Simulators: Military “Games” that Train
By Scott Clay, Bishop & Associates Inc.

Anyone who has played a video game has the basic idea of a simulator. Numerous game makers offer a flight simulator game that typically run from $19.95 to $100, depending on the graphics, operating speed, extra features, and controllers. The flight training simulator for the F-15E Mission Training Center at Seymour Johnson Air Force Base in North Carolina is exact in every detail to an actual F-15E cockpit, right down to the parachute pack on the Aces II ejection seat. The displays, gauges, dials, switches, control stick, rudder, and control pedals all are exactly what a pilot would see in the same position in a real Boeing F-15E fighter bomber. This is the fourth system purchased by the Air Force, and they plan to purchase at least two more. These simulators have full 360 degree fields of view via high-definition displays, all helmet and flight suit hook-ups, full communication systems, fully operating functional avionics, and even the ability for the pilots to use night vision goggles. This particular simulator, built by a division of Boeing, cost from $15 to $20 million, but are so much like flying the real airplane that the Air Force is giving pilots a percentage of their monthly flight time requirements when they fly in approved simulators. These new systems can even be linked electrically to other simulators and replicate an actual two or four plane flight mission, giving the pilots in training a true feel for working (and flying) with other F-15s on an exercise.

Simulators go back to early World War II, when the newly established Link Company built actual small wooden airplanes—much like the ones on a carnival ride—with rudimentary controls to help start the learning process for the thousands of pilots the armed forces needed. These early simulators gave instructors and evaluators quick impressions of flight candidates, and were good indicators if the candidates had the natural skills and abilities to be pilots. The latest-generation training systems are as different from the early Link systems as the aircraft that those pilots were training to fly and the F-15E Strike Eagle in service today.

There are modern simulators for every aircraft the United States Air Force flies, and the same goes for most other planes throughout the world. Airlines pilots use simulators at key locations in the world to review their skills for current commercial aircraft, learn more about major changes in those planes as next-generation avionics and controls are introduced, and get their first opportunity to fly the newest aircraft in simulators. Pilots from numerous airlines went through extensive simulator time getting ready to fly the Airbus A380, not only the newest type of aircraft in commercial service, but also the largest civilian jet devoted to passenger travel in service today.

These immensely useful devices are used not only to train pilots, co-pilots, and flight engineers, but also to show the technicians, who maintain these aircraft, how to keep their airplanes in full mission-ready status. These systems can train several maintenance personnel at one time, allowing them to work together testing and adjusting all the complex programs and electronics in a full crew environment, just as they will on an actual airplane. This generation of simulators also has expanded to many other sectors and platforms.

Systems have been built and installed at key Army training bases throughout the world, where vehicle crews can increase and improve their skills in all areas of operation, from maintenance to driver’s skills to actual mission training and combat/fire support. Army crew members can train on the latest weapons in use, and even become familiar with new vehicles that have not been introduced into the inventory yet. An example of this is the new Future Combat Vehicle, planned for introduction to the new Combat Brigade’s by 2014. For existing weapons systems, U. S. companies have supplied the Army with new training devices that help crewmembers work well as a team. Link, a division of L3, has built and delivered five of the Army’s Fire Support Combined Arms Tactical Trainer units to show today’s artillerymen and women how the latest upgrades and new electronics have been built into the M-109 Paladin self-propelled 155mm howitzer. This cannon has been in service for over 30 years, and these new upgrades are aimed to keep it a frontline weapon for at least another 20. The same goes for all the vehicles and weapons in the Army inventory, from the most modern tanks to the Transport Corps’ medium- and heavy-duty trucks. Troops do not have to be at central training bases in order to test drive these large vehicles. It also does not use fuel or add excessive wear to all parts of the platforms, and gives the operators far more training than when they only had the vehicles to drive in order to get hours of operation.

New training systems have been built and delivered for all the Army’s helicopters, robot vehicles, missiles, radios, and even a large portion of today’s troop’s small arms practice is done with simulators. Several large companies now provide today’s soldiers with simulation firing ranges, which allows them to practice with their rifles, machine guns, and side arms in a controlled environment, without the large expenditure of live ammunition, large training areas, (firing ranges), noise problems, and they even eliminate the potential for on-range accidents. And since today’s recruits, have in large percentage, not fired a weapon, this allows instructors to teach the proper techniques, gun familiarity, and introduction to the Army’s side arms without the fear of an accidental discharge. After hours of simulator training, instructors follow through with range and live fire shooting. There are also a new generation of wearable computers that offer troops graphics and situational concepts that are as good as mainframe driven units that cost millions of dollars and take up a whole room. These training tools can offer combat-type situations for troops in the field that are more realistic and combine the actual movement of individual scouts and squad level tactics. They can combine field exercises with real vehicles and help train all ranks how to best handle IEDs, snipers, ambush reaction, enemy attacks, and other threats.

The Navy and Coast Guard also have training systems for their personnel to practice on everything from the ship’s engine room operation and maintenance sections throughout the ship to full command and control centers for all the ships of the fleet, including the most modern submarines. There is even a simulator in Newport News Naval Shipyard that is used to train the crews of the newest generation of aircraft carriers, the CVN class. And this carrier will not be in service for five to six years. The goal is to have crews trained and familiar with these complex $5 billion ships when they are launched. Modern Navy simulators are mirror images of the various interior sections of modern submarines, which are built in Groton, Connecticut and where these training systems are located. These trainers are updated with the latest systems and electronics at the same time these radical new improvements are installed into the actual boats. Simulators are now in use to train the crews at all ranks for the DDX-1000 and Littoral Combat Ships, the newest ships under construction in shipyards and neither of which has formally been added to the active fleets. Here again, the goal is to have the crews ready, and obtain savings in fuel, wear and tear, and avoid the logistics of ships leaving port to train their crews, saving the Navy millions of dollars a year.

Simulation systems are used also in many areas of the civilian marketplace. Factories are using these systems to train workers in the use of robots, modern automation techniques, upgrades in modern inventory systems and tools, new assembly methods, and the incorporation of new computers and software throughout industry. When new automation equipment is added to an assembly station or cell, training of the operators can start even before the equipment is ready to run. With factory simulation systems, workers can train on the consoles, computers, and software that control all the facets of the cell’s new operation. They can even learn how to address problems or malfunctions before an event ever happens. Workers also can learn through trainers to do various jobs and to fill in for each other in the new system. All of this can occur before the new equipment is even installed, if the company has provided the equipment for the proper simulation training.

Other sectors using this technology are air traffic controllers, product distribution, language training, new equipment familiarization, study of the oceans and geology, and medical and surgical practices, to name just a few.

Connector use in these complex systems extends far beyond the detailed military cockpit controls and avionics, all of which have their wired connectors installed. These must function like the real fully linked system, plus all these are routed through huge wire harnesses to control or “command” centers, which monitor all the activity within the simulator. The unit must have very large power cables throughout the control section and the training area, as the power requirements are huge to properly enable the system to function like the real thing. Add to that the large displays, huge amounts of data and signals, actual controls to make it realistic to “fly” the airplane, and this becomes a natural environment for fiber optics, microwave and RF systems, and miles of wire of all gauges. Also, since many of the training systems are in large climate-controlled buildings, the makers can use fiber cable systems, many types of VME and other connector systems, like USB, large backplane units, networking systems, multi-function I/O cards, all types of connectors that, while not rugged enough for aircraft, vehicles, and ships, can be used in a simulator in a controlled environment or location. This is how electronics can be used to make these trainers look and operate just like the real thing. The VME market, which has numerous uses in this market sector, is expected to grow to almost $900 million in 2008. VME is used in many locations in these pieces of equipment. Along with these newer products, there will always be a place for the venerable Mil-C circulars, which still have great uses in the cables and wiring, especially on the large pass-through cables that feed all the power and data to the screens, controls, switches and buttons, displays, and other areas that make the F-22 simulator look just like the cockpit of the real airplane sitting on the ready-ramp at Langley Air Force Base in Virginia. The same rules and product uses apply to the factory expansion of an auto assembly plant in Alabama.

Major companies in this sector include CAE, Boeing, L3 Link, Simula, Lockheed Martin, Thales, FlightSaftey, FRASCA International, NLX, General Atomics, NH Industries, MPRI, Raytheon, C-ITS, Barco, AAI, RSI, General Dynamics, Elbit Systems, and Quantum3D.

To give you an idea of the size of this market, the 2009 budget, which is devoted to all types of simulation and training, is over $5.5 billion. At the end of 2007, two orders for the most modern fighter aircraft, with full multiple aircraft flight capabilities from the Air Force and Navy, totaled almost $1 billion for just these systems. Growth projections for new programs, upgrades to current systems, and new, not yet fully designed “star wars” operations, are set at almost 25 percent per year for the next five years. Also, as key new technologies are developed, these upgrades will replace older systems, if one can call 3-5 year systems older, with the latest technologies. These upgrades save the military huge amounts of fuel, time, and wear on equipment, and teach the troops valuable lessons built on actual feedback from veterans and troops that have been in combat situations that are programmed into the training. Remember, a simulator may cost up to $20 million, but with a price tag on a new F-22 Raptor now over $300 million, a future Raptor pilot can get a lot of simulator time to fully acquaint him or her with all facets of the craft, saving future problems and damage to a very expensive airplane. This means the market could actually double in size over the next two years, especially considering the high price of fuel.

The rest of the world is keeping very close pace with the U. S. in the use of training platforms. Many new programs and systems are being built for all aircraft in service, with the air forces of almost every country. Also, buyers of various pieces of American equipment often are sold simulators as part of the larger deal, to give their operators as much experience as they see necessary to make them fully aware of their new equipment. China, which is easily the second largest spender on arms systems, has numerous trainers built by European companies such as EADS, Thales, and many others. These simulators extend all across the military sector, from the Navy to the Army, and all the forces therein. With world competition for oil in all its forms, the price of all types of military fuels increasing weekly, and equipment for the military so complex and expensive, the use of simulators can save a fortune in fuel costs alone. Additional savings can be made in equipment life, wear and tear on the aircraft, vehicles, and systems, all saving millions of dollars. In the Navy, all officers can train on an almost exact copy of the bridge of the real ship they are going to serve on. And they can learn all its operations, systems, and controls without even taking the vessel out of the harbor. And simulators exist to train them on any ship in the Navy, from a small patrol or PBR boat, to the newest 1,000-foot-long CVN class of aircraft carrier.

Scott Clay, Director Military & Aerospace, Bishop & Associates Inc.
Scott Clay has worked for more than 25 years in the connector and wiring systems markets. He has held various positions in field applications and marketing for Molex, Tyco, Methode, and ITT. For the past 15 years, Clay has focused on the military/aerospace sector, and five years ago formed his own company for consulting and application engineering. He has worked on design-in and electronics on F/A-18E/F, F-22, F-35, C-130J, C-5M, C-27, P-8, A-10, and numerous other aircraft. Some of the Navy programs Clay has participated in are SSN-774 Virginia class subs, CVX, DDG-1000, and the Littoral Combat Ship class. He has extensive expertise in land vehicle systems, and has worked closely with the worldwide locations of GD, BAE, AM General, and other key manufacturers. He is currently working on variations of MRAP, JLTV, upgrades for the Bradley fighting vehicle, M-88 recovery vehicle, FMTV, and other platforms in the wiring and systems areas, plus portions of the future combat systems.