Head-up displays (HUD) for the F-22 Raptor are now being maintained by the 523rd Electronics Maintenance Squadron, Display and Indicator Shop, thanks to a partnering arrangement with Lockheed Martin and BAE Systems England.
The squadron has trained five members to test, calibrate and repair the F-22 HUD using a test program and equipment developed by BAE Systems. The tester simulates symbology the pilot sees, allowing the squadron to check the unit for accuracy.
"The technicians were first trained to use the automated test equipment," said Gary Hintz, Force Sustainment Flight chief. "Once the software was loaded, they were taught about the HUD."
The work area features a refrigerator-sized computerized test station linked to a test bench that holds the HUD. The HUD overlays flight, navigation, attack and other information on the pilot's forward field of view.
"The utility software we're running is windows-based software -- you click on what you want to test and the station walks you through it," said Paul Scheel, an electronics mechanic working on the project. "We calibrate the fixture for accuracy."
The shop is presently testing and repairing the HUD and soon will be doing the optics workload to test the mirrors and other glass in the display. The HUD also includes a camera to record real-time video as the aircraft flies, which is tested and replaced as needed.
"We're the only ones in the United States doing this workload," Hintz said. "Otherwise, they have to be shipped back to England for BAE Systems to repair. That takes anywhere from eight to 16 weeks to get back because they have to go through customs and other routing.
"We are able to do the work a lot quicker as the items remain in the U.S. and are repaired organically -- it takes three days to ship them here, one to three days -- about 30 hours -- to repair, then three days to get them back to the customer."
The workload was assigned to Hill Air Force Base by the Air Force with the activation taking 18 months of planning and preparation to reach where we are today.
"Shortly after the stand up this week and capability demonstration, the technicians have already successfully repaired one HUD and have another coming in. It's awesome!" said Malcolm Troy, BAE Systems Project Manager responsible for the F-22 HUD Depot Maintenance Partnering program delivery.
Lance Hall, the Lockheed Depot Partnering Program manager who leads the HUD team agreed, adding "we worked together, put all the equipment together and trained them. The shop is wonderful -- anything we needed in the past 18 months, Gary Hintz provided. The teamwork between Lockheed, BAE Systems and the shop, it's been great."
Squadron mechanics working on the HUD appreciated not only the training provided by Lockheed and BAE Systems, but also the new technology.
"The new technology is much more user friendly," said Tarra Heywood, electronic systems mechanic. "We still follow our technical orders step by step, but the equipment does the safety checks and directs us where to focus next.
"The HUD repair process is set up more as a combined effort for preventive maintenance, to where we actually communicate with BAE Systems to make sure that the aircraft stays out in the field longer."
The 523rd plans to produce 1,800 hours -- about 30 units -- this year, increasing to 2,200 hours in 2011 and 2,500 hours in 2012.
"We're going to use a rotating repair table, designed by Hill engineers, that allows the part to be turned without sensitive parts touching the deck," Hintz said. "It's very unique and Lockheed Martin and BAE Systems are thinking about buying it. The rotating table makes it a lot easier for the technicians to work on the parts because the HUD weighs about 50 pounds and for safety, it takes two people to lift it. Rotating the part will also protect the optics of the F-22 HUD."
The BAE Systems tester has the potential to test head-up displays for the F-16 and other display equipment, Hintz noted, requiring only a change of Test Program Software to perform the task.
"Partnering agreements like this are the future for new workloads," said Sami Mansour, director of the 523rd Electronics Maintenance Squadron, "and we look forward to doing many more."
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