
Advanced nuclear pool manipulator simulation system with real-time physics and control integration
Nuclear Systems · Remote Handling · Real-Time Simulation
Mission Profile
Degrees of Freedom
4 (X · Y · Z · Fi)
Simulation Engine
Unity — real-time
Frame Rate
60–120 fps
Positioning Accuracy
Sub-millimetre
Architecture
Modular / additive scenes
Camera Views
Multi-viewpoint + HMI
What This Actually Is
Spent nuclear fuel is stored underwater. The pool is not decoration — several metres of water absorb radiation while still letting operators see what they are doing, so the fuel can be moved and inspected safely from a platform above the surface. Nothing down there can be touched by hand, which means every operation is carried out by a manipulator: a rigid, precisely controlled arm that reaches down into the pool and handles material on the operator's behalf.
That makes the manipulator a safety-critical machine. It must move exactly where commanded, never exceed its permitted envelope, and never collide with the pool structure or the fuel racks. Because the consequences of a mistake are severe and the hardware itself is expensive and often radiologically controlled, operators cannot simply practise on the real system, and engineers cannot casually test new motion logic on it either.
This is where simulation earns its place. A high-fidelity digital model of the manipulator and its pool lets operators build competence, and lets engineers validate motion limits, control response, and failure behaviour, before anything is attempted on real hardware. The same techniques underpin remote handling in space robotics, deep-sea intervention, and any other setting where a human directs a machine through an environment they cannot physically enter.
Overview
Developed a real-time Unity simulation of a nuclear pool manipulator system, focused on replicating the behavior of a 4-DOF industrial manipulator operating in a constrained and highly controlled environment. The project includes independent motion control for the X, Y, Z, and Fi axes, with carefully defined movement limits to maintain mechanical realism and prevent the manipulator from leaving its intended workspace. A custom diagonal wall-following constraint was implemented to keep the arm aligned with the pool barrier while avoiding geometry clipping, giving the simulator a more accurate and polished mechanical behavior. The system was built with a modular architecture that supports additive scene loading, allowing different pool configurations to be swapped in and out at runtime without restarting the application. This approach improves flexibility, makes the simulator easier to expand, and keeps performance stable during demonstrations. Multiple camera viewpoints were integrated to provide clear visual inspection from different angles, including operator-focused and validation-oriented perspectives. A streamlined HMI overlay was also created so users can switch cameras and environments through a simple menu interface while the simulation remains organized and responsive.
Role
Head and Lead Design Engineer
Collaborated with nuclear engineering specialists and control systems team
Key Requirements
Real-time physics simulation
6-DOF manipulator control
Radiation safety protocols (simulated)
Precision positioning
Approach
In Detail



Engineering Notes
Tools
Assumptions
Ideal actuator response, simplified radiation effects, perfect sensor feedback
Limitations
Computational performance constraints, simplified environmental interactions
Validation
Position accuracy testing, control response validation, safety protocol verification
Results
Sub-millimeter positioning accuracy
Real-time simulation at 60-120fps
Integrated safety monitoring system
Reduced training time by 70%
Deliverables
Complete simulation software, user manual, technical documentation, training materials