Attachment B Part I.pdf
PDF 1 MB Posted
- Attached to
- Crane & Heavy Equipment Operator Simulator
- Solicitation number
- RFP GIS 210000000111 3
- Issued by
- Genesee County, Michigan
About this file
This is an attachment to a state and local contract opportunity that outlines detailed technical requirements for a Crane and Heavy Equipment Training Simulator system. The supplier is requested to provide pricing and comprehensive descriptions for one immersive simulator station equipped with multiple training modules including flat-top tower crane, rough terrain mobile crane, luffing tower crane, crawler crane, backhoe, excavator, articulated dump truck, wheel loader, dozer, and motor grader simulators. The scope of supply also includes a student performance database, remote installation services, train-the-trainer support, and three years of warranty, maintenance, and support coverage. The immersive operator station must feature an adjustable operator seat, electromechanical motion platform with pitch and roll capabilities, a rugged shock-mounted computer system housed within the base, and a pivoting display system with one 65-inch full HD LED monitor capable of landscape and portrait orientation. Controls must be based on actual original equipment manufacturer designs rather than gaming peripherals, and all hardware for motion systems must be contained within the operator station itself.
The simulator software requirements specify that the dynamics simulation engine must be engineering-grade rather than gaming-based, with realistic physics-based simulation of equipment, load dynamics, and collision interactions. The system must include high-resolution graphics with dynamic shadows, realistic collision and friction modeling, structural dynamics simulation with boom deflection and vibration effects, comprehensive cable and hoist simulation, accurate vehicle drivetrain and suspension modeling, and dynamic terrain interaction for earthmoving equipment. Environmental conditions must be easily modifiable including weather and lighting parameters. Each simulated equipment type—ranging from the 40-ton rough terrain crane to the motor grader—requires specific training exercises with progressive learning paths, realistic construction site environments, and comprehensive student performance tracking metrics. The student database must enable instructors to create accounts with varying permission levels, monitor real-time operator performance, generate individual session and long-term performance reports, and set pass/fail determinations.
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Other files
| File | Type | Posted |
|---|---|---|
| Attachment D Vendor Certification_.pdf | ||
| Addendum No. 1.pdf | ||
| Attach C Familial Statement_.pdf | ||
| Attachment B Part II Bid Form.pdf | ||
| Attachment B BID FORM Part III.xlsx | XLSX spreadsheet | |
| Acc Attachment A Project Description.pdf |
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Text version
Crane & Heavy Equipment Training Simulator Requirements
1 Scope of Supply The supplier is asked to provide pricing and detailed descriptions for the following scope of supply:
Simulators
1x Immersive simulator station equipped with :
o Flat-top Tower Crane simulator o Rough Terrain Mobile Crane simulator o Luffing Tower Crane simulator o Crawler Crane o Backhoe o Excavator o Articulated Dump Truck o Wheel Loader o Dozer o Motor Grader o Student performance database
Services
Remote installation
Train the trainer
3 Years Warranty, maintenance & Support
The following sections provide detailed requirements for each of these items.
Attachment B Part I
2 Immersive Simulator with Motion Operator Station The operator station must include the following items:
Operator seat
Motion platform
Computer system
Display system
Controls
Operator touch screen
It must be possible to use a single operator station to train on several crane/heavy equipment.
2.1 Operator Seat & Base
The operator seat must be similar to seats found in actual cranes and heavy equipment. It must be possible to adjust the seat position (back/forth/recline) to accommodate various users.
To facilitate transport and to minimize simulator footprint, the computer system used to power the simulation and display system must be housed within the operator station base itself. The 1-display simulator setup should not require more than one (1) computer. Furthermore, exposed cables should be kept at a minimum and any exposed cables must be neatly bundled and attached.
2.2 Motion platform
Operator station must be equipped with a electromechanical motion platform. The motion platform must include pitch and roll to realistically simulate the effects of the real equipment such as:
Structure stress/bending/vibrating while lifting heavy loads
Collision impact
Machine level/out-of-balance
Boom whiplash while swinging
All hardware needed for the motion (controllers, actuators, etc.) must be housed within the operator station.
2.3 Computer
The simulator must be powered by rugged shock-mounted computer located inside the base of the simulator. Although computer should be hidden in a housing compartment, it must be easy to access the computer housing without needed any tools.
The 1-display simulator should not require more than one (1) computer. Computer specifications must be powerful and recent enough to ensure adequate performance for at least
3 years. Software upgrades & updates for 3 years following installation should not require computer upgrade or replacement.
2.4 Display System
The display system consists of:
Pivoting Display Frame
1x 65” Full HD (1080p) LED flat panel monitor
Required Cabling
The motion-based operator station must be equipped with a 1-display system that can accommodate different fields all training modules in this request. The display system must pivot, providing the option to have 1 display in landscape orientation or in portrait orientation. The switch must be easy to do for a single person without the need for tools.
Monitor provided must be able to display correctly both in landscape and in portrait orientation.
2.5 Controls
Gaming controls, such as Logitech joysticks, steering wheels and pedals are not acceptable.
Controls must be based on actual OEM controls and designed to feel and operate like the real equipment. Joysticks, pedals and steering wheel must have the same look and feel as those found on real equipment.
It must be possible to use the same controls for all training modules.
3 Software Requirements
3.1 General Simulation Requirements
The simulation of the equipment, load dynamics and collisions with objects in the virtual environment must be realistic and based on physics. The dynamics simulation engine must be of engineering grade; no gaming engines will be accepted. This shall be supported by relevant past project examples, papers and other supporting data.
The equipment simulation must address the requirements specified in this section. The vendor is requested to describe the core dynamics engine used to do the simulation and present evidence of its suitability for the simulation of mechanical equipment.
3.1.1 Simulation Graphics
The simulation graphics must be of high resolution and high quality. This includes the machine graphics as well as environment graphics.
Shadows
Shadows must be realistic, of high resolution and dynamic. Dynamic shadows mean they are not static objects but change depending on time of day, weather conditions and moving objects.
Construction Site
Training exercises must take place in realistic construction sites withproper barriers.
Machine Details
The simulated machine (crane, excavator, etc.) graphic representation must be detailed enough to be able to examine components for faults.
3.1.2 Collision & Friction
The equipment must be able to collide with other objects in the virtual environment – the boom, wheels, chassis, hook attachments, loads, surrounding objects, and terrain must all collide with each other.
3.1.3 Structural Dynamics
While lifting a load, boom deflection shall cause the radius to increase while lifting a load, leading to load pendulum if boom tip is not corrected.
Structural vibration and deformation shall be simulated and the operator will feel these motion queues via the motion platform.
Axis motion shall be simulated for hydraulic cylinders or electrical motors, including proper speed, acceleration and reaction time.
3.1.4 Cable / Hoist and Sling Simulation
For the mobile crane and flat top tower crane simulation, multiple parts-of-line shall be simulated and changeable by the operator at any time during the exercise.
Collision and contact between the hook and all other objects in the scene shall be simulated.
The hoisting system shall be fully simulated including cable simulation from the hoist drum to the hook including pulleys, sheave blocks and multiple parts-of-line. Drum braking systems must be simulated. Hoist speed, acceleration, and reaction time, are simulated and the effect of load on these systems is simulated.
Limit switches and slowdowns shall be simulated when reaching boom tip, lowest position or proximity sensors.
3.1.5 Driving and Vehicle Dynamics
In order to achieve proper operator training of vehicle driving tasks, the vehicle simulation shall feature the following capability:
Accurate simulation to replicate vehicle specific drivetrains (mechanical, hydrostatic, torque converters, automatic and semi-automatic transmission types)
Accurate steering and suspension modelling for wheeled and tracked vehicles. Accurate simulation of tire/track and terrain interaction for different terrain materials and profiles
Realistic transfer of vehicle acceleration and chassis attitude to the motion platform system; allowing to train the operator in understand the stability of the equipment
Accurate simulation of braking systems
Vehicle–specific steering systems shall be simulated, including accurate steering geometry.
3.1.6 Soil Dynamics / Dynamic terrain
Earth moving equipment training requires the accurate simulation of the soil, vehicle and earthmoving tool interactions. The earth moving simulation shall provide the feature the following functionalities:
Simulate the terrain cutting operations performed by various earth-moving tools, such as blades and excavator buckets
Digging / cutting forces shall be accurately transferred to equipment and motion platform
Soil shall have inertial properties and impact vehicle behaviour
Soil mass shall be accurately conserved when transferred from one container to another
(soil transfer from an excavator to a dump truck for example)
Terrain shall remain deformed after earth moving operation and shall impact vehicle handling (rolling over newly created trench for example).
To avoid negative training, dynamic soil behaviour shall fully correlate with the visual representation of the soil.
3.1.7 Crane Outriggers
The operator shall have the ability to extend the outrigger when applicable to the vehicle type.
The operator shall have the ability to, at any time, virtually exit the cab of the machine and examine the setup.
3.1.8 LMI (Load Moment Indicator)
A load moment indicator shall be displayed for the operator and be functional to configure the crane for the specific scenario.
The simulated LMI shall provide the actual load information to the operator. The simulators shall, according to boom length, radius, outrigger positions, and other parameters, provide the current allowed load information to the operator.
The crane’s load charts shall be simulated and reflect typical load charts for the type of crane.
The load chart shall be documented.
3.1.9 Dynamics on the Motion Platform
Motion effects including the dynamic shock loading, structural flex, collision with objects, vibration in the equipment, travelling on uneven ground and slope shall be simulated and correspond to real-time dynamics of the simulated vehicle
3.1.10 Environmental Conditions
It shall be possible to easily modify environmental parameters of a simulation such as weather conditions (clouds, rain, wind, etc.) and lighting (time of day and month). The weather conditions shall impact visibility, load swing, etc. to create a realistic training environment.
3.1.11 Sounds
All simulators shall provide realistic sounds for audible feedback of the simulation including equipment and environmental sounds.
3.2 Training Exercises Requirements
3.2.1 Scenario Introduction
Scenarios must start with an introductory animation or video highlighting and showing brief sections of the scenario in action. User must be able to skip the introduction.
3.2.2 Orientation Scenario
Each module should contain an orientation scenario for beginner operators with no experience.
These exercises should take the student though all controls and basic operations of the machine with no interaction from an instructor.
3.2.3 Heavy Lift Scenarios
Crane simulations must have heavy lift scenarios which consist in lifting at 90% of the crane capacity. There should be various heavy lift scenarios per machine such as pick and carry, and moving heavy objects to a predetermined height.
3.2.4 Student Information Database
The simulator must be equipped with a database in which the result of training sessions, per student, can be stored and retrieved at a later date for reporting purposes. More specifically, this database will allow instructors to:
Create new accounts (Student, Instructor, Administrator) that have different levels of permissions
Able to reset passwords (as administrator)
Change passwords
Set up a class by grouping students
Monitor operator performance at runtime
Graph two (2) performance metrics at runtime
Provide general feedback for a training session (entering comments to be recorded on student report (non-time stamped)
Generate a report for an individual session: at the end of the session the instructor will be able to set pass/fail or no action and then generate report
Report on long-term student performance: ability for instructor or student to view all historical exercise reports
3.3 Simulated Equipment Types
The following types of equipment shall be simulated. The simulators shall provide an accurate reproduction of the actual equipment which includes all primary equipment controls as well as physical layout and correct cabin view of operations.
Rough Terrain Mobile Crane, approx. 40T capacity
Tower Crane, Saddle & Luffing jib type cranes
Lattice Boom Crawler Crane, approx.. 80T capacity
Hydraulic excavator, approx. 36ton capacity type
Backhoe, approx. 100hp
Wheel Loader, approx. 15ton
Bull Dozer, 20ton
Articulated Dump Truck, approx. 25ton, 315hp
Motor Grader, 44,500lb operating weight, 275 Variable HP, 8-speed PowerShift
3.4 Rough Terrain Crane Requirements
The simulated crane shall be approximately a 40 ton capacity, rough terrain, 4-section telescopic boom crane with the following features:
Simulated engine and hydraulics system to correctly model the power, torque and RPM dependence. This shall be noticeable to the operator when lifting various loads.
Operator controlled outriggers
Telescopic boom simulation shall include boom length dependent boom deflection
Simulated stow-away jib that can be deployed during the exercise
Operator shall have the option to turn the boom tip camera on or off
Operator shall have the ability to change the parts of line during the exercise
3.4.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic urban construction site with various buildings, machines and humans.
The various exercises shall include, at a minimum:
Various lift objects such as concrete blocks, steel I-beams, pipes.
Loading and unloading materials off a trailer operations
Unloading materials in to a building
Constructing a steel structure
3.4.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Time to complete exercise
Pressure under each outrigger
Number of collisions, divided into various types of collisions
Number of objects moved during exercise
3.5 Flat-Top Tower & Luffing Tower Crane Requirements
The simulated crane shall be approximately a 12-18 tons flat-top slewing or luffing tower crane with the following features:
Configurable crane height
Simulation of mast and jib bending in response to load
Realistic simulation of all rigging and hoisting cables, including tension, slack and swing
Ability to change from 2 to 4 parts of line during the exercise
3.5.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic urban construction site with various buildings, machines and humans.
The various exercises shall include, at a minimum:
Various lift objects such as concrete blocks, steel I-beams, pipes.
Loading and unloading materials off a trailer operations
Unloading materials in to a building
Constructing a steel structure
Placing concrete panels
Concrete forming
3.6 Crawler Crane Requirements
The simulated crane shall be approximately an 85 ton capacity, 100 ft lattice boom crawler crane with the following features:
Simulated engine and hydraulics system to correctly match the power, torque and RPM dependence of the actual equipment. This shall be noticeable to the operator when lifting various loads.
Crane is equipped with 3 functioning winches, 4-parts of line hook block and functioning tracks
The crane will accurately warn the operator in anti-two block, overboom, and load moment warning alarms.
3.6.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic urban construction site with various buildings, machines and humans.
The various exercises shall include, at a minimum:
Various lift objects such as concrete blocks, steel I-beams, pipes.
Loading and unloading materials off a trailer operations
Unloading materials in to a building
Constructing a steel structure
Tandem lift operations using two simulators or one simulator and the instructor station
3.6.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Time to complete exercise
Number of collisions, divided into various types of collisions
Number of objects moved during exercise
Pendulum
3.6.3 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Time to complete exercise
Shock loads
Number of collisions, divided into various types of collisions
Number of objects moved during exercise
Grounding hook block
3.7 Hydraulic Excavator Requirements
The simulated excavator shall be approximately a 36 ton capacity tracked excavator with the following features:
Vehicle driving simulation
Simulated engine and hydraulics system to correctly model the power, torque and RPM dependence
Both SAE and ISO control schemes shall be available to choose from
Realistic simulation of amounts of soil excavated
3.7.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic construction site with various vehicles, machines and humans. Training exercises shall include:
Controlling the excavator bucket, stick, boom and swing
Loading and unloading the excavator from a flatbed trailer
Placing objects such as pipes in trenches
Bench loading
Trenching
3.7.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Time to complete exercise
Number of collisions
Volume of material in bucket shock loads
Time to fill dump truck (when applicable)
3.8 Backhoe Requirements
The simulated backhoe shall be approximately a 100 hp backhoe with the following features:
Vehicle driving simulation
Simulated engine and hydraulics system will correctly model the power, torque and
RPM dependence
Both SAE and ISO control schemes shall be available to choose from
Realistic simulation of amounts of soil excavated
Various working tools such as bucket, forks and truss boom
3.8.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic construction site with various vehicles, machines and humans. Training exercises shall include:
Driving exercises
Loading and unloading the wheel loader from a flatbed trailer
Excavating
Truck loading
3.8.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Time to complete exercise
Number of collisions
Spill quantity
Fuel Consumption
Volume of material in bucket
Percentage fill of the dump truck present in exercise
Time to fill dump truck
3.9 Wheel Loader Requirements
The simulated wheel loader shall be approximately a 13 ton capacity machine with the following features:
Vehicle driving simulation
Simulated engine and hydraulics system to correctly model the power, torque and RPM dependence
Simulated power-shift transmission
Rear-view camera simulation
Realistic simulation of amounts of soil excavated
Various working tools such as bucket, forks and truss boom
3.9.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic construction site with various vehicles, machines and humans. Training exercises shall include:
Driving exercises
Loading and unloading the wheel loader from a flatbed trailer
Excavating
Truck loading
3.9.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Time to complete exercise
Number of collisions
Volume of material in bucket
Percentage fill of the dump truck present in exercise
Time to fill dump truck
3.10 Articulated Dump Truck Requirements
The simulated Articulated Dump Truck shall have the following features:
Vehicle driving simulation
Simulated engine and hydraulics system to correctly model the power, torque and RPM dependence
Simulated power-shift transmission
Rear-view camera simulation
Working lights, automatic transmission, side camera mirrors
3.10.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic construction site with various vehicles, machines and humans. Training exercises shall include:
Team Training with excavator (Must be able to connect with another simulator running the excavator module)
Driving
Loading/Unloading a Trailer
Skills Challenge
3.10.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Machine metrics such as fuel consumption, average speed and engine power and torque
Wheel Slip
Load capacity
Safety violations
3.11 Dozer Requirements
The simulated dozer shall be approximately a 20 ton capacity machine with the following features:
6-way power blade with height, angle and tilt adjustments
Attachment B Part IAttachment B Part I
Diesel engine and hydraulic system simulation
Hydrostatic powertrain simulation
Oval drive tracks
Palm joystick steering
ECO and Auto-idle modes
Decelerator and Speed reduce pedals
3.11.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic construction site with various vehicles, machines and humans. Training exercises shall include:
Basic controls
Loading/unload trailer
Production Dozing
Material spreading
Creating a access road
Sandbox
3.11.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Fuel consumption
Blade efficiency
Cycle time
Grade quality
Safety violations
3.12 Motor Grader Requirements
The simulated Motor Grader shall have the following features:
Vehicle driving simulation
Simulated engine and hydraulics system to correctly model the power, torque and
RPM dependence
Simulated power-shift transmission
Rear-view camera simulation
Realistic simulation of blade positioning. Operator should have the ability to disconnect the saddle locking for blade offsets in either direction. True to real graders, the system should use sensors mounted on the machine to calculate the current slope of the blade and determines if the blade slope needs to be adjusted up or down to maintain the desired slope.
3.12.1 Training Exercises
Training exercises shall provide progressive learning that guides students from simpler to more complex operations. The exercises shall take place in a realistic construction site with various vehicles, machines and humans. Training exercises shall include:
Basic controls
Loading/Unloading a trailer
Windrow management
Material spreading
Leveling with obstacles
Creating a V-Ditch
3.12.2 Student Tracking
The simulator shall track student performance on a variety of key indicators, including as a minimum:
Machine metrics such as fuel consumption, average speed and engine power and torque
Grade quality
Blade efficiency
Cycle & Idle time
Safety violations
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