GKN WESTLAND Lynx - ©Copyright of Pennant PLC 2005. Use of these images (or linking to these images) by any other persons or organisation without express permission from the afore mentioned parties is strictly prohibited and may result in legal action. GKN Westland helicopter Navy Lynx electrical system emulator.

As a ground engineer's training aid for the Westland Lynx, a comprehensive emulation of the helicopter's electrical, mechanical and hydraulic systems was needed. The most accurate and cost effective method was to create a full working 3D model of the helicopter and test equipment. Pennant PLC created a complete model down to nut and bolt level. This was done by taking Catia CAD data and engineering drawings, and working from photographic reference produced a detailed replica which could then be used to provide scripted animation for use in a software controlled training application. It allows the engineer to click on any part of the helicopter to remove panels, push switches, turn on lights, activate the pilot and co-pilot controls, connect up cables etc.. It provides feedback for the test equipment and updates all parts of the helicopter in real-time... so switching a switch in the cockpit may activate the exterior landing lights and show this accordingly.

As part of this project VISUALS-3D's services were contracted to assist in several areas of the 3D creation, most notable being the complex gearbox and hydraulic flight controls. Working with the team on-site and liaising directly with the client and SMEs (Subject Matter Experts) was essential for such a detailed job.
Frontal view of hydraulic systems - fairing removed Gearbox hydraulics / fairing removed

From this image you can see the complexity and detail of the model.

This gives an idea of the nature of the actual interactive image from the system emulator. Clicking on particular 'hotspots' in the image activates items of the system, which allows for a non-linear learning approach. For instance clicking on a certain hydraulic hose to disconnect it and show it in it's disconnected state may highlight that the procedure wasn't undertaken in the correct order.

For this particular image the mechanical control linkages had to be animated to show how they operate the main servo units to manipulate the angle of the rotors and pitch of the blades. With so many different components from different manufacturers and suppliers, bringing all this information together in order to virtually build the model was a massive undertaking.
Lynx_noseFront nose detail

As the complexity of such a vehicle, and maintenance so critical, the model has to be immensely accurate right down to the last rivet or electrical connector. Think of it as the equivalent of producing 3D imagery for a colour illustrated Haynes Manual along with all ground based test equipment and support vehicles.

Although the production costs were high, the assets can be reused for further support contracts and modified as and when necessary. The costs for having a real aircraft out of service, with such small numbers of engineers to train on, is actually far more expensive and impractical in the long run. Although cutting edge at the time, the exponential development of 3D hardware is now allowing data-sets such as these to be visualised in real-time systems rather than through pre-set image views.
Side view of hydraulic systems - fairing in forward positionBelow - Side view of the gearbox hydraulics with the front fairing in it's open position

This side image shows a state where the gearbox fairing has been triggered to show an open position. With a number of engineers using this system simultaneously, it builds situational awareness as to the safety of other maintenance crew. Therefore if somebody operates the flight controls in the cockpit while an engineer is checking control links, the software can report a connection error or provide hazard warnings to ensure safety checks are first undertaken.

 

*The above images are ©Copyright of Pennant PLC 2005.

*Written permission has been granted by Pennant PLC & GKN Westland for VISUALS 3D to use these images.

*Use of these images (or linking to these images) by any other persons or organisation without express permission from the above parties is strictly prohibited and may result in legal action.