors therefore physical devices don´t exist and wires for carry
signals cannot be placed. Then connection between VM and external controller also has to be
emulated by software, what does that VRM´s connection process be particular. This is integrated
by 3 steps: Identification, addressing and programming.
Identification.
Once that animation process finishes, the VM gotten has all controls and indicators used for its
programming. These include as those that help to VRM´s animation programming as controls
and indicators that need to be used for the external controller for starting or stopping VMM in
case of controls or from where the change of virtual sensor’s state can be read for the external
controller in case of indicators. Then the first step for connection process is, identify and separate
the signals that external controls and indicators affect. For this must be considered what signals
needs the control programmer engineer or student for carry out the correct control strategy on the
VRM.
Addressing.
After indentifying VMM and virtual sensors signals is necessary to give a hardware address to
everyone of the signals used for external connection. However as wire cannot be placed for
interconnecting external controllers outputs with VM inputs and vice versa this has to be
emulated by software. Then for addressing VM with external controller is necessary to make a
mapping of external controller addresses with the names of the signals used in VM´s LabVIEW
programming as the PLC programmer uses this addressing in the control program which by the
addressing access to the LabVIEW signal name. The LabVIEW signal name is used for internal
VM programming. VRM addressing, specifies the address of every one of its virtual sensors and
VMM inside the VRM that the user can affects. The final addressing is organized, presented and
described in a Pin Out table similar to those used in real automated control systems.
Programming.
Once that every one of the VMM and VRM´s virtual sensors have been addressed. VMMs are
linked with external controller outputs and VRM´s virtual sensors with external controller inputs
by interconnection and communication programming inside the VRM connection process.
Interconnection programming: As VRM receives and sends change of signals state from/ to the
external controller. There is a programming part inside VRM oriented to the reception of signals.
Whose objective is to get from the external controller the state of each one of signals used for
VMM; and other programming part oriented to sending of signals. Its objective is recollecting,
organizing and sending the state of each one of the virtual sensors signals. Communication
Programming: Once that VRM´s I/O mapping is done in interconnection programming. Is
necessary a programming part oriented to send and receive the data to/ from the external
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controller and doing the communication task. For this has been developed a set of ActiveX
libraries programmed in .Net whose instructions are called and reprogrammed in LabVIEW
these communicates the VRM with PLC software libraries.
Automation validations Process.
Once created the VRM, a general validation of its functioning have to be done before of creating
the executable file of the LabVIEW VRM program and finish the VRM creation process. In this
process is validated the complete functioning of the VRM and is assurance that the VRM correct
functioning depends totally of the correct control sequences programmed in the external
controller by the VRM´s user. This means that if a mistake occurs or there is an incorrect
visualization this depends totally of the control program created for the PLC programmer not of
the VRM functionality. The validations carried out in this process are: Validation of VMM
functionality, virtual sensor´s signal validation, animation validation, automation validation.
(1) VMM functionality validation: VMMs are activated first by LabVIEW front panel´s controls
and later by signals change sent from PLC software. In general is checked that VMMs
functioning is correct and the closest to the real mechanism. This is done by validating that
VMMs start or stop when receive the correct signal, that visually their functioning is the correct,
that spatially they don´t crash with other VMMs or VMEs, that their dimensions are correct, that
their movement is adequate and according to the signal or control sequences that are receiving,
etc.(2) Virtual sensor´s signal validation: virtual sensors are activated from VRM´s and its estate
is checked first in VRM´s front panel and later in PLC software. In this process is validated that
sensors activate enough time for being read for the PLC. The activation time depends of the
sensor´s limits programmed in LabVIEW. In addition is also validated that sensors are in the
correct X, Y, Z coordinate when change the estate of their signal.(3) Animation validation: By
the VRM functioning is validated that correct animations executes in way and time that have to
be executed. For example if a translational or rotational movement affect the VME in the desired
way, that color change of the VME is activated in the correct moment and that the VME changes
to the color needed, in general that visually the behavior of the VRM is the correct. (4)
Automation validation: For this validation an automation task that uses virtual sensors and
VMMs addressing of the VRM is created, debugged, loaded, tested and monitored in PLC
software. With this is assurance that VRM´s signals change of VMMs and virtual sensors are
interchanged correctly and that with these signals is possible carry out correct control sequences.
VRM Application.
After validation process VRM’s process creation finishes. Then now from a LabVIEW project
the VRM program is compiled and an executable file and an installer of the final VRM
LabVIEW program are created15. The installer makes possible that LabVIEW developed
application behave as a any commercial software when is installed in PC. The capability of
turning VRM in an executable file has the advantages of: VRM portability, minimums software
required for execution, organization of all files in a single one, easy installation. But the principal
advantage is that licensing is not required for VRM execution and can be used in PCs only
installing a LabVIEW runtime which is gotten free from LabVIEW website. This makes possible
that VRM be practically free and one viable learning option for control engineers, automation
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students, universities’ laboratories, training centers, etc. regardless their economic possibilities.
After installation when VRM is executed for being controlled, initially a configurations box like
shown in figure 3 is displayed. In this the users choose the type of connection that want to
establish between the external controller and the VRM according to the controller that they have
available and the communication protocols this handles. In figure 3 in box are shown a set of
communication protocols available for one VRM, in this example these are PLCSIM, Industrial
Ethernet, TCP/IP, MPI/ Profibus, WinLC.
Figure 3. VRM Connection configuration.
Communications Protocols handled for the VRM.
According to the protocol chosen is necessary write the address of the external device used for
control the VRM. This is the number that indentifies the controller where data are going to be
sent and received, this is necessary for communication libraries and varies depending of the
protocol.VRM is a new virtual commissioning tool that so far has only be tested and validated
with SIEMENS automation hardware and software and whose communications libraries have
been developed oriented to this vendor as VRM doesn’t use OPC communication. This affects
VRM application only in interconnection capabilities, the VRM concept and developing
procedure if the same regardless the external controller’s brand. VRM developing continues
oriented to adding OPC communication and developing communications libraries for others
automation hardware vendors as Allen Brandley, Schneider, ABB, etc. as VRM concept is
intended to be used with any commercial external controller vendor. In figure 4 is shown the
VRM communication diagram when SIEMENS hardware and software are used for automate the
VRM. This illustrates the VRM´s communication with external control devices15.
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Figure 4 shows, that there are two options for using the VRM; with S7PLCSIM or a real
controller. If PLCSIM connection is chosen VRM and PLCSIM will communicate only by
software this means that won’t be connection to a real hardware and the VRM’s user will work
with a PLC emulation PLCSIM musts be installed and running in the PC that will communicate
with the VRM, monitoring of the I/O signal and manual activation of actuators can be done in
the PLCSIM software in figure 5 a) is shown a VRM using PLCSIM. When TCP/IP, Industrial
Ethernet, MPI/Profibus, WinLC protocol is used is necessary to have an external PLC with the
communication interface that support the protocol that is chosen in figure 5 b) is shown the same
VRM being controlled by an external controller and in box is shown SIMATIC S7 software used
as for programming the machine as for monitoring the execution of the program.
Figure 14.10 VRM controlled by PLCSIM.
Figure 5. VRM controller options.
Automation equipping solution.
For plenty accomplishing its objective, automation and control laboratories need an
infrastructure that in addition of counts with industrial automation hardware and software also
includes a process or plant where students implement, test, debug and validate their control and
automation strategies. However this represents the highest costs for laboratory equipping and in
the best scenario laboratories are equipped with few real automated devices used in industry
which for their high cost are used commonly only for professors with demonstrative objective.
Training workstations of vendors as Festo, FISHER tecnics, etc as consequence of their price,
are used only for a reduced number of universities. Other practice is testing students control
programs in a set of individual industrial sensors and actuators that activate according to the
control programmed, however these don’t represent a real industry manufacturing process. A
common practice is the construction of home-made systems that are a set of buttons, actuators
and led indicators that with imagination try to represent a process. The construction of primitive
structures as elevator, mixer, etc. is also a common practice. In addition that any one of these
options has a cost some of these don’t achieve to impact totally in the students understanding as
some students don’t visualize the essence and sense of automation and control strategy carried
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out on these. For this reason the automation and control laboratory station shown in figure 6 is
proposed. This represents a viable solution to the lack of equipment that face many universities,
as the highest cost of laboratories´ equipment is represented for the process to control, what is
solved with the VRM as this emulates a real process. Even a set of VRM’s can be used for
students as many VRM can be installed in the same PC. In addition VRM makes possible that
laboratory has a set of VRMs in every station without additional cost what means that every
student can has his/her own process to automate. The Automation Lab Workstation proposed is
integrated for a Real PLC, a touch panel and a PC where VRM executes, in addition in this PLC
and Touch panel software is also installed.
Figure 6. Automation & Control Laboratory equipping proposed.
VRM ´s impact and interaction with students.
For illustrating the impact of the proposed automation learning platform, is used a laboratory
equipped with SIEMENS CPU315F PLC and a SIEMENS Touch Panel as hardware and
SIMATIC S7 and SIMATIC WinCC as control developing software and as plant a VRM called
Process Line which represents a machining process which has 19 Input addresses and 15 output
addresses. In addition to automation hardware and software and to the VRM in laboratory
students receive a pin out table with the address and description of all VRM’s virtual sensors,
VMM and document with the plant description that includes the description of the process that is
represented for the VRM, description of the functionality and position of virtual sensors and
VMM and VRM dynamic, this information is all what they need for starting with their
automation task.
The objective of automation is according to the criteria of the laboratory’s professor as VRM can
serves as for carry out simple control sequences as for a total automation of the process that
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represents. In laboratory the students develop the control strategy that is going to be
implemented on the VRM just like is done in a real process, this depends totally of the user
knowledge and what is asking for the professor. There aren’t restrictions in programming the
VRM, interruptions, counters, memories, timers, etc can be used without affecting its
functionality. Once that the student finishes his/her automation task in SIMATIC S7 and the
HMI programming in WinCC the control programs created are compiled and downloaded to
their respective automation hardware. Then having the external controller turned on and the
VRM in execution, the automation strategy programmed for student is tested and validated on
the VRM checking that the functionality of the behavior of the VRM is correct and goes
according to what was asked for professor.
The user interaction with the VRM is shown in figure 7, here is observed that students do three
principal tasks in laboratory: 1) Task developing. Where students program and debug their
automation strategy. 2) Hardware programming. This is the process where the program
developed is compiled and downloaded to the automation hardware. 3) Test and Validation
stage. Where students validate their control program and skills and the teacher secure that
students have acquire the knowledge transmitted in classroom and that have the capability of
implementing and using these knowledge in automated systems that are very close or equal to
used in industry.
Figure 7. VRM’s Interaction with students.
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Considering that problems faced for universities in automation and control careers are focused in
laboratories. The equipping proposed respects the traditional and actual automation and control
teaching method that begins with professor in classroom transmitting principles, basis and
fundamentals of automation and control to students and is complemented with commercial
automation hardware and software commonly used in laboratories. However the key aspect of
the proposal is the incorporation of the VRMs as final processes for supporting the classroom
theory with laboratory practices that involve automation and control scenarios similar or equal to
those found in industry.
Conclusions
In engineering theory is closely related with practice. The level of integration between theory
and practice and how they are complemented in universities is reflected directly in students’
formation as the lack of practice and the deficient training received for students in universities
impact directly in their competitive advantage, what is reflected in the job opportunities for
students. In many countries where manufacturing is one of the principal activities, automation
and control careers are a key aspect for industry, and engineers with this orientation are
constantly wanted. However because of lack of practice many of these engineers haven’t the
skills needed for some manufacturing companies, what is reflected in some aspects as of their
personal life as in the country growing.
According to the VRM’s features presented, the usage and implementation of these as process
emulation where students test, debug and validate their automation and control strategies, is an
option for educational institutions with a not enough laboratory infrastructure, as these are a high
performance and low cost solution that resolves the problem of lack of laboratory equipping that
face many low resources universities principally in developing countries. Even help to any
university to complement and supporting the automation and control course offered. Despite that
with VRM investment in automation hardware and control must to be done this cost represents
only an small portion of the total investment required for equipping a laboratory with traditional
methods, as the final process where to implement the control is the most expensive part of the
equipment necessary in laboratory. With VRM this cost hasn’t to be paid as there isn’t necessity
of licensing. Despite with VRM equipping there isn´t a real process to control the emulation are
so close to reality that for automation and control practice objective can be considered just like
real process, as the knowledge transmitted to students when the control strategy is programmed
is the same that if this would has been carry out in a real process. VRM offers to student the
possibility of complement his/her educational training, supporting the knowledge acquire in
automation and control courses with process emulations that impact directly in the grade and
quality of training received in laboratory, skills acquired and knowledge won in classroom and
laboratory. This practicing impacts directly in the student formation and training what reflects
later in their professional life as gives add value to student’s resume and prepare them for some
of the problems that will face in industry.
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Appendix A.
Table 1. Principal Features of Automation Simulation tools in market.
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Acknowledgment
The authors wish to acknowledge the support of the Tecnologico de Monterrey, Campus
Monterrey to develop this research which is a contribution of the Product Development for
Emergent Markets Research Chair, Registration No.CAT121.
Bibliography.
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ALFREDO R. IZAGUIRRE holds a B.Sc. in Electronics and Communications Engineering
from Universidad Autonoma de Nuevo Leon (UANL). Studied a Master Degree in Management
and Business at UANL. Currently he is a Student of Master in Electrics Systems with especially
in Electronics (MSE-E) at ITESM, Campus Monterrey. He is Tele-Engineering and Industrial
Electronics labs instructor and participate in some projects on, Virtual Labs to enhance
Learning/Training in the areas of Control and Automation.
MANUEL E. MACIAS holds a B.Sc. in Electronics and Communications Engineering from
Monterrey Tech (ITESM), Campus Monterrey and a Ph.D. in Power Electronics from Technical
University of Dresden in Germany. Currently he is an Associate Professor in the Electrical
Engineering Department at ITESM, Campus Monterrey, where he teaches Electronics and Power
Electronics courses. He is in charge of the Tele-Engineering and Industrial Electronics labs and
leads some research projects on Computer-Assisted Learning, Virtual Labs and Remote Labs to
enhance distance Learning/Training in the areas of Electronics and Automation.
February 2-4, 2011
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Virtual Reality Machines to improve training in Control and Automation

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