Context: A legacy of simulation & innovation
Simformotion LLC, a women-owned business based in Peoria, Illinois, has been at the forefront of simulation-based training technologies since 2009. As a licensee for Cat® Simulators for Caterpillar Inc., Simformotion customizes simulators that replicate the real-world experience of operating heavy machinery. Working closely with both programmers and hardware engineers, they design, assemble, sell and ship simulators worldwide, providing training solutions across industries such as construction, mining, forestry and agriculture. Their dedication to accuracy and realism in training is supported by in-depth collaboration with subject-matter experts, ensuring that each simulator reflects the true functionality and techniques used in the field.
Challenge: Making training more engaging
While Simformotion’s Cat® Simulators provided a robust training solution, there was a notable gap in replicating the physical feel of operating heavy machinery. Operators often mentioned that they operated machines “by the seat of their pants,” meaning they relied on instincts when operating. Therefore, in order to understand how the equipment moves and behaves under different conditions, motion became critical for realistic training on Cat® Simulators.
The challenge lay not only in integrating motion into the simulators but also in overcoming the internal and client reluctance to adopt this new technology. The addition of motion systems came with a higher cost, and getting buy-in from both internal stakeholders and clients was a hurdle. Clients needed to be convinced that the added expense would result in better-trained operators and more efficient and safer environments through the added realism.
Solution: Integrating motion for realism, letting clients feel the results
Simformotion addressed these challenges by turning to the industry leader in motion training, D-BOX. The collaboration filled the realism gap by replicating the full range of movements and vibrations that operators would experience in real machines. The system was designed to simulate pitch, roll, and heave, along with intelligent vibrations that match the machine’s engine output and terrain interaction.
The integration process involved two years of development in collaboration with Caterpillar, during which time Simformotion and D-BOX's teams ensured that the motion effects were finely tuned to replicate the machine’s behavior. For instance, when training operators on tasks like navigating slopes or ditches, the motion system replicates the feeling of tipping or shifting weight, giving operators a clear understanding of the machine’s limits and responses before they encounter such situations in real life.
The D-BOX motion system sends signals 60 times per second to ensure precise and up-to-date feedback, providing operators with an experience closely aligned with what they would feel on an actual job site. This accuracy enables trainees to build muscle memory, which is crucial when transitioning from a simulator to a real machine. The motion system also supports incident response training, allowing operators to safely practice handling emergency scenarios like brake failure, which can be difficult to replicate on actual equipment.
Results: A new standard in simulator training
Since implementing the D-BOX haptic system, Simformotion has seen significant improvements in the realism and effectiveness of Cat® Simulators. The inclusion of motion has become a standard feature, especially in the U.S. market, where clients recognize the value of motion-enabled training. The motion system accentuates the training process, as operators can transfer the skills learned on the simulator to real machinery with greater confidence from having experienced hazardous scenarios on the simulator.
Feedback from clients has been overwhelmingly positive. Clients report that the enhanced realism helps operators develop a deeper understanding of machine operations and improves situational awareness, resulting in safer and more efficient work environments. Additionally, the use of original equipment controls ensures that the transition from simulator to real-world machine is seamless, further speeding up the learning curve.
Although it took several years to establish motion as a standard feature in simulator sales, the return on investment has been clear. Clients report that simulation-based training with D-BOX motion technology has improved operator performance, reduced equipment downtime, and increased safety on job sites. With the integration of motion systems, Simformotion has set a new standard for realistic and effective heavy equipment training.
Partner testimonials
We wanted the real-world feel, the movement in the seat. We wanted the simulators to feel as much like sitting in the seat and behind the stick of a real machine as they possibly could. And that's what Cat Simulators offer.
Michael Staton
Associate Director
Collins Career Technical Center
The Cat® Sim program is very immersive—that is the best thing about it. If the simulator doesn’t have the motion platform, it isn’t the same experience. Motion means it feels like you are digging a hole, pushing dirt or picking up a log.
Michael Budd
Career & Technical Education
Nevada Department of Corrections
"The reason we chose cat simulators is because they are the best because of the training modules because of the OEM controls. A student can go directly from the simulator right to the real iron and it's like they're putting on a comfortable pair of blue jeans. The transition is seamless and after beta testing this program with our own employees, we found that once our employees went from the simulator to the real equipment, they found that the real equipment was easier than the simulator. So from an education standpoint, you can't ask for anything more than that, that really prepares them for the real iron that we need to build the roads for tomorrow."
Jeremy Whitaker
Director of Training & Recruitment
C.W Matthews Contracting Co., Inc.
