Home : Services : Research & Technology : Part Task Trainers : IITSEC
 
 

CREATING MILITARY SIMULATORS AT ARCADE GAME COST

George Katz
Scientific Management Associates SMA (Aust)
Sydney Australia

ABSTRACT

In these times of shrinking budgets and increasing equipment complexity, training for major equipment acquisitions requires carefully selected, cost effective life of type solutions. This paper briefly reviews the types of solutions used to provide effective training for complex real equipment. The introduction briefly outlines the advantages and costs of different solutions. The body of the paper provides a case study of a solution developed by SMA for a Royal Australian Navy gun operator training requirement. Our approach has been to exploit popular commercial off the shelf (COTS) hardware and software. In particular, in the area of graphics, we chose to go in the direction of Direct 3D (as opposed to Open GL) because of the benefits of the parent Direct X suite of code, which supports sound, networking, IO, as well as 2D and 3D acceleration. The paper concludes that, although Part Task Trainers are not a simple panacea to all training problems, advances in PC technology mean that they provide a highly cost effective training solution - in fact at arcade game cost.

AUTHORS’ BIOGRAPHIES

Mr. George Katz, Lead Software Engineer, SMA Research & Technology
Bachelor of Engineering (Computer Eng.) Honours

Since completing his degree in 1993, George has gained experience in the use of several computer programming languages, including Microsoft Visual C++, Borland Turbo C, Watcom C and various assembly languages (68000; Hitachi SH-2; 68HC11). Prior to joining SMA George worked in the USA for 2.5 years developing video games for Realtime Associates. His experience included the design and implementation of a multi-processor 3D game engine for Sega Saturn and for Sony Playstation (Lead Programmer); design, development and implementation of several computer games, including "Crusader: No Remorse" – Saturn and Playstation (Co-lead Programmer); "NBA Live ’98" - Saturn (Lead Programmer). George was also involved in the design and construction of electronic and computer interactives for public exhibitions for the Australian Museum from November 1994 – April 1995. He has also constructed a number of mobile robots currently in use by PhD. students at the University of NSW. George is currently leading the development and integration of the software required to implement the two part task trainers used as a case study in this paper. This task includes working with and synthesising the efforts of the group’s educators, hardware engineers, technicians and graphics designers.

Mr Andrew Wise, Manager, SMA Research & Technology
Bachelor of Engineering (Mechanical) Honours

Andrew has over nine years experience with the Royal Australian Navy (RAN) as a Marine Engineer Officer. He therefore has a detailed understanding of both the technical and operational requirements of complex equipment within the Defence environment. Andrew joined SMA as the Lead Instructor for Platform Systems for the RAN’s new Minehunter project. He was subsequently promoted to Deputy Project Manager for this program, and has most recently been promoted to manage SMA’s Research and Technology Group. This Group designs and develops technology based solutions for SMA’s international training and Integrated Logistics Support projects. A particular focus of the Group has been the development of a number of Part Task Trainers and PC based simulations. These were developed to support the Minehunter project, and two of these products form the basis of the case study outlined in this paper.

 

CREATING MILITARY SIMULATORS AT ARCADE GAME COST

George Katz, Scientific Management Associates SMA (Aust), Sydney Australia   

INTRODUCTION

In these times of shrinking budgets and increasing equipment complexity, training for major equipment acquisitions requires carefully selected, cost effective life of type solutions.

One approach to this problem has been to embed sufficient training functionality into the real equipment. This approach can add significant cost to real equipment – a major budget driver where multiple units are purchased. This also creates the need to trade off operational time against training time.

A second approach is to use high fidelity simulation, such as full motion simulators or training centres with a significant fit of real equipment. However, this involves a high initial acquisition cost and high consequential costs associated with software development/maintenance, design-forced long lead times, and through life operation and maintenance. Budget constraints often dictate that high fidelity simulators are kept to a minimum. Where they do exist, they are often used for non-core training purposes such as tactical development. They are also frequently used for non-training purposes such as a system test bed.

An alternative approach is to place more emphasis on the lower fidelity/cost end of the training spectrum. This approach reduces the loading on a high fidelity simulator or real equipment by ensuring that trainees have previously mastered the basic skills. This can allow use of the high-end simulator to focus on tactical or team based skill development.

While traditional knowledge based learning supported by computer based training, models, equipment parts and cutaways has its place, it cannot prepare trainees fully for the tactile and spatial elements of the task.

As a provider of training solutions for military projects, SMA's challenge has been to develop training solutions that address these issues. One approach has been the design of Part Task Trainers (PTTs) to fill the gap in the training spectrum between traditional knowledge based training and full simulators or real equipment.

Even within multi-billion dollar projects, the budget allocated to training equipment is relatively small. Typically the budget for even a particularly complex PTT is in the order of US$100,000.

Our approach has been to exploit popular commercial off the shelf (COTS) hardware and software. We decided that the massive user base and ongoing investment in continuing development by companies such as Microsoft might work to our benefit. In particular, in the area of graphics, we chose to go in the direction of Direct 3D (as opposed to Open GL) because of the benefits of the parent Direct X suite of code, which supports sound, networking, IO, as well as 2D and 3D acceleration. The benefits include the large established user base, a degree of hardware independence, frequent updates, and backward compatibility.

This approach has reduced coding by nearly 90% compared to ground up development. It also enabled a successful progressive upgrade of the hardware, Operating System and software with little or no cost or schedule impact.

This paper presents a case study that expands on the nature of the problem, the design solution applied and the success in achieving the technical and commercial requirements.

BACKGROUND

In this paper we present two examples of Part Task Trainers (PTTs) developed by SMA (Aust) as part of an articulated training solution for a new class of minehunter being built for the Royal Australian Navy. These PTTs emulate the 30mm Gun and the Electro-Optical Surveillance System (EOSS). As a result of a detailed training analysis the PTTs emerged as the most appropriate means to develop the identified operator skills.  

Importance of Human-Machine Interface (HMI)

The Human Machine Interface (HMI) of the real equipment is a key factor in determining how effectively the overall system is used. The operator manipulates the HMI to achieve the desired system outcomes, and receives visual, aural and tactile feedback.

Therefore, regardless of the quality or utility of the real equipment’s HMI, the PTT must replicate its features as accurately as possible. This ensures that the trainee develops the physical and cognitive skills necessary to use the system in its operational environment. The fidelity of the PTT impacts directly the degree of learning transfer that is achieved in the operational environment. The higher the fidelity of the simulated HMI, the greater is the degree of learning transfer that can be achieved.

Motivation Behind Development

Why would you choose to build a PTT? The main reasons are cost and student throughput. A PTT cannot always replace a high end simulator nor can it always eliminate real equipment training. Rather, it often can be used to complement these.

The PTT is used to familiarise the student with the procedural aspects of operating the piece of equipment. By the time the student uses the high end simulator or the real equipment they are not wasting time learning where a switch is or what it is supposed to do. Due to the lower cost and task specificity of PTTs, training throughput can also be increased.

Portability is also a major design criterion. Often it is difficult to move a full motion simulator from site to site as training requirements change. Both designs presented here took into consideration that they must fit through a single door, run off a single standard power point, and be transportable on an aircraft palette.

We will now give a brief description of the two PTTs and describe what was done to keep development costs low, yet still provide an effective training solution.

30mm GUN PART TASK TRAINER

Background

The entire training solution for the 30mm gun in the context of the minehunter consists of a complementary suite of three components:

  • The 30mm Gun PTT, which will be used to train operators in the aiming of the gun.

  • A real gun assembly and loader, which will be used for ordnance training.

  • A gun simulation, which will be used for aspects of maintenance training.

Our training specialists identified the required training outcomes and we worked to achieve those (rather than our engineers simply building what was possible). This meant that a significant amount of time was spent on making the user interface look and feel virtually identical to the real piece of equipment, rather than implementing features that would have been desirable, but not necessary.

The gun has a relatively complex HMI (the reason the PTT was required). Because the gun is stabilised only in elevation and the operator is not, he has to constantly move his head to follow the gun sight, which is attached to the stabilised gun. The operator has two handgrips with switches and joystick, which he has to operate, as well as a control panel and two dials to look at. He also wears a set of headphones and a microphone, to receive fire control instructions.

The spatial relationships between the student and the significant physical elements of the PTT were a key design criterion. This included the student’s visual field, the physical location of switches, dials, hand grips, seat position, etc.

Design

The solution consists of a static base frame to which is attached an operator’s subframe and the screen assembly. A facsimile cockpit and seat are mounted on the operator’s subframe. The screen assembly consists of a partially enclosed screen that is curved in the elevation plane.

Mounted to the base frame is a frame that supports a rotating shaft that is driven by an AC electric motor.

A data projector and the gun sight are mounted to the shaft, and pivot as the ‘gun’ is elevated. The image is projected onto the curved screen such that the centre of the image remains in the centre of the gun sight. The software generates a moving "window" onto the virtual world as the gun moves up and down.

Figure 1

30mm Gun
Part Task Trainer

     

EOSS PART TASK TRAINER

Background

The real EOSS consists of two main components: The director head which is located mid way up the mast and houses a daylight TV camera and high definition thermal imager, and the Bridge Command Console located on the bridge. The EOSS PTT implements only the Bridge Command Console.

Our training analysis again identified that the EOSS bridge console required a part task trainer as a training aid. The HMI is also relatively complex, with two video screens, a touch screen, VCR, function keys, keypad as well as a joystick.

 

 

Figure 2

EOSS Part Task Trainer

The idea behind the EOSS PTT is not to teach the student to recognise a person in the water at night at one mile, but rather to teach them how to most effectively configure the EOSS to enable them to do that on the real ship.

An operator must become efficient at using the interface because all his/her concentration must remain on the video screens during search activities.

Almost complete functionality of the EOSS menus and operation has been implemented in the PTT. The main difference between it and the real system is that the displayed images are computer generated rather than an actual camera view.

As with the gun, the trainer is controlled from an Instructor’s Station located nearby. This consists of a desk mounted PC networked to the simulator.

APPROACH

The following sections describe the approach we have taken to achieve a cost-effective solution.

Code Technology

All the software developed for the PTTs was developed with Visual C++ (V5.0) using Microsoft’s MFC and DirectX (V6.0) technologies. Both of these large bodies of code helped cut down the development cost significantly. Only a total of ~40,000 lines of PTT specific C++ code needed to be written for each PTT and support applications (of which around 75% is common to both). This also made for simpler testing and debugging.

In developing the PTTs we wanted to be able to reuse as much software for future PTTs as possible. The overall code structure is layered in nature as described in Figure 3.

 

 

Figure 3

Hierarchical Structure of the
PTT Software
(click for full view)

The top-most layer contains the code specific to the simulator, such as the state machine of the gun, the menu systems of the EOSS, all the target AI, how the ship behaves, etc.

The next layer contains the core or generic simulation engine that implements the non-specific code. This includes how to communicate with other computers, how to load and play sound effects, how to represent 3D models and textures, and the overall flow of the simulation.

Below this are the DirectX and MFC libraries that handle all the low-level communication between the operating system and peripherals. This layer also contains any special drivers for the IO peripherals used.

The lowest layer contains the operating system. The DirectX and MFC libraries enabled us to make the PTT code largely Windows Operating System non-specific. This was a major advantage as we migrated the code from Windows NT to Win’95 and now Win ’98 for performance reasons. We also went from Direct X3 to 5 and now Direct X6 with minimal code change. We are able to utilise easily the new technology improvements in the OS as well as DirectX.

Using this structured approach we were able to reuse approximately 75% of all Gun simulator code in the EOSS PTT. All the support tools for scenario generation, control and result analysis were also used.

The only new features that had to be added to the EOSS were multiple monitor support and the touch screen menu system. All the virtual world generation was directly used from the gun.

PC Technology

All the software for the simulators runs on a standard high-end PC. (Pentium II 300Mhz, with 128Mb RAM and a 4Gb Hard Disk). Two 3D graphic accelerator cards were used for 3D scene rendering, as well as an IO card to talk to all the external hardware.

One of the key advantages of using a PC as the target platform is that the development environment runs on the actual PCs that went into the final simulator. We did not need to buy or invest in several development stations to develop the part task trainers. The same PCs were used to write the documentation and handle the day to day office duties. It was great to have the fastest word processors around.

Hardware – Electronics and Mechanical

Very little specialised electronics had to be developed in the case of both Gun and EOSS, as most was off-the-shelf.

We chose to develop facsimiles of the real equipment in many instances rather than purchasing actual military hardware. Facsimile parts were often priced at about 10% of the actual military equivalent. For example the real gun sight alone was worth about half the total PTT budget. The part task trainers were designed to operate indoors in a controlled environment, so mil spec standards did not have to be met. We used commercial standards for all parts and construction.

In some instances we bought the switches and indicators from the real equipment manufacturer, because suitable equivalents were not available from commercial sources.

Small Team Size

All the simulator code and the hardware design for both the Gun and EOSS were developed with the following team size: 3 programmers, 1 mechanical engineer, 1 electronics engineer, 1 3D-modelling artist / draftsman, 2 management positions and 2 training specialists. A small team size means that the management overhead can be kept low.

Manufacturing of individual hardware components was contracted out to local companies.

Occupational Health and Safety Aspects

Safety was a critical design consideration, as there are moving parts close to the student. Following is an example of the safety features that have been incorporated into the design of the Gun PTT.

  • Hazard Warning Signs. Signs and black and yellow striped labels are placed in all locations that may constitute a hazard to people.

  • Software Procedure Control for initialisation and instructor confirmation. The control software is written so that a set sequence of steps must be followed and confirmed at each step, to ensure that a student is correctly seated and secured before the simulation begins.

  • Watchdog Timer Motor Cutout. This timer is set to detect a hung or crashed computer during a simulation. If the timer fails to receive a periodic reset signal from the computer it will cut the motor power.  

  • Student and Instructor Emergency Stop Motor Cutout Switch. Both the student and instructor have their own motor cut out "chicken" switch.    

  • Sight-Arm Shear Pin. The sight arm is fitted with a shear pin that will allow the sight arm to swing freely if excessive force is placed upon it.

All aspects of the part task trainer have been designed with safety as the foremost consideration. The most appropriate safety factors have been built into all calculations. Where there has been any doubt the components have been over-engineered.

   

PTT Main Software Components

The total part task trainer software solution consists of a number of different applications.

The 3D Simulator Engine. This is the main part of the simulator where the simulated world is generated. The operator interacts with the simulator engine in real-time. The frame rate achieved is 30 to 40 fps, with a resolution of 1024x768 pixels and 65,000 colours. The resolution of the projected image is currently limited by the data projector.

 

 

Figure 4

Screen Shot of Typical
Operator View

     

Instructor Control. This is a real-time application running on a separate computer that the instructor uses to control a training session. It gives the instructor a tactical display of the entire scenario and allows him to set various scenario parameters and induce faults.

 

Figure 5

Screen Shot of Scenario Controller

     

Scenario Generator. This is a tool used by the instructor to build various training scenarios. These can be designed on any PC and saved to a file. These files can then be downloaded onto the simulator.

This application sets the sea and environment conditions such as cloud cover, fog, time of day etc. The instructor can add the flight paths of all targets, as well as ship manoeuvres. Faults can also be added to the scenario. A preview feature allows the instructor to see the scenario in real-time so that he can verify all time related information.

 

Figure 6

Screen Shot of Scenario Generation Tool

     

Magazine. This tool is used by the instructor to create various magazine load-outs for a particular scenario. These magazines can also be also designed on another computer and downloaded to the simulator later.

 

Figure 7

Screen Shot of Magazine
Load-out Tool

     

Result Analysis. This tool enables the instructor to see the gun and target elevation and training and user interface operation over time. It gives the instructor feedback on how well a student is tracking and using the gun. An analysis is performed on the data to determine how well the student tracks a particular target.

 

Figure 8

Screen Shot of Result
Analysis Tool

Extensibility

An important commercial consideration was the ability to reuse and extend the core products to develop similar products in the future.

The underlying software structure allows us to easily implement other types of guns, missile launchers etc. The multiple monitor capability of the EOSS can be applied to driving simulators such trucks, trains or ships.

SUMMARY OF THE BENEFITS OF PART TASK TRAINERS

Increasing pressure to reduce both the capital and through-life costs of major acquisitions directly impacts the training budget on major projects.

A training analysis driven approach is essential to ensure that the solution is tailored to satisfy the specific training requirement without unnecessary embellishment.

Using the 30mm gun as an example, the purchase of a real gun for training would cost in the order of $1 million. Additionally, ammunition and maintenance add significant through life costs. Our COTS based approach to the training suite outlined in this paper satisfied all required training objectives for less than one-quarter of the capital cost, and minimal through life cost.

Additionally, Part Task Trainers and PC based simulations offer training benefits not available using real equipment. The ability to progressively move from simplified task elements through to full operation provides a more effective training path. The ability to perfectly repeat specific scenarios ensures consistency of training and assessment. The ability to record and analyse results is an invaluable instructional tool.

While high-end simulators can similarly offer these additional training benefits, their cost is often close to (or sometimes in excess of) the real equipment cost.

CONCLUSION

Part Task Trainers are not a simple panacea to all training problems. However, advances in PC technology mean that in many cases they provide a highly cost effective training solution - in fact at arcade game cost.

Top