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Visual System Upgrades & Replacement

In order to improve the visual system performance, partial or full replacement has to be done.  SimHelp team advices to go through the several factors before starting your actual upgrade:

  • Cost of upgrade
  • Required time for upgrade
  • Quality of upgrade
  • How difficult  it is to maintain the new visual system
  • Cost of maintaining the new visual system
  • Whether the new visual system will help to meet the standards.

At the moment SimHelp is offering a variety of different visual system upgrades:

 

Mirror Reskins and Mirror Wash

Our technical team has a vast experience in the repair and replacement of all manner of mirrors. The proven track record of success ensures improved geometric accuracy with a cost effective approach.
 
Theodolite results taken prior and following re-skinning activity provide ample demonstration of the improved geometry that is achieved using the proprietary tooling and techniques.
 
Utilizing unique re-skinning technique pioneered by partners’ engineering team and refined over the past years, SimHelp is following a new standard for geometric accuracy.
 
The proprietary mirror washing technique allows SimHelp to consistently provide effective mirror repair services. As a result, unnecessary mirror skin replacement can currently be avoided.

 

SupraVue® MIRROR 150 & 180 EXTENSION

For the first time, this product provides the customers with a realistic alternative to the problems of achieving the latest certification requirements for Part 60, JAR and MPL without the cost and schedule impact involved with replacing the entire display system.
 
Utilizing the unique re-skinning technique refined over the past years, SimHelp is capable to successfully deliver the innovative SupraVue.

 

The SupraVue Collimated display

The SupraVue product range delivered by SimHelp is providing the flight simulation market with the low cost, high fidelity display solution. By utilizing the latest technology composite materials and innovative design processes SupraVue offers the end user a lightweight and high strength visual display solution offering industry leading geometric accuracy.
 
Front Projected Display
 
The display system is entirely NVG and FLIR compatible and can be supplied in both Front and Rear projection layouts to provide optimum customer driven solutions to any display requirement.

SupraVue is optimized for the full flight simulation market and offers the latest generation displays solution at the most cost effective price and the promise on time delivery.
 
Rear Projected Display
 
Using our unique motion interface SupraVue provide optimum flexibility and ease of installation while sacrificing nothing. The latest in composite technology allows the lightest weight and lowest profile display system currently available.
 
Maintenance Considerations
 
Industry leading geometry, low maintenance and ease of access have been the principle design drivers for the SupraVue® display system.

Optimized for integration with the latest single lens projectors including LCoS & DLP, the SupraVue display solution offers an affordable low maintenance option for your simulator display requirements. SupraVue® can be offered in a range of configurations ranging from 180 to 225 horizontally and in various vertical fields of view ranging from 20/20 to 15/25 and 20/25.
 
The industry leading expertise of the SimHelp engineering team together with the application of the unique re skinning technique pioneered by SimHelp which has already utilized on a number of display systems throughout the world provides ample demonstration of the capability of the tooling and skill set.

 

Monitor to Projectors Upgrade (Raster-Only Monitor Replacement Projector)

Partner engineers have successfully installed and certified the first LCoS MRP system at United Airlines in Denver, CO. The Alion supplied system was retrofitted to a 747-200 and has provided uninterrupted training now for some months.
 
Short Description
 
This specification describes the latest Raster-Only Monitor Replacement Projector (hereafter referred to as the MRP). The MRP provides a form, fit and function replacement option for display solutions that currently use 25 inch shadow-mask color CRT in wide-angle collimated (WAC) optical systems as used by XKD and E & S (CSM).

The MRP achieves this requirement using fixed-matrix projectors instead of 25-inch direct view CRTs.

The MRP is designed for use as a visual simulation display, primarily in conjunction with WAC optical systems that operate up to a maximum of 64 kHz line frequencies. It supports up to nine high-resolution channels with image matching between adjacent channels. MRP can achieve raster distortion necessary to accommodate the requirements of the infinity optical system, in a juxtaposed configuration.
 
Equipment Configuration
 
The MRP can be operated at either 50 Hz or 60 Hz field/frame rates. The MRP can pre-store adjustments of geometry, convergence, shading, focus, contrast and brightness.
 
The MRP consists of the following major assemblies:

  1. Display Head Unit
  2. Remote Control Unit (one per system)
  3. Interconnect Cables

The JVC model HD-2K DILA projector, incorporates LCOS technology that produces picture resolution of 1920 horizontal pixels by 1080 vertical lines. The vendor incorporates a custom lens modification to optimize the performance for simulation application to match the radius of the applicable back screen. The HD-2K operates in raster mode with a horizontal raster and support line rates at 60Hz.
 
Due to the modular nature of the MRP it is possible to fit many different types of projector within the housing. This provides the end-user with a high degree of flexibility in design to allow for varying requirements in resolution, cost and brightness.
 
The housing and components are designed to avoid observable effects on the picture stability and presentation due to runway rumble, stall buffet or other vibrations in the motion systems. Maximum motion system acceleration and deceleration will not damage any of the display system hardware, nor cause any degradation to optical or electronic alignments. The overall weight of the housing and components does not exceed 150 lbs.
 
Video RGB signals, synchronization signals, and defocus signals shall be input to the DHU via VGA or DVI input connections.

A secondary communication port using RS232 protocol will also be provided for maintenance functions and host communications of hour meter readings.

SupraPan™ Wide Projector Upgrade

Due to the escalating cost of refurbishment of existing SupraLux tubes together with the increasing difficulty of supporting these obsolete CRT’s from a single support office in the USA (with attendant increase in shipping costs and turnaround times), SimHelp is delivering an alternative to the SupraLux CRT™. The proposed upgrade resolves the aforementioned concerns whilst providing a significant reduction in cost of ownership for the modified assemblies.
 
Using the latest nine-inch, commercially available Panasonic cathode ray tube (CRT) along with associated Glycol cooling coupling is used as an integral part of this upgrade. This upgraded assembly is combined with a custom design lens to focus the image on the WIDE back projection screen and minimize the requirement to alter the projector base-plate position.

The selected lens has "twist" barrel adjustment for both static and dynamic optical focus. Additional attention to the mechanical coupling has been incorporated with respect to the relationship of the lens and the CRT face. The coupling employs a high tolerance machined interface negating further adjustment controls of the lens (typically Scheimpflug calibrations).
 
In line with the design objective, utilization of the existing drive electronics and mechanics are achieved. This is accomplished by retaining the rear tube housing along with the scan coil, focus coil and Gimbal assembly.
 
By retaining as much of the existing CRT assembly as possible, including deflection and focus coils, gimbals assembly and utilization of the existing drive electronics and mechanics, SimHelp is able to provide the end user with a seamless upgrade path and significantly reduces risk and cost.
 
This approach allows SimHelp to offer a solution that addresses the major supportability issue of the CRT’s without adding further costs and complexity issues by modifying the deflection amplifiers which may render these items unsupportable by either Rank Brimar or TT & S OEMs.

SupraPan and SupraLux comparison table:

 Indicator  SupraPan™  SupraLux™
Tube Manufacturer  Commercially available Panasonic 9" CRT  Prroprietary custom built & Sole sourced
 Life Expectancy Typically 15,000 hours when running 5 to 6 Ft Lb systems-Due mostly to reduced Anode Voltages and dispenser cathode technology  10,000 to 15,000 Hours at 2Ft Lb.
 Tube Assembly Cost - Spare  2,800$  8,000$
 Buyer Repairable Assembly  Yes  No
 Tube "Warm Up" Time  None  20 to 30 minutes
 Secondary Imaging  None  Very Noticeable
 Light Point profile  2.5 Arc Minutes (Center) 4 Arc Minutes (Corners)  3 Arc minutes (Center) 6 Arc Minutes (Corners)
 Contrast Ratio  Greater than 30:1  20:1
 Brightness Variation Across Tube  30%  60%
 Triad Green Tube Placement  Green Centered  Green Off-Axis
 Edge Blend Color at Scene Joins  Evenly distributed - Uniform  Hard Edge - less Uniform
 Convergence "Day-Night" Shift  None  Green Drifts - 6 Arc Minutes
 Tube to Tube Focal Length Variations  Lens Mechanically Adjustable for both Static and Dynamic Focus  No Adjustment Available - Focus "tradeoffs" between tube colors
 Tilted target causing poor Corner Focus  Not Applicable  Common problem caused in shipping
Shipping constraints No shipping induced "Tilted Target" Susceptible to handling damage due to fragile nature of design and extended shipping from USA

Maintenance considerations
 
The design philosophy behind the upgrade to the 9 inch Panasonic tube does not change any of the electrical/electronic calibration procedures as outlined in the original Operating and Maintenance Manual. This applies to the deflection, video and power supplies of the projector. In addition to that, no deviation from the Image Generator calibration is necessary, therefore the IG Operations and maintenance manuals should also be strictly adhered to.

As a part of the tube update program, in order to add further enhancement to the displayed picture, the blue and green tube positions were transposed from the original design.

Due to the fact that the majority of the brightness is derived from the green tube (70%) it follows and field experience shows that the tube will require change out prior to the red and blue. Therefore with the green tube being in the uppermost position, the light rays with respect to the optical system and finally the pilot’s eye will be more ‘on axis’ providing greater brightness for the same drive. Thus resulting in a clearer better-defined scene, longer CRT life and offers better access for maintenance personnel when required.
 
The high performance hybrid lens was designed specifically to project flat face CRT images onto a spherical screen.

This lens is air coupled; fully color corrected, mounted in an all aluminum black finish barrel, and designed for mechanical and thermal stability.
 
Suprapan Lens
 
This lens has the advantages of both “twist type” controls for both static and dynamic focus adjustments. When replacing tubes, the projector will remain in its current position and any focal length can now be adjusted for optimum optical performance, utilizing the lens individual adjustments for each tube. Rather than moving the entire projector and trying to optimize the red green blue tube for best average case as with the original tube. Overall focus is greatly improved.
 
The wiring harness in the projector is configured in a “triad” format; therefore all connections remain as is.
Further benefits with this modification are realized with respect to the soft edge blanking between adjacent pictures. This tube has less brightness variation across the field of view, and with the green tube in the same position in each projector, the light is more on the same axis, resulting in a superior edge blend, giving the appearance of more uniform and less objectionable joins.


Modified CRT Assembly

CRT replacement costs

The SupraPan™ upgrade will for the first time free the simulator users from the sole source pricing policy that has been a major concern for a number of years. It is evident that the cost of subsequent overhauls with the modified assemblies will be significantly cheaper than provided currently by the OEM.

CRT life

The Panasonic CRT is currently fitted to many hundreds of projectors used within the commercial simulation market world side. This CRT has become the standard for all modern display systems delivered by all the major projection system suppliers and regularly has CRT life exceeding 15,000 hours or two years of commercial simulation operation.

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