ETD 351 Izaguirre

7/27/2019 ETD 351 Izaguirre

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Conference for Industry and Education Collaboration

American Society for Engineering Education

February 2-4, 2011

San Antonio, Texas

Virtual Reality Machines to improve training in Control and Automation

Alfredo R. Izaguirre, Manuel E. MacasElectrical Engineering Department

Tecnolgico de Monterrey

Monterrey N.L., Mxico

Abstract.

Current market requirements in industrial sector have motivated the development and adoptionof digital manufacturing software tools for control systems design, training, and processoptimization to validate and ensure the production systems programming control andautomation equipment. This practice, known as Virtual Commissioning, emulates the realprocess behavior in a computer software environment. This technology represents an opportunityfor education where the virtual emulation of real processes can be used to equip Control andAutomation laboratories where students can test, validate, and debug their control andautomation strategies, contributing to student formation and solving the need of having costly,real industrial machinery to reinforce the understanding of classroom theory, with practice. Thisis an excellent option for universities without enough resources, mainly in developing countries,where laboratories are commonly equipped with improvised homemade systems that dontrepresent what students will face in an industrial environment. However, the integration of thistechnology in education cannot be transparent, as a majority of present market applications arenot designed for education and others, dont cover the actual education needs. Because of this aset of features, that intends to enhance the advantage of this type commercial applications isproposed its principal objective is to integrate and motivate the spreading of these tools ineducation and make them affordable for low-resource universities. In this paper, an applicationcalled Virtual Reality Machine (VRM), that covers the set of features needed in education, isintroduced. A methodology for VRM creation is also proposed, supported by a set of LabVIEWapplications consisting of CAD solid creation, conversion process, assembly process, animationprocess, and connection process, followed by the automation validation process. Finally, anexample of VRM capabilities, scope, usage, and impact in student formation is presented.

Introduction.

The consumption world market constantly is increasing and changing its requirements. Day byday more and better quality products are asked for customers what shrink the market product lifecycle, encourage a more extensive product variety and reduce product launch times. Moreoverthis is happening while market price erode, global sourcing increases and quality product must tobe keep high1. This represents challenges that manufacturers have to face in a high competitionenvironment what forces companies to implement technologies, processes, and practices thatenhance their competiveness and differentiate from the others. Product improvement, constantproduct offer changing, process standardization and optimization, price and cost reduction,quality, etc. are some of the practice that companies implement daily oriented to accomplish newmarket requirements. However some of these practices appear to be opposed, by one side havinga fresh product offering requires constantly production lines changing what opposes to cost


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reduction and process standardization. Then to remain successfully in market and in some caseseven to survive, companies must be able to keep a constant innovation. This targeted to look fornecessary practices and tools that support them to face actual challenges and assurance them thatchanges in any production aspect, will impact in the planned way all related company sectors.

Market globalization has forced that companies increases production quotes motivating thatthese open plants in other countries, increase production lines, change or totally replace theirprocess and the way of fabricate goods, etc. This growing has brought a bigger organizationstructure inside companies, more process and equipment to control and manage. In addition atthe same time, practices like lean manufacturing, six sigma, QFD, ISO quality certifications andother production quality activities are being implemented. This is translated in more productsspecifications, processes and procedures information to handle. For solving this, many softwaretools focused to different sectors and with different scope have arisen as support formanufacturing companies CAD/CAM (Computer Aided Design/Computer AidedManufacturing), CAE(Computer Aided Engineering), CAPP (Computer Aided ProcessPlanning), PPC (Production Planning and Control).Some of these can be implemented

individually, however in the highest level these are integrated in a software manufacturing suiteknown as PLM (Product Lean Manufacturing) whose principal objective is to enable companiesto achieve the business imperative of timely and cost effective product launches. This softwaretools oriented to improve and enhance manufacturings resources and production are known asDigital Manufacturing tools (DM) as merge the virtual and physical manufacturing world.

Digital Manufacturing (DM).

DM is an integrated suite of software solutions that supports manufacturing process, tool design,and visualization through 3D virtual simulation tools. The factory environment and theproduction process can be modeled including buildings, production lines, transportation,workflow, and other facilities that represent the complete physical production environment1. Onthese environments, manufacturing engineers can validate and optimize the processes, designing,synchronizing, and validating production lines, robotic workcells, machine centers, productionequipment, control systems functionality and requirements completely prior to the purchase,installation, and commissioning of physical equipment. In essence, DM facilitates the completeview of product and process design as integral components of the overall product life cycle. Thisvirtual validation and commission have turn more important lately as the looking for majorproduction and trusty processes have causes that totally automated complex manufacturingsystems be used more frequently in industry. Because of this there is a section of DM that allowsmanufacturing engineers to merge virtual models of production equipment with automation andcontrols what enables the complete validation of controls logic, automation strategies and HMIfunctionality in a process called Automation Simulation2. This extended level of manufacturingprocess design let executing perfect launches and production changes by validating totally allaspect related with the process from the tool and machine design to the final automation strategy.

Automation Simulation.

Automation simulation involves the entire process of modeling, animation, evaluation,optimization, and validation of controls systems for automation equipment and systems in a


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virtual environment. Which represent manufacturing workcell with 2D image or 3D solidselaborated in CAD that may represent from single process with primitive graphics to elaboratedproduction systems, including multiple robots, complex tooling and fixtures, clamp automationand PLCs. Automation Simulation intends mimic and simulate the real process to be automatedby animation sequences, with the objective of commissioning and debugging total or partial

control logic changes of the manufacturing workcell

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. This can be done even weeks or monthsbefore the real machinery be present in shop floor, as control logic strategy is simulated in virtualcell where interaction and control sequences of tooling, robots, clamps, safety devices, electrical,hydraulics and pneumatics, etc. can be tested. Inside automation simulation this practice isknown as virtual commissioning and helps to assurance that any change in automation systemwill cause the desired impact in production, providing to manufacturing and controls engineersan opportunity to ensure controls design before production starts.

Virtual Commissioning.

Virtual commissioning principal objective is assurances optimizes and validates control and

automation implementation and changes in virtual automated production systems prior to realcommissioning. This is on state-of-the-art digital manufacturing simulation technology; suchdepends on advanced simulation methods that truly represent the merging of 3D virtualsimulation environment, to accomplish the level of automation and synchronization required,with the physical automation world of control logic and control platforms that perform theproduction processes3. Virtual commissioning is carried out on virtual prototypes of productionsystems and equipment which are based on direct real model capabilities and appearance.Originally was intended for allowing the debugging of the control code on an actualProgrammable Logic Controller (PLC)3. However its scope goes further as allows the userefficiently and cost effectively optimizes and validates any implementation or change inmanufacturing processes control strategies, testing different control scenarios, accelerate learningcurve and enables control engineers with the ability to reduce costly errors occurrences, andmitigate risks in a virtual environment well before using real equipment to accomplishcommissioning. This Virtual Commissioning features have caused that also be used in industrywith training purposes, as learning process can be carry out on this.

Virtual commissioning is intended to validate control strategies in virtual production systemenvironment and then move these to real production system. However moving is not necessaryas if virtual commissioning stops in virtual environment the control strategy validation can bedone anyway what makes it useful for validating control engineers programming skills, as theknowledge necessary for controlling virtual production system is exactly the same for controllingthe real one. Then automation simulation can be used with didactic objectives as a teaching toolin automation and control curses as offers a process to control where students can observe thecorrect or incorrect functionality of their control program. This way, automation simulationsupported by virtual commissioning is used for industry and for education. In the first one it hastwo orientations; production systems optimization and validation, and control engineers andlaborer training. In the second one it is used in control and automation courses where finalapplications are used for supporting engineering students formation with practice.

Optimization and Validation.


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The virtual 3D world created by automation simulation technologies of solid model product,digital mockup, and manufacturing process simulation goes further that only simulate productionsystems behavior. As its objective is to assurance a control and automation strategy that can beloaded to real automation hardware and controls a real production systems; making the final link

to the actual production work environment by the connection to machine control systems. Inaddition to model and simulate the machine tool, conveyor line, robotic workcell, PLC, etc;automation simulation generates accurate information capable of driving correctly controlsystems, shorts the ramp-up of production lines during commissioning and product launch,reduces cost, time, design changes, and risk of errors2. These advantages represent critical factorsin product delivery and ultimately company profit or loss; as production lines, workcells, andcontrol systems must be designed, installed, and deployed in the shortest possible time, workingcorrectly with the least amount of test and validation what has become automation simulation ina key piece for manufacturing industry.

Automation simulation gives to production engineers the capability of building virtual

production systems based on real automation events. What enable them to virtually model, themost correct physical and logical interface and material handling operations that can occurbetween the components of workcells and production lines. Because it permits control strategiesor production scenario construction for experimentation, that would otherwise be expensiveand/or time-consuming. This empowers engineers to try ideas in a dynamic, syntheticenvironment while collecting virtual response data to determine the physical responses of thecontrol system. During virtual commissioning engineers are typically finding over 100mechanical and electrical errors in logic, HMI, and drawings per cell1. Problems are normallyfound and fixed with minimal disruption to operation as are solved more quickly since engineerscan narrow them down to items such as physical connections, confident that the validated controlcode works. With automation simulation consequences two to three man weeks are saved duringstartup, saving thousands of dollars in engineering and production labor costs.

Training.

There are two training orientations. For engineers that carry out added value activities inproduction systems and for laborer who are final machines users. According to orientationautomation simulation objective, scope, and usage are different. In training for engineers usuallycontrol or manufacturing ones, automation simulation is used for building virtual environmentswhich can emulates real production systems that are already present on shop floor or that will bein a future. The objective of these training simulations is to serves as a virtual commissioningtool where engineers gain a proper understanding of the process testing control strategies;observe production systems limitations and scopes; known production times and response toprocess changing. These aspects are principally important for beginner engineers or for new onesin a specific area2. Once that the virtual environment is built engineers training consist inconsecutive virtual commissioning on the same simulation. With the objective of acquire thenecessary knowledge for understanding and control the production system. Laborers inmanufacturing companies receive training when are hired, when are moved from productionprocess, when new machinery is going to be used or a product change is planned, actualmanufacturers constantly draw on to some of these situations what means that laborer needs to


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be trained frequently. Training for laborers uses virtual environments created by automationsimulations tools, but these emulations are not intended for a constant virtual commissioning, theobjective is to train machine operators that will use real production systems. With virtualautomation simulation is available for operators the virtual model of the real production systemconnected to a human machine interface (HMI) or a control panel similar to what is used in the

real machine

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. Then operators can observe how the machine emulation reacts to control devicethat is the same that will use in the real machine. With emulation, possible human errors duringreal machine operation can be illustrated, avoiding the risk of costly machinery damage andabove all is assurance that the laborer will known what happens when a human mistake occurs.This is achieves without endanger laborers health or machine hardware. Training simulatorsplay a significant role in reducing the time for plant to go operation and reduces learning curvetime and risks, as empowers the plant operators, to perform the needed tasks needed, with adeeply understanding of the machine that is going to be operated.

Education.

Automation simulation software tools are used with two orientations in education. The first oneis their usage principally in Universities focused in control, automation, mechanical,manufacturing and electrical careers. In universities automation simulation tools are taughtprincipally in advanced engineering courses where students learn about the automation toolitself, its features, limitations, scope, etc. What means that students work with the developmentenvironment not with final emulations, as the teaching is oriented to the automation simulationtool. The second one automation simulation orientation consists in using final emulationapplications for teaching engineering students and supporting automation and control theorytaught in classrooms with practice. This is done in laboratories where students control andautomation strategies can be tested on emulation of production systems that are really used inindustry, without risk to damage costly equipment. This is done taking advantage of the fact thatis also possible carry out all the virtual commissioning process, and never deploys theautomation in a real model, just like is done for engineers training in industry. Having thisemulation enables students to deploy different control strategies in each one of these, makespossible that they relate with different sensors, actuators, machinery functionality, etc.

From this point of view, automation simulation well used in education opens the opportunity ofsolving the problem that faces many universities in what refers to control and automationlaboratories equipping. That is the fact of having a process where students practice theknowledge acquired in classrooms. As usually real workcell used in industry are very expensiveand universities cannot paid for some of these. For this reason, the possibility of having a varietyof virtual emulations process where students increment, reaffirm or practice automation andcontrol skills is an opportunity for educational institutions for complementing and supportingtheir automation and control courses, and increase the knowledge, abilities and formation of theirstudents. However in market there isnt a big offer of final virtual application. There are only areduce number of companies like Festo by Ciros Mechatronics, SIEMENS by SIMIT SCE andEasyPLC that offer 3D final application for carry out virtual commissioning and learningautomation. Prologix an independent tool offers 2D final virtual applications, others like DelmiaAutomation by Dassault Systemes, Tecnomatix by SIEMENS, RsTestStand by Rockweel, UnityPro by Schneider are oriented to give the software tool for building virtual applications and not


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offer final virtual environments where students can testing and validate their programs. Thenfrom the reduced vendors group in market, there is a more reduce group that offers finalapplications for training oriented to Educational Institutions whose scope varies. Applicationparticularities cause advantages and disadvantage between final virtual applications what impactdirectly in the students learning level. Although the strong impact that can cause these final

application in education, these have not been broadly used, as these are not as popular ineducation as could be. Considering their scope in training the lack of popularity has beenmotivated principally for particular tool disadvantages and the small number of option in market.

Automation Simulation software tools in market.

Automation Simulation is practically new and has been exploded and developed only for areduced group of software vendors. The software solutions present in market are very different,everyone with its own particularities and scope. Differences are found principally in aspects likeorigin, target sector orientation, cost, origin country, visualization capabilities, connectivitysupported, licensing, usage complexity, integration level, programming environment,performance, flexibility, graphics quality, etc.4 The origin of the tools present in market varies asdifferent companies whose orientation are sectors some way related to manufacturing andautomation have created these tools, or some others have been developed for a small group ofindividual programmers with specific purpose. Origin seems to be closely related with toolparticularities and scope. Some aspects of the software tool developer company as expertise,know-how, objective, availability of means as previous software developments, productsportfolio, etc. dictate some of the principal features of the tool and therefore its scope. Origin ofthe tools refers to orientation of the company that created or commercializes the software tool.Principally there are three origins of the tools present in market. 1) PLM software tools. 2)Automation hardware and/or software vendors. 3) Software tool from Third Party.

PLM software tools.

Companies that develop this kind of tools are the beginners in this field and who more aredeveloped and exploded the automation simulation and virtual commissioning concept; the scopeof these tools is extended. These are the most broadly used in industry by big companies likeGM, Ford, Airbus, etc. as are supported by a renowned company. There are principally two PLMsoftware vendors that offer automation simulation tools inside their product portfolio. These areDelmia from Dassault Systems powered by IBM and Tecnomatix powered by SIEMENS. Fromthese with previous experience in CAD/CAM and CAP software Delmia is the beginner of thistechnology and who establishes and defines the automation simulation and virtualcommissioning concepts, Delmia Automation is the tool offered for this vendor2. Tecnomatix ismore recent and arises from the integration of Unigraphics with SIEMENS; it offers a tool calledeM-PLC oriented to virtual commissioning with SIEMENSs PLCs5.

Automation Hardware or Software Vendors.

Automation tools that have been developed and are offered in market for automation hardwaremanufacturers are part of this classification. In automation technology software is closely relatedand necessary for using automation hardware. Companies that are automation hardware vendors


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like SIEMENS, Rockwell, Schneider, ABB, etc. offers in their product portfolio differentsoftware application oriented principally to own PLC programming and PLC emulation, some ofthese also offers automation simulation software that is intended for being virtual emulationsdeveloping software. The resulting applications vary in visualization, scope and complexitydepending of the vendor. Visualization of these tools goes from primitive 2D objects to

importation of 3D solids created in CAD; the scope of these tools is principally oriented tovalidate PLC programming. Despite these tools dont offer the features and capabilities that offerPLM tools and is scope is more reduced, as its principal objective is to validate automation andcontrol PLC programming, these are considered as automation simulation tools. The principalfeature of this kind is that are compatible only with developer automation hardware. SIMIT bySIEMENS, RS TestStand by Allen Bradley and Unity Pro by Schneider are examples of these.

Software tools from third party.

The origin of tools in this classification is very heterogeneous some of these are developed bysoftware companies with orientation to automation. Despite that arent part of PLM solutions

some of these are supported for renowned software companies with brand positioning andexpertise in automation. These are robust and have a high level of integration with proprietaryand external applications. Some examples are EasyVeep, Cosimir PLC & Ciros Mechatronics byFesto, InControl and InTouh from Wonderware suite by InvenSys. Tools developed by softwarecompanies without automation orientation but with expertise in software developing are also inthis classification, either in independent way or by joining with automation hardwaremanufacturers, taraVRcontrol by Tarakos is an example of these. A third division what isprincipally intended for own training and is the most varied group is integrated for automationsimulations tools created for individuals or little groups of programmers principally automationsprofessor or PLC fans, oriented to helping to understanding PLC programming some of thesetools have an extended scope and offer other possibilities. However because their origin thesearent so robust and their capabilities are poor compared with tools in others two classifications,EasyPLC, SPS-VISU, Prologix are examples of these. In table 1 in appendix A in the end of thepaper is shown a brief resume of the principal features and capabilities of these 12 automationsimulation tools in market. These, are the most common used, and cover almost all the toolspresent in market. In case of some omission, tools mentioned describe well the status andcapabilities of simulation tools in market.

From table 1 eM-PLC and Delmia Automation are the most used in industry principally in bigcompanies as have a high integration level and capabilities, however the licensing cost of thetools is high. InControl and InTouch are used for automation companies, who develop finalapplication for industry these are oriented to developing and are based in 2D visualization,licensing is required. RS TestStand Unity Pro, SIMIT in industry version are oriented to middlesize companies where are used for manufacturers and for external automation companies forvalidating PLC programs, these only work with hardware from Allen Bradley, SchneiderElectric, and SIEMENS respectively licensing is required for it use. SPS-VISU has achievedintegration with SIEMENS10 however visualization capabilities is poor as only uses 2D graphics.taraVRControl is also a developing tool final applications this use OPC server what makespossible communicate final application developed on this with any PLC6 however licensing andsomebody that develop applications are necessary. The rest arent intended for being used in


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industry as are created for small developing companies, EasyPLC, offers powerful visual processemulations, PLC and HMI programming environment and a suite called machine simulator forbuilding virtual applications. The principal objective of these tools is to be used as virtualenvironment developing software and dont offer final applications for practicing onlyEasyVeep, CIROS for Mechatronics and ProLogix are final applications EasyPLC and SIMIT

SCE offer some examples, but the rest are developing tools what makes necessary buying thesoftware or hiring a company that develop final applications. All these tools require licensingwhose price varies according with the tool.

Features for Virtual Commissioning in Education.

Despite that automation simulation is practically new and that there arent and extended offer ofthese tools in market this technology is being adopted more frequently for manufacturers. In thissector it has had the desired impact principally in the reduction of starting up and learning curveas for laborer as engineers. The impact in learning that automation simulation has in engineerscan be moved to educational sector where can impact in the same way to engineering students as

these seem to fit in the scenario presented for many educational institutions whose needs inautomation and control field are an opportunity for integrating them.

Automation Simulation tools in market are principally focused to industry and the context andneeds for education are different as there isnt need of adding developing tools but finalapplications for equipping laboratories with processes to control. Then the contribution thatautomation simulation software platforms can do to education lies in final application developedin these, not in the developing software. Where students can prove, test and validate their controlprogram, in a process closely to a real industrial one. As can be observed in table 1 From thetools in market only a reduced group of software companies have launched to market finalapplications with the objective of engineers and students training. However features as,licensing, price, connectivity, quality, etc of each one of these have caused that arent broadlyused in universities.

The need to create a virtual final application whose features, be oriented to education arises. Inaddition applications features must complement students formation with practice, representclosely real processes, accomplish equipping universities needs with a high performance, let thespreading of virtual final applications, enhance their impact in educational sector and at the sametime let that these kind of application can be implemented in universities with low resources withthe objective of making them available also for universities in developing countries. A set ofdesired features according to the presented educational context needs are proposed next. Inaddition an automation simulation final application called Virtual Reality Machine (VRM) thattries to fulfill these features, its developing procedure, and application are described.

Set of Features.

(1) The student must be capable of analyses and understands the sense of automated processsystems their time and space relations and limits, how sensors and actuator mechanically work,how mechanism are formed and impact the process, identify the function and mode of operationof the individual components. For these 3D graphics applications are needed. As there is more


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visual information transmitted with 3D graphics than with 2D. (2) Applications must berepresentations of processes found in industry to familiarize students with the operation of thesystem and to understand the product and the processing method. The ability to experiment withreal process models creates an environment close to a real manufacturing system, which is thereal objective of training. (3) Interconnection with principal commercial automation software

vendors is optimums as with programming as with softPLC software. While more relation havestudents with industry controllers software easier would be their adaptation in industry.Compatibility with softPLC or PLC simulators helps for testing programs without a real PLC. (4)Connection with real control devices as PLC, touch panels, etc. As this gives more reality to theprocess, provides to student industrial hardware familiarization and interaction. The feature ofproving and debugging the programming in a real controller takes the students from the processvirtuallity to the real PLC controller interconnecting the simulated world with the real world. (5)The final virtual automation application must to add the less possible cost to the solution as theapplication is software the prices is principally in licensing for this reason licensing for runningapplications has to be the cheapest possible. (6)The hardware necessary for running theapplications, with a high performance, has to be the most common and commercial possible for

avoiding high costs. (7) The simulation must to have short response times; high performance andspeed when 3D visualizations, simulation and virtual commissioning is being carry out. (8) Easyinstallation of final applications for avoiding complicated configuration or many and specificinstallation steps.

Virtual Reality Machine (VRM) Concept.

There isnt a single term for calling final automation simulation. In market every vendor gives adifferent name, trying to cover the particularities of everyone. The features of the virtual finalapplication that is going to be presented, explained and developed turn it different from thosementioned in table 1. For this reason the concept of Virtual Reality Machine (VRM) isintroduced and defined next.

A VRM is a computational application that models and emulates appearance and behavior of areal machine, process or production system. It is based in a set of 3D solids that mimic as closeto a real machine as possible, visual, audible and functional aspects of the machine elements,(mechanism and sensors).The VRM dynamic and behavior is controlled by virtual sensors andvirtual mechanism defined and programmed during VRM creation process. These are ready forconnecting with external devices and sending and receiving control signals from/to either realPLC or SoftPLC. Communication of control signals is done by addressing virtual mechanismand sensors in a VRMs pin out table. By itself a VRM is not capable of carry out controlledsequences as this needs the implementation of a control strategy previously programmed inexternal automation hardware. This makes that dynamic and functionality of the VRM dependsonly of the control logic sequences programmed by the user.

General Procedure for VRM developing.

For every process that is going to be emulated a VRM has to be created. Despite that every VRMhas a specific final functionality when these are created share certain general developing aspectsthat repeat every time that a new VRM is developed. These aspects can be summarized;


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organized and separated in a set of steps according to their developing objective. In every one ofthese steps a developing method is followed. Conjunction of all steps integrate a general VRMdeveloping procedure that can be clearly separated in 6 steps: 3D CAD creation, Conversionprocess, Assembly process, Animation process and Validation process, every one of VRMdeveloping method stages and its procedures are described next. In figure 1 is shown the

organization of stages, order and their interaction inside general procedure, the VRMs part thatis created in every one of these and some application tools used for helping in the VRMdeveloping.

3D CAD Creation.

The first step for creating the VRM is the Virtual Machine Elements (VME) modeling in CADsoftware, the only requirement from the CAD software to use is that it has the capability forsaving the solid created in VRML 2.0 (97)12 format. Requirement that must be accomplished forfuture conversion in LabVIEW. Two consideration must to be taking in care when modeling inCAD software that later are reflected in the VME due to VRML structure features. The first oneis solid number. When the VRML file is converted in a VME this turns in a LabVIEW VirtualInstrument (VI) turning the solid information in LabVIEW code part. This make more efficientthe final application, extends manipulation capabilities, and enhance the features that can berepresented, accessed or gotten from it before or during simulation running. This is deeper

detailed in Solid Conversion Section. The second is solid functionality for defining if a part or anassembly is going to be created is necessary consider the dynamic that will have the solid tomodel in the final VRM. Similar to real machine in VRM there are two classes of VMEs,dynamic VMEs, that move as result of a PLC input signal and static VMEs that are part of theVRM structure, this has to be considered when the decision of what solid include in an specificVRML that is going to be converted is taken.

Figure 1. General procedure for VRM developing.


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Conversion Process.

Once that the VRML file is created it is processed in an application that has been developedcalled VRML-VME Converter. The VRML file structure contains in ASCII code the completeinformation that defines the solid, this is separated in object nodes, where each one of this

contains information about the triangles coordinates vertex, normal, color values and index ofeach solid part that forms the solid12. The application recognizes this structure and processes theVRML files, gets and organizes the important data required for render the new file in LabVIEW.Then the VRML file is processed only once by LabVIEW. As result a VME (Virtual MachineElement) is created. This is a LabVIEW Virtual Instrument (VI), which represents exactly thesolid models as the VRML file, since nothing of information is lost during the conversion. Oncethat the process finishes the new VME in saved in a library. Then the VME now is a LabVIEWnative file and has all the information necessary for representing and rendered the 3D solidwithout need of VRML or any CAD software or file. Having the 3D solid as VME representssome advantages as: faster execution time, deeper control of the 3D solid, integration of VMEcode to other LabVIEW applications, makes available the usage of some special properties

because all solid data are available during execution. There are two classes of VME for VirtualMechanisms and VME for Environment.

VME for Virtual Mechanism: A Virtual Machine Mechanism (VMM) is integrated by two ormore VMEs which are related by at least one dynamic action one over another and at least one ofthem is affected by a change of signal received from the external controller. Inside VME forMechanism classification there are two VME types: VME part this is gotten when a VRML thatcontains information of individual part is converter. VME assembly this is gotten when a VRMLthat contains information from solids set is converter. Both can be affected with translational androtational movement or color and shape change animation.

VME for Environment: This VME type objective is to serve as VRM decoration exclusively thisrepresents for example floor, walls or any other solid in the scene that has not connection withthe real controller. This can have movement or be static during VRM functionality.

Assembly Process.

A set of virtual machine mechanisms (VMM) is used for creating a VRM. These VMMs areintegrated by a set of animated VMEs which first have to be placed spatially in theircorresponding position inside the VRM in a previous VRM assembly process, for this, a processsimilar to the assembly that is carried out in CAD software, where assemblies or parts have to beplaced in certain (X,Y,Z) coordinates has to be done. However as LabVIEW is not intended forbeing a CAD Software this process is not easy and friendly to realize. This assembled has to bedone because when a set of VMEs are called and rendered in the same LabVIEW scene bydefault are placed in the position where were saved in CAD software during the Solid Creationstage, usually this position is the origin (0,0,0) however this can be any point in the space and notprecisely the correct place inside the VRM final assembly, for this reason a set of VMEs whenare rendered are placed normally overlapped in origin and is necessary to place them in theircorrect spatial position.


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Inheritance.

Inheritance is defined as parent and child relations among VMEs that command how rotationaland translational transformations applied on one VME affect others VMEs in a VRM.Inheritance must be specified for a correct VMM functionality. Whether this is defined, when a

movement transformation is applied to one parent VME this affects also its children VME butwhen is applied to a child VME this affect only itself. VMEs inheritance structures can varyfrom one single branch to a set of branches complexly related in the VRM. Complexity ofrelations depends directly of the VMM dynamic relations and functionality inside the VRM.

Subassembly concept.

To fulfill the requirements of the VRM functionality and defined inheritance, a subassemblymust be specified. A subassembly is a set of VMEs or others subassemblies which are affecteddynamically by the same transformation. In addition it contains an internal inheritance structurewhich relates all the subassembly components. Subassemblies are generally used for VMM

definition as the elements inside a subassembly can be affected individually by transformations,defining their dynamic relations inside the VMM and the subassembly as a whole can also beaffected by a different transformations, defining its dynamic relations inside the VRM. Then asthese two transformations need to be handled in the VRM subassemblies must to be used anddefined considering the VRMs functionality and its VMM.

Assembler.

The VME assembly process carry out in LabVIEW is time consuming, is complex and requires acomplicated programming structure. This motivated the developing of a LabVIEW nativeapplication called Assembler, whose principal objectives are: Optimizing VRM assemblyprocess, reducing programming time, organizing VMEs data and turning friendly VMEtransformations addition. The Assembly process has two principal objectives; placing VMEs intheir correct spatial position and establishes inheritance relations. The first one is repetitive forevery VME that is assembled and the second one differs only a little depending of thecomplexity of the mechanism. The Assembler takes advantage of this repetitively letting that theuser set only some parameters as X, Y, Z position, angle and axis for spin and inheritancedefinition, these data are processed, organized and structured only once every time that the VRMis executed this way of assembly the VMEs reduces the programming time as avoids that theuser generates all the programming structure optimizing the assembly process. The file gottenfrom this process is a Virtual Machine Assembly (VMA).

In figure 2 is shown the Assembly process in a VRM this is composed in total for 8 VME whichare organized in one static VME that is the principal assembly parent and 7 dynamic VMEs.Three of the dynamic VME are parents in subassembly 1, 2 and 3 and four of them are individualVME subassembly 3. In a) is shown the VME origin position when they are rendered, in b)subassembly 1 which contains 1 VME and to the subassembly 2, in its principal branch, ismoved and only the principal assembly parent keeps in its positions. In c) subassembly 2 whichcontains 1 VME and to the subassembly 3, in its principal branch, is moved. In d) thesubassembly 3 which contains 4 VME, in its principal branch, is moved. In e) the 4 individual


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VME inside subassembly 3 are moved. In f) a top view of all VMEs in the VRM is shown in g)and h) the assembly process is illustrated when one VME is placed in its correct position. In i)the final correct assembly is shown. As was mentioned a subassembly can contains VMEs orother subassemblies for example subassembly 1 contains 1 VME and subassembly 2, but assubassembly 2 contains also 1 VME and to subassembly 3 and subassembly 3 contains 4 VMEs

subassembly 1 could be referred as a subassembly that have 7 VME in all its branch structure orthat contains 1 VME and to subassembly 2 in its principal branch just like in CAD.

Animation Process.

In this process is defined the internal programming of the VRM. It includes all aspect related to

VRM functionality as VME movements inside the virtual machine mechanism (VMM), sensorsprogramming, conditions validations, signal generations, is necessary to specify that thisprocedure doesnt refer to VRM programming control but animation sequences required forVMR acts dynamically according to control sequences received from external controller. Thisprocess is done in LabVIEW using the necessary operations, conditions, structures, subVIs,validation and instructions that the VRM needs for having a behavior the closest to the realprocess as possible. For achieving this objective many aspects have to be considered as a VRMnot only involves VMM functionality but all aspects related with the process emulated and itsenvironment. Then Animation depends of every VRM functionality and the way thatprogramming is done vary according to VRMs logic programmer. Despite every VRM has aparticular internal programming according to its functionality some important and general

aspects independent of the VRM can be underlined in animation programming. These are VMMprogramming, virtual sensors programming and extra animations programming.

VMM Programming.

During the animation programming VME are grouped and turned in a Virtual MachineMechanism (VMM) using inheritance defined in the Assembly process. A VMM is integrated by

Figure 2. Process of placing VMEs in their correct position.


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two or more VMEs which are related by at least one dynamic action one over another and at leastone of them is affected by a change of signal received from the external controller. In VMMVMEs behave as actuator. This means that when a change in an external signal is received VMEare affected during VRM execution usually with transformation operations like rotation,escalation, translation, color change, etc. until other change in the signal is received for achieving

this behavior. In VMM four tasks must be carried out, these are: validating the reception of anexternal signal, recognizing of the signal, deciding what action to take and execute the action.

Virtual sensors programming.

The reception and processing of signals from the external controller is closely related with VMMfunctionality as these are validated and processed inside the VRM. However the response ofVMM according to these signals has to feedback it somehow to the external controller as in thecontrol programming running in it the effects of these signals have to be validated for achievinga correct control of the process. In a real process, signals are sent from the process through manytypes of sensors that are placed in a specific position. As VRM emulates totally a real process,

this sending of signals must also be done, for this, virtual sensors are used. These are individualVME or part of VMM; that in addition include programming oriented to emulate the behavior ofthe real sensor and generates the signals that a real one would generate. When certain conditionsinside sensor programming accomplished a change in virtual sensors state occurs; this isreflected in the same indicator that communicates with the external controller which isestablished in connection process, this means that the output of a virtual sensor gotten aftervalidations must affect the same variable in the programming that serves as input to the externalcontroller something similar to real sensor.

Extra-Animation Programming.In addition of VMM and virtual sensors programming other animations sequences are alsorequired in VRM, these dont relate directly with VMM or virtual sensors functionality and theirobjective is making more real the VRM functionality. For example VME color change, VME ora VME part appearing or disappearing, movement of some VME that arent VMMs part insidethe scene, change of inheritance, addition of the real sounds to VMM movements, and any otheranimation required for the correct processs visualization that the VRM emulates and doesntreceive or send signals from/to external controller In addition sometimes controlled extra-animations have to be used because some sequences are difficult to program in LabVIEW as thisis not intended for being an emulation process program then the use of extra-animations helps tosolve these difficulties.

Connection Process.

After animation process the application gotten still cannot be considered as a VRM as this stillhas not connection to external control devices. This means that a control strategy cannot be carryout on this as a VRM has not internal control sequences saved. At this stage it can be consideredonly as a VM (Virtual Machine). Then for accomplishing the control and automationfunctionality, is necessary the connection of the external controller outputs with VMs VMMinputs and external controller inputs with VMs virtual sensors. Similar to real automated control


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systems where control devices I/O are interconnected for communication with manufacturingprocesss sensors and actuators by voltage signals that are carry usually over electrical wires.This is done in VM through a connection procedure whose objective is turning VM into VRMaddressing, organizing and describing in a Pin Out table the VRMs VMM and virtual sensorsfor being available for the external controller. However the VRM is a software application that

emulates mechanism and sensors therefore physical devices dont exist and wires for carrysignals cannot be placed. Then connection between VM and external controller also has to beemulated by software, what does that VRMs connection process be particular. This is integratedby 3 steps: Identification, addressing and programming.

Identification.

Once that animation process finishes, the VM gotten has all controls and indicators used for itsprogramming. These include as those that help to VRMs animation programming as controlsand indicators that need to be used for the external controller for starting or stopping VMM incase of controls or from where the change of virtual sensors state can be read for the external

controller in case of indicators. Then the first step for connection process is, identify and separatethe signals that external controls and indicators affect. For this must be considered what signalsneeds the control programmer engineer or student for carry out the correct control strategy on theVRM.

Addressing.

After indentifying VMM and virtual sensors signals is necessary to give a hardware address toeveryone of the signals used for external connection. However as wire cannot be placed forinterconnecting external controllers outputs with VM inputs and vice versa this has to beemulated by software. Then for addressing VM with external controller is necessary to make amapping of external controller addresses with the names of the signals used in VMs LabVIEWprogramming as the PLC programmer uses this addressing in the control program which by theaddressing access to the LabVIEW signal name. The LabVIEW signal name is used for internalVM programming. VRM addressing, specifies the address of every one of its virtual sensors andVMM inside the VRM that the user can affects. The final addressing is organized, presented anddescribed in a Pin Out table similar to those used in real automated control systems.

Programming.

Once that every one of the VMM and VRMs virtual sensors have been addressed. VMMs arelinked with external controller outputs and VRMs virtual sensors with external controller inputsby interconnection and communication programming inside the VRM connection process.Interconnection programming: As VRM receives and sends change of signals state from/ to theexternal controller. There is a programming part inside VRM oriented to the reception of signals.Whose objective is to get from the external controller the state of each one of signals used forVMM; and other programming part oriented to sending of signals. Its objective is recollecting,organizing and sending the state of each one of the virtual sensors signals. CommunicationProgramming: Once that VRMs I/O mapping is done in interconnection programming. Isnecessary a programming part oriented to send and receive the data to/ from the external


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controller and doing the communication task. For this has been developed a set of ActiveXlibraries programmed in .Net whose instructions are called and reprogrammed in LabVIEWthese communicates the VRM with PLC software libraries.

Automation validations Process.

Once created the VRM, a general validation of its functioning have to be done before of creatingthe executable file of the LabVIEW VRM program and finish the VRM creation process. In thisprocess is validated the complete functioning of the VRM and is assurance that the VRM correctfunctioning depends totally of the correct control sequences programmed in the externalcontroller by the VRMs user. This means that if a mistake occurs or there is an incorrectvisualization this depends totally of the control program created for the PLC programmer not ofthe VRM functionality. The validations carried out in this process are: Validation of VMMfunctionality, virtual sensors signal validation, animation validation, automation validation.

(1) VMM functionality validation: VMMs are activated first by LabVIEW front panels controlsand later by signals change sent from PLC software. In general is checked that VMMsfunctioning is correct and the closest to the real mechanism. This is done by validating thatVMMs start or stop when receive the correct signal, that visually their functioning is the correct,that spatially they dont crash with other VMMs or VMEs, that their dimensions are correct, thattheir movement is adequate and according to the signal or control sequences that are receiving,etc.(2) Virtual sensors signal validation: virtual sensors are activated from VRMs and its estateis checked first in VRMs front panel and later in PLC software. In this process is validated thatsensors activate enough time for being read for the PLC. The activation time depends of thesensors limits programmed in LabVIEW. In addition is also validated that sensors are in thecorrect X, Y, Z coordinate when change the estate of their signal.(3) Animation validation: Bythe VRM functioning is validated that correct animations executes in way and time that have tobe executed. For example if a translational or rotational movement affect the VME in the desiredway, that color change of the VME is activated in the correct moment and that the VME changesto the color needed, in general that visually the behavior of the VRM is the correct. (4)Automation validation: For this validation an automation task that uses virtual sensors andVMMs addressing of the VRM is created, debugged, loaded, tested and monitored in PLCsoftware. With this is assurance that VRMs signals change of VMMs and virtual sensors areinterchanged correctly and that with these signals is possible carry out correct control sequences.

VRM Application.

After validation process VRMs process creation finishes. Then now from a LabVIEW projectthe VRM program is compiled and an executable file and an installer of the final VRMLabVIEW program are created15. The installer makes possible that LabVIEW developedapplication behave as a any commercial software when is installed in PC. The capability ofturning VRM in an executable file has the advantages of: VRM portability, minimums softwarerequired for execution, organization of all files in a single one, easy installation. But the principaladvantage is that licensing is not required for VRM execution and can be used in PCs onlyinstalling a LabVIEW runtime which is gotten free from LabVIEW website. This makes possiblethat VRM be practically free and one viable learning option for control engineers, automation


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students, universities laboratories, training centers, etc. regardless their economic possibilities.After installation when VRM is executed for being controlled, initially a configurations box likeshown in figure 3 is displayed. In this the users choose the type of connection that want toestablish between the external controller and the VRM according to the controller that they haveavailable and the communication protocols this handles. In figure 3 in box are shown a set of

communication protocols available for one VRM, in this example these are PLCSIM, IndustrialEthernet, TCP/IP, MPI/ Profibus, WinLC.

Communications Protocols handled for the VRM.

According to the protocol chosen is necessary write the address of the external device used forcontrol the VRM. This is the number that indentifies the controller where data are going to besent and received, this is necessary for communication libraries and varies depending of theprotocol.VRM is a new virtual commissioning tool that so far has only be tested and validatedwith SIEMENS automation hardware and software and whose communications libraries havebeen developed oriented to this vendor as VRM doesnt use OPC communication. This affectsVRM application only in interconnection capabilities, the VRM concept and developingprocedure if the same regardless the external controllers brand. VRM developing continuesoriented to adding OPC communication and developing communications libraries for othersautomation hardware vendors as Allen Brandley, Schneider, ABB, etc. as VRM concept isintended to be used with any commercial external controller vendor. In figure 4 is shown theVRM communication diagram when SIEMENS hardware and software are used for automate theVRM. This illustrates the VRMs communication with external control devices15.

Figure 3. VRM Connection configuration.


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Figure 4 shows, that there are two options for using the VRM; with S7PLCSIM or a realcontroller. If PLCSIM connection is chosen VRM and PLCSIM will communicate only by

software this means that wont be connection to a real hardware and the VRMs user will workwith a PLC emulation PLCSIM musts be installed and running in the PC that will communicatewith the VRM, monitoring of the I/O signal and manual activation of actuators can be done inthe PLCSIM software in figure 5 a) is shown a VRM using PLCSIM. When TCP/IP, IndustrialEthernet, MPI/Profibus, WinLC protocol is used is necessary to have an external PLC with thecommunication interface that support the protocol that is chosen in figure 5 b) is shown the sameVRM being controlled by an external controller and in box is shown SIMATIC S7 software usedas for programming the machine as for monitoring the execution of the program.

Automation equipping solution.

For plenty accomplishing its objective, automation and control laboratories need aninfrastructure that in addition of counts with industrial automation hardware and software alsoincludes a process or plant where students implement, test, debug and validate their control andautomation strategies. However this represents the highest costs for laboratory equipping and inthe best scenario laboratories are equipped with few real automated devices used in industrywhich for their high cost are used commonly only for professors with demonstrative objective.Training workstations of vendors as Festo, FISHER tecnics, etc as consequence of their price,are used only for a reduced number of universities. Other practice is testing students control

programs in a set of individual industrial sensors and actuators that activate according to thecontrol programmed, however these dont represent a real industry manufacturing process. Acommon practice is the construction of home-made systems that are a set of buttons, actuatorsand led indicators that with imagination try to represent a process. The construction of primitivestructures as elevator, mixer, etc. is also a common practice. In addition that any one of theseoptions has a cost some of these dont achieve to impact totally in the students understanding assome students dont visualize the essence and sense of automation and control strategy carried

Fi ure 14.10 VRM controlled b PLCSIM.

Figure 5. VRM controller options.


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out on these. For this reason the automation and control laboratory station shown in figure 6 isproposed. This represents a viable solution to the lack of equipment that face many universities,as the highest cost of laboratories equipment is represented for the process to control, what issolved with the VRM as this emulates a real process. Even a set of VRMs can be used forstudents as many VRM can be installed in the same PC. In addition VRM makes possible that

laboratory has a set of VRMs in every station without additional cost what means that everystudent can has his/her own process to automate. The Automation Lab Workstation proposed isintegrated for a Real PLC, a touch panel and a PC where VRM executes, in addition in this PLCand Touch panel software is also installed.

VRM s impact and interaction with students.

For illustrating the impact of the proposed automation learning platform, is used a laboratoryequipped with SIEMENS CPU315F PLC and a SIEMENS Touch Panel as hardware andSIMATIC S7 and SIMATIC WinCC as control developing software and as plant a VRM calledProcess Line which represents a machining process which has 19 Input addresses and 15 outputaddresses. In addition to automation hardware and software and to the VRM in laboratorystudents receive a pin out table with the address and description of all VRMs virtual sensors,VMM and document with the plant description that includes the description of the process that isrepresented for the VRM, description of the functionality and position of virtual sensors andVMM and VRM dynamic, this information is all what they need for starting with theirautomation task.

The objective of automation is according to the criteria of the laboratorys professor as VRM canserves as for carry out simple control sequences as for a total automation of the process that

Figure 6. Automation & Control Laboratory equipping proposed.


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represents. In laboratory the students develop the control strategy that is going to beimplemented on the VRM just like is done in a real process, this depends totally of the userknowledge and what is asking for the professor. There arent restrictions in programming theVRM, interruptions, counters, memories, timers, etc can be used without affecting itsfunctionality. Once that the student finishes his/her automation task in SIMATIC S7 and the

HMI programming in WinCC the control programs created are compiled and downloaded totheir respective automation hardware. Then having the external controller turned on and theVRM in execution, the automation strategy programmed for student is tested and validated onthe VRM checking that the functionality of the behavior of the VRM is correct and goesaccording to what was asked for professor.

The user interaction with the VRM is shown in figure 7, here is observed that students do threeprincipal tasks in laboratory: 1) Task developing. Where students program and debug theirautomation strategy. 2) Hardware programming. This is the process where the programdeveloped is compiled and downloaded to the automation hardware. 3) Test and Validationstage. Where students validate their control program and skills and the teacher secure that

students have acquire the knowledge transmitted in classroom and that have the capability ofimplementing and using these knowledge in automated systems that are very close or equal toused in industry.

Figure 7. VRMs Interaction with students.


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Considering that problems faced for universities in automation and control careers are focused inlaboratories. The equipping proposed respects the traditional and actual automation and controlteaching method that begins with professor in classroom transmitting principles, basis andfundamentals of automation and control to students and is complemented with commercialautomation hardware and software commonly used in laboratories. However the key aspect of

the proposal is the incorporation of the VRMs as final processes for supporting the classroomtheory with laboratory practices that involve automation and control scenarios similar or equal tothose found in industry.

Conclusions

In engineering theory is closely related with practice. The level of integration between theoryand practice and how they are complemented in universities is reflected directly in studentsformation as the lack of practice and the deficient training received for students in universitiesimpact directly in their competitive advantage, what is reflected in the job opportunities forstudents. In many countries where manufacturing is one of the principal activities, automation

and control careers are a key aspect for industry, and engineers with this orientation areconstantly wanted. However because of lack of practice many of these engineers havent theskills needed for some manufacturing companies, what is reflected in some aspects as of theirpersonal life as in the country growing.

According to the VRMs features presented, the usage and implementation of these as processemulation where students test, debug and validate their automation and control strategies, is anoption for educational institutions with a not enough laboratory infrastructure, as these are a highperformance and low cost solution that resolves the problem of lack of laboratory equipping thatface many low resources universities principally in developing countries. Even help to anyuniversity to complement and supporting the automation and control course offered. Despite thatwith VRM investment in automation hardware and control must to be done this cost representsonly an small portion of the total investment required for equipping a laboratory with traditionalmethods, as the final process where to implement the control is the most expensive part of theequipment necessary in laboratory. With VRM this cost hasnt to be paid as there isnt necessityof licensing. Despite with VRM equipping there isnt a real process to control the emulation areso close to reality that for automation and control practice objective can be considered just likereal process, as the knowledge transmitted to students when the control strategy is programmedis the same that if this would has been carry out in a real process. VRM offers to student thepossibility of complement his/her educational training, supporting the knowledge acquire inautomation and control courses with process emulations that impact directly in the grade andquality of training received in laboratory, skills acquired and knowledge won in classroom andlaboratory. This practicing impacts directly in the student formation and training what reflectslater in their professional life as gives add value to students resume and prepare them for someof the problems that will face in industry.


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Appendix A.

Table 1. Principal Features of Automation Simulation tools in market.


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Acknowledgment

The authors wish to acknowledge the support of the Tecnologico de Monterrey, CampusMonterrey to develop this research which is a contribution of the Product Development forEmergent Markets Research Chair, Registration No.CAT121.

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6. Tarakos Gmbh, Tarakos 3D visualizer manual 2003, Werner HeisenbergStr.www.tarakos.com/eng/Produkte/control.

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ALFREDO R. IZAGUIRRE holds a B.Sc. in Electronics and Communications Engineeringfrom Universidad Autonoma de Nuevo Leon (UANL). Studied a Master Degree in Managementand Business at UANL. Currently he is a Student of Master in Electrics Systems with especiallyin Electronics (MSE-E) at ITESM, Campus Monterrey. He is Tele-Engineering and IndustrialElectronics labs instructor and participate in some projects on, Virtual Labs to enhance

Learning/Training in the areas of Control and Automation.

MANUEL E. MACIAS holds a B.Sc. in Electronics and Communications Engineering fromMonterrey Tech (ITESM), Campus Monterrey and a Ph.D. in Power Electronics from TechnicalUniversity of Dresden in Germany. Currently he is an Associate Professor in the ElectricalEngineering Department at ITESM, Campus Monterrey, where he teaches Electronics and PowerElectronics courses. He is in charge of the Tele-Engineering and Industrial Electronics labs andleads some research projects on Computer-Assisted Learning, Virtual Labs and Remote Labs toenhance distance Learning/Training in the areas of Electronics and Automation.

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