The virtual reality for maintainability (Revima) VR system supports maintainability simulation in aeronautics. Within this project we have developed and integrated a haptic device, the large haptic interface for aeronautic maintainability (LHIfAM). We use this device to track hand movements and provide force feedback within the large geometric models that describe aircraft engines. The user movements are the same as those that occur when testing physical mock-ups. An integrated haptic device and VR system for testing aircraft engines reduces development costs and avoids the necessity of physical mock-ups formaintainability.

Aeronautics, in the context of industry 4.0, is continuously evolving to respond to the market dynamics and has incorporated automation to many stages of aircraft manufacturing. However, most of the final assembly line processes are still done manually and remain a challenge. Virtual Reality (VR) technologies can be leveraged to study the incorporation of automation systems involving Human-Robot Coexistence (HRC) in assembly processes before the physical system is available, which is beneficial for increasing the productivity and identifying issues beforehand, thus, preventing unexpected costs. In this context, a VR simulation environment was developed with two innovative factors: (1) The possibility to evaluate multiple new automated and semi-automated cabin and cargo processes and select the best one in terms of specific Key Performance Indicators (KPIs) for a future implementation in the physical system and (2) the capability to study the ergonomics of the human worker inside the narrow space of the fuselage while assembling the parts and coexisting with robots, without compromising the worker’s safety. The results show that most of the new proposed strategies improve the assembly time, worker cost, or ergonomics of the process, with an investment varying between 100 K and 200 K euros and ROI of 1–2 years.

Virtual reality (VR)- and augmented reality (AR)-based simulations are key technologies in Industry 4.0 which allow for testing and studying of new processes before their deployment. A simulator of industrial processes needs a flexible way in which to model the activities performed by the worker and other elements involved, such as robots and machinery. This work proposes a framework to model industrial processes for VR and AR simulators. The desk method was used to review previous research and extract the most important features of current approaches. Novel features include interaction among human workers and a variety of automation systems, such as collaborative robots, a broader set of tasks (including assembly and disassembly of components), flexibility of modeling industrial processes for different domains and purposes, a clear separation of process definition and simulator, and independence of specific programming languages or technologies. Three industrial scenarios modeled with this framework are presented: an aircraft assembly scenario, a guidance tool for high-voltage cell security, and an application for the training of machine-tool usage.

Simulators provide significant advantages in training operators of concrete spraying machinery, such as economic savings, the practical absence of safety risks, and environmental and educational benefits. The main challenge in developing a real-time training simulator for concrete spraying machinery lies in the modeling of shotcrete application. This article presents a novel method that models and simulates in real time the three main factors influencing shotcrete sprayability: adhesion, cohesion, and rebound. Furthermore, thanks to the addition of an obstacle model, the method makes it possible to spray onto additional supporting elements, which is a typical shotcrete application. The proposed method considers a wet-mix thick flow spraying process and is based on experiments that were run with a real concrete spraying machine and complemented by expert advice. The method was developed and evaluated using a user-centered methodology, resulting in realistic shotcrete application modeling that meets the needs for training concrete spraying machinery operators.