Case studies - CAE 5000 Flight Simulator

Case study of the CAE 5000 Flight Simulator
By: Gad Shaanan

The Challenge:

We were commissioned by CAE to work on a new aesthetic and ergonomic design for their new flight simulator, the CAE 5000 Series.

Historically, CAE has focused its simulation products on fully-customized full- flight simulators (FFS) to serve the training requirements of medium and large airline customers. Those simulators are also used in CAE’s training network to offer such services to small and medium airline operators, to medium to heavy business jet operators and to turboprops and rotary aircraft personnel.

CAE spoke to its customers and got input from technical advisory boards regarding the changing nature of the airline business and what markets they should consider for future products. They considered the changing market realities including new pilot training regulations that place more emphasis on simulator-based training and the emergence of low-cost jet aircraft known as Very Light Jets (VLJ) which are expected to enter the airspace in large numbers within the next few years. In addition, pilot demand is seeing tremendous growth in emerging markets and airlines are facing increased financial pressures.

Full-flight simulator technologies are changing too. Electric motion systems are the new standard replacing hydraulic systems. CAE’s visual image generators now use Commercial-Off-The-Shelf (COTS) hardware. Visual projectors have changed from Cathode Ray Tube (CRT) to much smaller and lighter Liquid Crystal on Silicon (LCoS).

Inventing : Solution:

In order to address the needs of its customers and these new market demands, CAE determined that it needed to develop a very innovative, standardized and cost-effective full-flight simulator to complement what is already the industry’s most comprehensive portfolio of simulation and training solutions.

The requirements for this new full-flight simulator (as determined by collaboration between our team of researchers and designer and CAE) design included: reduction in acquisition and operating costs, ease of manufacturability, smaller and lighter footprint, simplified maintenance, maximum commonality across aircraft platforms, optimized machine-made interface, and an environment for instructors with optimized housing for the latest new technologies. Additionally, there remained the need to meet all relevant regulatory requirements including those safety-related.

Result:

To design the interior of the new full-flight simulator interior, we first performed a human factors analysis by observing several training sessions, in order to get an in-depth understanding of the instructor’s working environment. In addition, a survey was sent to over 40 flight instructors to obtain additional input. This information was then used for the interior design, particularly the Instructor/Operator Station (IOS) and the Non-Simulated Area (NSA) where we focused on ergonomics, usability and comfort for Instructors. The NSA design also took into account ease of access and maneuverability for maintenance personnel and safe exit in case of emergency.

Highlights of the design of the Non-Simulated Area (NSA) of the CAE 5000 Series FFS include:

An ergonomic, modular design using composite materials and commercial off-the-shelf technologies allowing for uniformity across a wide range of aircraft, integrated features and ease of upgrades.

An instructor station and seating which are repositioned to ensure controls and writing surfaces are within easy reach of the instructor and to facilitate interaction between instructor and pilots.

Attractive, robust, and comfortable seats which provide maximum back and lateral support that are also easy to adjust.

In place of regular incandescent lighting, LED wash-lights were used to provide uniform light throughout the whole cabin and require virtually no maintenance.

Access to the visual projector deck was moved to the inside of the NSA, a significant departure from existing full-flight simulator designs. This created more interior space – up to 60% more than legacy designs because it removed the need for an external walkway. It also allowed for a more aesthetic exterior design since it eliminated the need for external safety railings for maintenance personnel.

The challenges in designing the exterior’s aesthetics included reducing the motion envelope and increasing mobility while keeping in mind the full range of motion in all six degrees-of-freedom. Rendering a successful exterior design was one of the main highlights in designing the CAE FFS. Other highlights include:

Eliminating the huge exterior cat walk and support structure and having only one access door to the interior allowed for a reduction in exterior size while increasing the interior space.

Composite materials were used rather than the traditional aluminum and metal cladding, which allowed ease in manufacturing (less welding and molded parts facilitate large scale manufacturing), and quick and easy on-site assembly (modular design with integrated features). In addition, this approach facilitated the use of electric motors and servos, rather than bulky and heavy hydraulics for motion control, since the simulator was of a much lighter weight adding enhanced maneuverability.

The platform was constructed of aluminum to increase ease of manufacturing and assembly, yet retain structural integrity.

A color scheme based on different shades of titanium was selected instead of the all-white finish of conventional full-flight simulators.

The simulator is now lighter and features a sleek, futuristic, aerodynamic look significantly improving the exterior aesthetics of the device.

The CAE 5000 Series is easy to manufacture. Aluminum and molded composite materials allow for shorter lead times, which give greater flexibility and reactivity to customers needs. In addition, it facilitates inspection at the manufacturing level which enhances the speed of production. Furthermore, maintenance costs are significantly lower, thereby reducing lifecycle costs.

The interior design has an ergonomic, user friendly and customizable work space. It was engineered to be reconfigurable to suit the varying needs of different aircraft types and customers.

The CAE 5000 Series FFS is a truly state-of-the-art low-cost, low-maintenance, Level D full-flight simulator that fulfills the needs of the burgeoning commercial narrow body and business jet markets.

By designing the CAE 5000 Series with a modular approach, utilizing off-shelf components and low weight metals and composite materials, the end result was a truly innovative product that stands apart from the competition in both design and functionality.