There are hundreds of crane simulators in the world. They range from small video game like systems designed for entertainment purposes to multi-display professional simulators that provide an immersive training experience. For over two decades, GlobalSim has been considered one of the leading crane simulator manufacturers and has been involved in various projects throughout the world. Among the world’s crane simulators, the grandest of them all is the 270-degree massive dome-based system that was commissioned in 2009 by the National Port Authority of Morocco (ANP) based in Casablanca.
“The system itself is really a computer and engineering marvel” says Dan Olsen, Vice President of Operations of GlobalSim. Dan was involved in the development and installation of the simulator, and currently leads the team that provides support and maintenance to the system in Morocco. “It was a massive project that took over 3 years to complete from the time GlobalSim was selected to build the system until the final installation.”
Developing the system was no easy task for GlobalSim – the company had to lease a separate warehouse tall enough to build the 10.6-meter (34-ft) tall simulator. Once testing was complete the entire structure was disassembled and shipped it to Morocco in six 40-foot shipping containers. Upon arrival in Casablanca it took a team of six GlobalSim engineers and several local contractors three months to install the system in a special-built training center in Casablanca. There is even a 5-ton crane installed on-site for the assembly and maintenance.
Just as impressive as it is enormous, the dome features a 240-degree horizontal field of view (FOV) and 150-degree vertical FOV. This gives the operator an unobstructed view of the scene below. High-resolution images shine onto the dome from 12 high-power projectors that are specially designed to run 24-hours-per-day if necessary. The projector lamps can be high-maintenance to adjust manually, so GlobalSim installed software that provides both auto-alignment and color blending to properly calibrate the system.
“The motion system is another feature that sets this simulator apart” says GlobalSim President Jonathan McCurdy. “Many premium simulators have some type of motion system, typically it’s underneath the operator chair. In this simulator the 6 DOF (degree of freedom) motion system is situated above the cabin – which is suspended from the top of the structure.” The result, according to McCurdy, is a realism and feel that’s extraordinarily life-like. “It’s truly a state-of-the-art solution.”
Behind the scenes, there are over 26 high-end computers that power the system. There’s also a full-featured instructor station that’s integrated with the simulator – which gives administrators and training managers absolute control over what happens in the simulator. Instructors can change weather and environmental conditions in real time, and even create faults and malfunctions to test trainees – all while observing the situation on one of several display screens. They even have the ability to create scenarios where the student can see the Hassan II mosque in the distance, just like at the real port.
The simulator is equipped to run with multiple crane models including the following: STS (single and dual hoist), RTG, Double Jib Luffing Crane, Gottwald Mobile Harbor Crane, Bulk gantry Ship Unloader and Straddle Carrier (4 high side facing cabin and 3 high with front facing cabin).
Since installation was completed in 2012, the National Port Authority in Morocco has assembled an excellent team of trainers and instructors to manage the training center. Today they provide instruction in Arabic, French, and English to crane operators in Morocco, but also throughout North Africa and beyond. “As one might expect, they are gaining a reputation throughout the world” says GlobalSim President Jonathan McCurdy.
Organizations interested in viewing the simulator or partnering with ANP to receiving crane training on the system can contact ANP directly by visiting their website.
Watch this video to learn more about the training facility and simulator.