Comprehensive flight simulator diagnostics – how to ensure uninterrupted pilot training?

Flight simulators are now an integral part of training for both military and civilian pilots. Their operational readiness directly affects the efficiency of the training process and crew safety. At A&D Serwis, we have spent more than 15 years providing full-lifecycle service support for such equipment — including systems still under active use and those already withdrawn from OEM warranty coverage.

How does simulator maintenance differ from servicing standard electronic equipment?

A simulator is an integrated system made up of numerous subsystems:

• Server infrastructure and software – responsible for generating flight scenarios, logging data, and integrating all simulator subsystems. This is exactly why regular servicing and system-wide calibration are so important.
• Motion base platform – typically six-axis, reproducing g-forces and spatial motion. It requires cyclical inspection of actuators, hydraulics, and safety systems.
• Visualization system – a multi-projector setup displaying imagery on a spherical screen. Every calibration must account for geometry, luminance, and synchronization with the control system.
• Avionics and cockpit panels – replicate the aircraft cabin layout. They require functional testing and verification of compliance with real-world aviation systems.

What does the diagnostic process look like?

Every inspection begins with a detailed test plan:

• Technical condition audit – mechanical and visual inspection, assessment of wear on key components.
• System tests – activation of individual modules, log analysis, simulation of emergency scenarios.
• Calibration and synchronization – particularly critical for the motion platform and visualization system.
• Service report – includes repair recommendations, an action timeline, and an assessment of operational readiness.

Why choose an external service provider?

Many simulator operators — especially military ones — face limited spare parts availability, lack of OEM support, or products discontinued from production. A&D Serwis specializes in exactly these situations:

• We ensure continued operation even without OEM support.
• We recover and refurbish components that are no longer available.
• We engineer replacements or reconfigure systems to match user requirements.

Training readiness is not a luxury – it's an obligation

A simulator that isn't working means interrupted training, wasted time, and a risk to a unit's operational schedule. Our mission is to ensure the continuous operation of these advanced systems — so that pilot training can proceed without disruption.