The design process involved complex system models and these models tested the design to ensure that the required performance was met. The main challenges faced were achieving the high pivot point from which the controls rotate while ensuring the mechanical system remained compact. At Stirling Dynamics, we adopt a tried and tested systems engineering approach to our designs and this approach was crucial to this particular project, fundamentally due to the complexities involved covering mechanical, electrical and software design. Controls to support simulators at this high-level demand a collaborative development team that includes the customer, to help define the requirements for the new product. The challenge with simulator equipment is to provide the identical feel and capability of the flightworthy units but without the overhead, driven by flight safety, and of course, cost. The CH-53K aircraft controls have been designed to include multiple redundancies to ensure the safety of flight, including both its mechanical and software systems. PRODUCT DESIGNįor simulation purposes, it’s not just about copying the flightworthy controls. Test pilot, John Rucci, eloquently described flying the CH-53K in a recent article and shared his favourable views on the aircraft’s active controls and cockpit configuration. The deviation from the conventional helicopter controls demonstrates the advanced thinking that Sikorsky has applied to this development. This aircraft is one of the few aircraft programmes worldwide that has adopted fly-by-wire active control technology and in addition to being active, the controls feature side arm controllers that replace the more conventional central cyclic controls. The Sikorsky CH-53K is unique to its predecessor, the CH-53E, as it features fly-by-wire technology with active flight controls, continuing a technological trend for heavy-lift rotary-wing aircraft. These controls needed to match the flightworthy units in every way, including electronic linking, force feedback, dynamics and position specification, including the computer control of the infinitely variable range of soft-stops, ramp forces and control shakers that will be commanded from one of the most advanced flight control systems. Having successfully produced several bespoke active control simulator cockpit designs ranging from the UH60, CH47 and the F-35, we were approached by our customer to create a set of replica cockpit controls for the CH-53K.
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