LTTS’s Virtual Reality Based Training Solution Helps Users to Customize Assembly of Transformer Tap Changers

LTTS’s engineering expertise in power electronics is helping customers create products for multiple applications ranging from heavy machinery to solar grids.  They developed a virtual reality (VR) based training simulator and solution for transformer tap changers for a major European heavy electrical equipment manufacturer. The customization options and virtual site inspections eased the process for engineers as well as users in creating the needed product.

Background and Business Needs: According to LTTS, when it comes to transformer tap changers, there are three needs:

1. Customization: Tap changers have loads of components, all of which are not required in every application. End-customers need a software that can help them to select required components and visualize how their customized end-product would look like.
2. Feasibility: An important step in procuring transformer tap changers is to do a site inspection and confirm the feasibility of installing the product on-site (considering space and other environmental constraints). However, doing a physical site inspection can be cumbersome and time-consuming.
3. Complexity in assembling: The task of assembling individual components into a finished switchgear product is complex. The client had to spend a lot of time and resources to train their staff on product assembly. 

Solution Developed: LTTS developed a virtual model with the following components to help the client in visualizing the various aspects involved.

• Product customization configurator: This provides a 3D visualization of various switchgear models and individual components. It helps end-customers to swiftly create a customized product and visually understand the physical components of their custom creation.
• Virtual site inspection: Virtualization of field sites to understand the feasibility of assembling transformer taps. All necessary changes to product are done in the virtual environment. Individual components are then seamlessly ordered based on the results of the virtual inspection.
• VR based assembly training: The VR program provides 3D models to understand, visualize and assemble each individual component. Engineers can effortlessly assemble customized transformer taps for customers with minimal training.

Quantifiable Benefits: The software solution thus developed helped in simulating the end-product that users desired and simplified training needs.

• Ease in product selection and configuration: Enables end-customers to quickly put together a custom product and visually understand its various components and technical specifications.
• Minimize training effort: Helps engineers in the manufacturing team understand custom specifications and quickly assemble a finished product with minimal training.
• Significant time savings: The virtualization of field inspections eliminates the inconvenient process of physically inspecting installation sites and making changes to the products post inspection.
• First-time-right installation: The VR software gets all stakeholders on the same platform (supply chain, manufacturer and end-customer), and minimizes miscommunication and human errors. The entire process is seamless and delivers a first-time right custom product.

Keywords: Power Electronics, Virtual Reality, Training Simulators, LTTS, ARC Advisory Group