Brookhouse technology behind the scenes in USAF helicopter simulators

Citation

(1999), "Brookhouse technology behind the scenes in USAF helicopter simulators", Aircraft Engineering and Aerospace Technology, Vol. 71 No. 2. https://doi.org/10.1108/aeat.1999.12771baf.008

Brookhouse technology behind the scenes in USAF helicopter simulators

Brookhouse technology behind the scenes in USAF helicopter simulators

Keywords Brookhouse, Flight simulators, Helicopters

Composites specialist, Brookhouse Paxford, has manufactured four complete SEOS PANORAMA screen assemblies as part of a project to upgrade United States Air Force helicopter training simulators at Kirtland Air Force Base, Albuquerque, New Mexico.

Under contract to display systems supplier SEOS Displays, Brookhouse Paxford produced mould tools, composite mouldings and performed construction, machining and finishing operations for the four assemblies, for installation at what is one of the world's most advanced military flight simulation centres. Design was undertaken by SEOS.

Each assembly has eight component sections, the largest being the screen, termed a mirror cell, onto which the image forming the simulator pilot's outside view is reflected. The size and 3-D curvature of the mirror cell enables the SEOS PANORAMA display system to present a continuous field of view of 220° horizontally and 40° vertically.

SEOS Displays apply a metalised plastic film to the inner surface of the mirror cell moulding, held under vacuum, which allows it to collimate and reflect the display image, from a back projection screen located above the simulator cockpit. A dimensionally accurate substrate is therefore vital to the performance of the finished mirror cell, in order to maximise fidelity of the image. Achieving this degree of surface quality over such a large area required exceptional skills in traditional toolmaking and hand lay-up, combined with accurate machining and rigorous inspection of the moulded component. Paintwork is carried out at an in-house facility to the customer's specification.

For each of the four SEOS PANORAMA display systems, Brookhouse Paxford used a fibre composite and foam core construction to produce the mirror cell and accompanying five petals, canopy and two extension "ears", which together form a wrap-around structure.

PANORAMA is a complete system manufactured by SEOS Displays, which in this case incorporates five high resolution projectors, and will allow special operations mission crews to be trained at Kirtland Air Force Base in the use of weapon systems and integrated navigation systems in adverse weather conditions and in hostile environments. The four systems involved in the upgrade programme will provide training on Sikorsky MH-53J, MH-60G; MC-130P and TH-53A aircraft.

Brookhouse Paxford, in Huntingdon, is one of seven Brookhouse companies whose manufacturing sites are also located in Darwen, Lancashire, and in Manchester. Brookhouse offers particular expertise and experience in the automotive and aerospace industries, in the design and manufacture of tooling and in the final manufacture of composite and metal components. It carries full BSEN ISO 9000 and CAA approvals.

Activities at Brookhouse Paxford focus on hand laminated and resin transfer moulded commercial mouldings for the automotive, defence and simulation industries. Advanced composite tooling and components are also produced for motor sport, aerospace and industrial applications.

Details from Brookhouse Paxford. Tel: +44 (0) 1480 453537; Fax: +44 (0) 1480 413125.