Finding efficient ways of training and up-skilling machine operators – while keeping safety at a maximum and time and costs at a minimum – are key demands in today’s highly competitive construction industry. Liebherr, a company known for its heavy-duty construction equipment, including crawler cranes, maritime cranes, piling rigs and drilling rigs, has developed
a state-of-the-art solution.
“Besides supplying the necessary machines, the trend in recent years has clearly been toward construction-site application and process consultation,” said Gerhard Frainer, managing director of sales for Liebherr Nenzing. “Liebherr identified this trend at an early stage and has incorporated it into its strategy. For example, our LiDAT®, Liebherr’s data transmission system, is a tailored telematic and fleet management system for Liebherr machines.”
The most recent example of this innovative thinking is LiSIM®, Liebherr’s simulator for crawler cranes and deep foundation equipment. The simulations offer sophisticated solutions that tick all the boxes, allowing trainees to significantly improve their skills in a virtual but realistic environment.
“The development of this advanced training tool was driven by Liebherr’s extensive experience in highly immersive crane operator training as well as in other simulations,” said Frainer. “Last year we launched a range of maritime simulators for ship to shore, rubber tyre gantry, mobile harbour and offshore cranes. In the deep foundation area, we publish a compendium on process technology and equipment selection, which acquired the status of a standard work of reference within a very short time.”
For the LiSIM® simulator, Liebherr modelled its successful LB 28 rotary drilling rig with a continuous flight auger (CFA), Kelly bar and casings, as well as an LR 1300 crawler crane. In addition, a realistic construction site was virtually created with adjacent buildings, roads and fences, and obstacles such as uneven ground, I-beams or rocks.
“The drilling rig simulation replicates all aspects of the machine’s real functions, from basic drilling with a Kelly bar, or travelling with a Kelly bar and CFA, to more complicated scenarios such as travelling inclinations or work under extreme weather conditions,” said product manager Marcel Flir. “The centre of mass changes automatically depending on the attachment. For example, different soil conditions and their effects on both drilling physics and the crawlers of the machine are considered.”
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With high definition flat screen monitors and high quality surround sound speakers to reproduce the views and sounds typically experienced in the operator’s cab, the sophisticated LiSIM® environmental and physics replication provides an unprecedented level of detail and realism. A motion platform ensures that the operator experiences realistic and accurate movements.
A major benefit of this type of training is the ability to simulate harsh environmental conditions when required, in a non-destructible virtual environment, allowing trainees to experience operational limits of the machine while gaining valuable experience in challenging situations without posing any safety risks. The resulting increase in skill allows for a safe and productive operation under similar conditions in the real world.
“The installation of original Liebherr control systems, software and hardware guarantees a realistic training experience. The control systems reproduce all movements with exact precision both in space and in real-time,” said Flir. “LiSIM® is the only realistic virtual solution available in the market for learning the precise handling of Liebherr’s crawler crane and deep foundation machinery.”
Customized solutions
Liebherr simulators are available in three configurations. Like all Liebherr products, the simulators are available for companies worldwide. Furthermore, Liebherr has already and is currently establishing training centres all over the world, starting with the U.S., Brazil, South Africa, Austria, Germany and Hong Kong.
“We are continuously working on improving the simulators and adding further training scenarios,” said Flir.
The solutions that Liebherr currently has available using the simulators:
Classroom solution: Easily integrated into existing and/or fixed training centres, the display, seat and controls are mounted on a base and a sturdy display frame. This is an attractive option in regard to price, with a high standard of monitors and control elements.
Space-saving cab solution: The most realistic configuration, since the trainee has the same view as in an actual machine. Featuring a high standard of monitors, this solution ensures that the operator becomes familiar with controlling the crane in a real life environment.
Easy-to-transport containerized solu-tion: Housing the simulator in a 40-ft. container, the container features a training room, utility room and cab simulator. Each of the three models is equipped with multifunctional instructor stations. This is a plug-and-play solution that can be easily transported.
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