VR Training in a Manufacturing Environment - Motor AssemblyLedet Araya, Jackson Gresham, Shams Jamal, Robert Raines, Quentin Plummer

Faculty Mentor: Dr. Dominik May

Project MotivationOur goal is to create a virtual reality (VR) simulation that successfully teaches a worker to assemble a motor. This simulation must effectively train new employees safely without interrupting production. By using a VR training solution the factory could save time, money, and equipment.

At ABB motors, Inc. they have found an issue with their training process. They must experience a slowdown on the assembly line in order to train a new employee. In the current training system, a trained employee will stand with the new trainee during their shift. This is an issue for two reasons. The assembly process is slowed down for a while and the employee doing the training is paid for an extra shift. In order to eliminate these two henderances, ABB wants to implement a VR simulation that will replace their current training system.

3D ModelingThe 3D modeling for our project was completed in blender. ABB provided us with their versions of their 3D models so that the parts we used in the simulation are exactly like the ones the user will encounter in the real world. They won't have to deal with any mysterious geometries.

UnityUnity was used for our project as the primary engine for our simulation. It allows us to visualize and build our environment. We had to utilize many different aspects of Unity. Most specifically, we had to design custom scripts so that the collision mechanics operated properly. As you can see below, we have a section of a flow chart for one of our custom scripts we developed in unity.

Hardware● Oculus Quest● PC for Development

Software● Unity● VRTK● Blender

Future goalsVirtual reality has many applications and there is an incredible amount of potential when it comes providing training simulations. Our project is demonstrating a baseline of providing a platform for training and education not only within our application but to all modes to learning experiences. In the future, this will serve as proof of concept for an avenue of training innovation at ABB.

This project specifically looks to add features regarding narration, metrics for evaluation simulation performance for individual employees, and adding informative text to educate the user on the individual parts and combined units.

EvaluationOnce a first iteration was completed, We did a few rounds of basic testing. We got a few users to use the program and provide feedback. The common theme was that we should make it more intuitive. Then after deliberation we implemented a way to see exactly which step was going to come next by making a ghost version of the part show up on the model the user is working on. Also, we developed a tutorial section for the simulation. The idea is that each step will be intuitive and the user shouldn’t have to guess what will come next. This simulation’s goal is for the user to fully understand the steps to the process of building an electric motor. This simulation does not focus on the details of the process as much as the order of the steps and how each piece operates with the others.

The flowchart above is modeled after a script designed to get 3d objects to snap together in unity.

The 3D models shown here were used in the development of our program. Clockwise from top left: Fan, Completed Motor, and Stator section

Virtual Reality Simulation demonstration, user must apply the green screw into the location specified by the transparent indicator. (Screenshot from Oculus)

We received an Oculus Quest headset so that we would have a platform for development. Using Unity as our game engine, VRTK for prefabricated assets and Blender fo the digital 3D modeling we were able to develop a sufficient solution to the problem of training inefficiency

Above is an expansion diagram of the motor we are basing the manufacturing process on. You can see all of the pieces it takes to assemble the NEMA 356 motor

Screenshot from Blender of the finished Motor