Advancing Operator Training with Heavy Equipment Simulators

The value of skilled operators is undeniable.  Finding them, however, isn’t easy, and training new ones is both time-consuming and costly. Most companies just don’t have extra equipment or hours to dedicate to traditional hands-on training.
 

Cat^® Simulators are a virtual training solution designed to deliver a near-real-life operating experience without the risks and costs associated with real machines.

Developed by Simformotion in collaboration with Caterpillar's expert instructors, these simulators are the most realistic on the market. They integrate cutting-edge technology with operational expertise, making them an ideal training tool.

Every feature has been carefully designed to closely mirror the real-life equipment, allowing new operators to easily transition to real-world machines. 

“The detail that goes into simulator development is incredible,” says Caterpillar Trainer Logan Rasch, a Caterpillar trainer involved in the development of Cat Simulators.

During the development process, technicians filmed Logan operating a real-life shovel, recording his every move and the machine’s sound in as many applications as possible. “I gave feedback on everything from monitors to joysticks to seat construction,” he recalled.

Virtual Reality (VR): VR features provide operators with depth perception and environmental awareness, similar to what they would experience on a jobsite. Whether looking down a trench or judging a bucket’s placement over a truck bed, operators have a realistic view of hazards and blind spots, just like in real-life operations.

Real-Life Sensory Experience: The simulators provide a real-world sensory experience through a sophisticated motion and sound system. This system delivers accurate pitch, roll, and heave at 60 signals per second, replicating vibrations and machine behavior, such as tipping or weight shifting. This helps operators understand a machine’s limits and improve their situational awareness.

Realistic Training and Evaluations: Simulators are pre-programmed with application scenarios that mimic real-world job sites. Operators can practice everything from safety walkarounds to productivity and technology use. After each session, operators receive a detailed evaluation of their skills, including safety and productivity scores, ensuring continuous improvement.

Once they had a prototype built, Logan operated it while engineers observed his every move. 

 “We’d sit with product engineers and go through all possible sequences from startup operation to shut down, making sure the simulator acted the same as a real-life machine.”

The result? A Cat Hydraulic Shovel Simulator that looks, feels and acts like a real yellow-iron, machine.

Authentic Controls: Every Cat Simulator comes equipped with the same Cat controls and components that you’d find in real machines.

The Future of Construction & Mining Simulators
While industries like the military and aviation have used simulators for years, the construction and mining industries are just beginning to embrace simulation technology. Rasch believes the time is right for simulators in these sectors. "Simulators are the safest, cheapest, and fastest way to get operators up to speed,” he explains. They capture data in real-time, allowing companies to monitor productivity and damage without pulling machines from the field or using fuel.