Talon Simulations demonstrates new mixed reality capabilities for US Air Force
Register at the following link to hear more detail about how this incredible B-52 air refueling training solution came together: https://varjo.com/webinar/building-an-xr-air-refueling-simulator-for-the-usaf/
August 2022 - During a two day period, dozens of Air Force pilots and instructors had the opportunity to test two state-of-the-art training prototypes as a part of the Strikewerx Mixed Reality Air Refueling Training Challenge. The goal was to find a system that could accelerate the training of new pilots to accomplish mid-air refueling in the B-52 bomber. Talon Simulations is grateful to have been a part of one of those teams where we showcased a one of a kind simulator with state of the art technology.
“These simulators go beyond what other Air Force AR/VR simulators can do in terms of flight realism and training efficiency,” said Dr. Donna Senft, Air Force Global Strike Command’s Chief Scientist. “This solution will result in reduced maintenance costs, no training delays, and improved pilot proficiency and readiness.”
VR Training, Inc. had invited Talon Simulations to be a part of their team in mid-2021 during the proposal process along with Magic Bytes, Bugeye Technologies, and Iris Dynamics. By December, we ended up being one of the two team’s chosen to build and deliver a prototype mixed reality flight simulator. Our concept was unique as it implemented the pilot’s real hands and real flight controls that exerted true to life force feedback. Combining this with the virtual environment allowed us to get as close as possible to what they might experience in the plane. Coupled with a 3 degree of freedom motion platform and the Varjo XR-3 display, we sought to provide a comparable training scenario to a Level D Full Flight Simulator, but at a fraction of the cost.
When the project kicked off in January 2022, we began testing various green screen methods in order to provide the most realistic overlay of the pilots hands and controls. Not only did we have to test out different types of screens and shapes, but also various types of lighting to minimize shadows and provide the cleanest display of the arms. We even tested a full light box with backlighting.
We settled on a shape and material of the green screen as well as proper settings for the Varjo XR-3 display and by May, the parts for the simulator started being delivered and assembly began. We mounted a cockpit built of 8020 frame onto the 3 DOF Motion Platform supplied by Delta Kinetic. The cockpit has electromagnetic linear actuators from Iris Dynamics in order to provide a smooth and powerful control force in the yoke handle similar to what the pilot would experience in the aircraft while refueling. We then installed the replica seat that has up, down, and tilt adjustment just like the real seat and the final piece was integrating the custom green screen system and lighting.
On top of mechanical engineering and hardware assembly, another specialty of Talon Simulations is software integration. We worked diligently with Specular Theory who is the software team responsible for EARL (Experiential Air Refueling Lightweight Simulator). The capabilities of our mixed reality simulator would be demonstrated through their software. This meant that it was important to ensure both actuators for the yoke provided input and output, the motion platform synchronized with the physics of the application, and the video passthrough would provide a clean display of the pilots hands and controls.
The entire system was delivered to the Cyber Innovation Center in two custom crates on time for the fly off challenge on August 10th and 11th. Our team fully installed the simulator and it operated for two whole days for instructor pilot evaluations. It was then moved over to Barksdale Air Force Base where continued tests will be performed and recorded to determine what features will be important for future simulators. This was a very rewarding opportunity for us and we appreciate the Air Force putting their trust in our team to deliver a robust one of a kind system that demonstrates the latest and greatest technologies available to our warfighters.