MAHINDRA
Tractor Engine Testing Simulation
A step-by-step procedural VR training simulation for rigging, docking, and testing industrial diesel tractor engines.
Video summary
The demo shows tractor engine testing practice on a virtual factory floor, including adapter plates, exhaust and hydraulic connections, tool-based fastening, live diagnostic panels, RPM calibration, and validation of the testing sequence.
The context
In diesel engine manufacturing, quality assurance testing is a critical bottleneck. Trainees must learn how to rig and dock heavy engines with high-speed dynamometer test rigs. Using real engines for hands-on instruction is high risk: a single error in mounting adapter plates, tightening fuel lines, or securing coolant hose clamps can lead to catastrophic equipment failure, personal injury, or production line shutdowns. To scale training safely, Mahindra needed an immersive VR simulation where trainees could master both rigging prep and test-cell protocols in a risk-free virtual environment.
The challenge
The primary technical challenge was representing realistic mechanical operations. This required precise tool-specific interactions (pneumatic guns, torque wrenches, manual spanner tools) and ensuring a strict procedural logic flow. Trainees must perform rigging operations in a specific order (adapter plate, exhaust stub, hydraulic dummy) before moving the engine trolley into the test cell, docking it, establishing fluid and air line connections, and calibrating the throttle RPM arm.
The Procedural Simulation
The VR training session splits the procedure into two main operational phases:
Phase 1: Rigging Activities (Engine Prep)
1. Adapter Plate Installation
Trainees attach a heavy adapter plate to the engine shaft, securing it with alignment pins and bolts using a pneumatic gun and torque wrench.
2. Exhaust Stub Pipe
The exhaust stub pipe is attached to the exhaust manifold section of the engine and secured using bolts and nuts.
3. Hydraulic Dummy
The final rigging component is the installation of the hydraulic dummy plate, which is affixed to the engine housing and tightened using a hand spanner.
Phase 2: Engine Testing Preparation (Test Cell)
4. Trolley Docking & Shaft Alignment
The engine trolley is rolled into the test cell and docked with the dynamo, ensuring the output shaft aligns correctly with the adapter plate.
5. Fuel & Oil Lines
Trainees install the oil pressure nozzle and connection pipe, then connect the fuel inlet and outlet ports.
6. Air & Exhaust Venting
A flexible air filter intake hose is clamped to the engine inlet, and a heavy-duty exhaust venting pipe is attached to the exhaust stub pipe.
7. Coolant Hose Clamping
Coolant inlet and outlet pipes are connected and secured using a mechanical clamp ring gun.
8. Accelerator RPM Adjustment
Finally, the speed controller RPM arm is attached to the engine's throttle lever and secured with a screw and nut, allowing speed testing.
Technical Highlights
- Step-based Validation Machine: Enforces that all rigging steps are fully completed and verified before the engine can be transferred, and all connections are sealed before starting the test cycle.
- Tool-specific Haptic Interactions: Implemented custom interactions for pneumatic guns (automatic torque sequencing), wrenches (rotational thresholds), and spanners.
- Telemetry Diagnostic HUD: Displays virtual engine readings (RPM, temperature, oil pressure) responding dynamically as the user manually adjusts the accelerator arm.