WO2012083409A1

WO2012083409A1 - Simulator with lift-in drop-out cockpit module

Info

Publication number: WO2012083409A1
Application number: PCT/CA2010/002027
Authority: WO
Inventors: Fernando Petruzziello; Thomas Allen; Joaquim FRAZAO
Original assignee: Mechtronix Systems, Inc.
Priority date: 2010-12-24
Filing date: 2010-12-24
Publication date: 2012-06-28

Abstract

A simulator cab employs a cockpit module that is fixed to the cab or attached to the cab frame via motion actuators. The cockpit module can be detached from the frame and the cockpit module can be lowered through a hole in the frame in order to remove the cockpit module from the simulator cab without disassembling or removing the visual system or any other portion of the simulator cab. In one embodiment, the motion actuators that attach the cockpit module to the frame are small-amplitude actuators that are capable of very limited movements.

Description

SIM ULATOR WITH LIFT-IN DROP-OUT COCKPIT MODULE

TECHNICAL FIELD

The present invention relates to a simulator system suitable for use in vehicle simulators such as flight simulators, locomotive simulators, ship simulators, truck simulators, automobile simulators, etc.

BACKGROUND

Flight simulation is simulation of the experience of flight and various aspects of the flight environment, and is used for various purposes including training and assessment of pilots and flight crews, aircraft development, and entertainment. In the former two cases, the simulation can be conducted using an interactive device called a flight simulator that, under computer control, provides the flight environment and monitors pilot and other flight crew responses. The flight simulator usually also has provisions for accommodating training personnel and other observers who are able to control the course of the simulation and directly observe the pilots and crew.

Many flight simulators include a structure (the simulator "cab") which houses the flight crew and also, in most instances, instructors and observers. The area of the cab intended for the flight crew (the simulator "cockpit") simulates the flight deck area, or the cockpit area, of the aircraft being simulated. The area of the cab intended for instructors and observers is called the "non-simulated area".

The cab may be fully enclosed, partly enclosed, or not enclosed at all. The visual system (the function of which is to provide the images that flight crew members see through some or all of the window area of the cockpit), may be internal to the cab, wholly or partly external to the cab, or absent. Many cabs are designed so that they may be mounted on a "motion base" that moves the entire cab to increase the realism of the simulation - this feature is called "full-cab motion". The most detailed and realistic simulators can provide full-cab motion with six degrees of freedom including three rotations (pitch, roll and yaw), and three linear motions (heave, sway and surge) by means of an interlinked array of hydraulic or electric motion actuators which move the entire cab.

Such a cab 100 is shown in Figure 1 in which the outer skin of the cab has been partially cut away to reveal the simulator cockpit 1 10 and other internal features. Cab 100 has a base frame 102 that can be supported by an array of motion actuators, of which actuators 104, 106 and 108 are shown. Typically, there are six actuators arranged in an interlinked pattern. Rigidly mounted on the base frame of the cab are a cockpit 1 10 and a non-simulated area 1 12.

In Figure 1 , the simulated view through the cockpit windows is provided by a typical visual system. The particular visual system shown uses a set of one or more video projectors 1 14. The light output of the projector 1 14 is reflected from fold mirror 1 16 and projected on screen 1 18. Screen 1 18, in turn, is observed by those in the cockpit 1 10 via a viewing mirror 120 to provide a wide-field visual display. Alternatively, in other visual systems (not shown), the fold mirror 1 16 can be eliminated and the projector 1 14 located to project an image directly on the screen 1 18, either from the front side of the screen or from the back. Other visual systems (not shown) use a projection screen (or screens) which is (are) viewed directly by those in the cockpit. This direct-view type of visual system can be advantageous, for example, with certain types of helicopter simulator.

Obviously, the actuators 104, 106 and 108 are capable of inducing only limited angular and linear movements of the cab, typically on the order of 35° for angular movements and one meter for linear movements. However, these limited movements can simulate real motions by a process called "acceleration onset cueing". In particular, in order to simulate an acceleration, the simulator is initially accelerated a short distance. After the initial acceleration, the movement velocity is decelerated to zero before the physical limits of the actuators cylinders are reached. When the velocity reaches zero, the actuators are slowly returned to their initial positions. This process produces a realistic feeling of acceleration and succeeds because human body motion sensors (including the inner ear, semicircular canals and otoliths, muscle and joint sensors and sensors of whole body movements) are more sensitive to acceleration than to steady-state movement and have acceleration thresholds below which no motion is perceived. Therefore, the initial acceleration can be reduced and the actuators returned to their initial positions at rates below the thresholds of perception so that only the initial acceleration is sensed by the pilots and crew.

The cueing method mentioned above is effective for simulating short-term accelerations but is not adequate for simulating sustained accelerations. Instead, for example, sustained forward acceleration is simulated by changing the platform pitch angle: tipping the nose up for acceleration and down for deceleration. Since the visual image presented to those in the cockpit is generated by a visual system that is attached to the cockpit, the visual image moves as the platform moves, resulting in the pilot receiving strong cues of longitudinal acceleration or deceleration rather than pitch angle changes. Conventional simulators have the disadvantage that the motion actuators 104, 106 and 108 must be able to support the entire cab structure and its contents, including the frame, the cockpit, the non-simulated area, the various visual systems and the people involved in the simulation, and to accelerate this combined weight rapidly. Consequently, these actuator devices are large, bulky and expensive and require a large amount of power to operate.

Further, depending on the purpose for which they are built, flight simulators have different degrees of detail and realism. These range from generic cockpit models with simple controls and rudimentary environmental modeling to actual aircraft cockpits with a complete set of interactive controls that have wide-field visual systems and motion platforms that provide a comprehensive visual and tactile flight environment. The most detailed simulators use cockpits that completely resemble a cockpit from a particular aircraft, including all gauges, controls and instrumentation as well as, in some cases, the actual seats found on the aircraft being simulated. Such cockpits are very expensive. In other instances, it is convenient to use a single cab structure which can support a variety of cockpit types. Consequently, in either case, it is desirable to be able to remove the entire cockpit module from the simulator cab so that the same cockpit module can be used with a different simulator or another cockpit module can be used with the same simulator. This allows: an expensive cockpit to be used in several different locations without shipping the entire simulator; a simulator to be upgraded when new vehicle models are produced without the need to replace the entire simulator cab, and; a single simulator to be used with multiple different cockpits, thereby simulating diverse vehicle types. However, conventional simulators in which the cockpit can be removed also have the disadvantage that they are often designed in such a way that they require removal and/or disassembly of other major elements of the cab: in some cases the visual system, including the mirror 120; in other cases, the non- simulated area. After a new cockpit has been installed, the parts that were removed or disassembled must be replaced, reassembled and realigned. These extra tasks consume considerable time.

SUMMARY

According to one aspect of the invention, the simulator cab frame is constructed to have a bottom aperture ("docking station") with a surrounding frame that is capable of providing the required support for the simulator. The entire cab assembly can be mounted on conventional motion actuators or not. The simulator cockpit module can be separated from the cab and is mounted to the cab frame by inserting the cockpit module through the bottom aperture. The motion actuators which provide full-cab motion can be given sufficient range of motion to raise the cab frame to allow the cockpit module to be lowered through the aperture in the frame and then slid out from under the simulator to remove a cockpit module.

This arrangement can also allow the simulator to be operated with small-amplitude movements using motion actuators that attach the cockpit module to the cab frame. It has been found that effectively-delivered, small-amplitude motion cues, when combined with a visual system and cockpit reproduction that are sufficiently realistic, provide a simulated environment whose training value is virtually equivalent to that of a simulator which uses large-amplitude motion actuators. Alternatively, this arrangement permits the combination of small and large movements using both sets of motion actuators.

In accordance with another aspect of the invention, a flight simulator employs a cockpit module that is not rigidly attached to the simulator frame but instead is attached to the frame via motion actuators. Because the motion actuators support and move only the cockpit module and those therein, they can be much smaller and less expensive that conventional motion actuators and cost less to operate.

In some embodiments, the motion actuators that attach the cockpit module to the cab frame are small-amplitude actuators that are capable of providing cockpit module rotational motions of 15° or less and translational motions of approximately five to fifteen centimeters. It has been found that even with these limited movements, appropriate acceleration onset cueing can be achieved.

In other embodiments, sustained longitudinal and lateral accelerations are simulated by pitching and rolling the cockpit module alone and controlling the visual system to move the visual image in the direction of the pitch or roll.

In still another embodiment, the simulator frame is mounted on vertical lifts that can raise the frame to allow the cockpit module to be lowered through the hole in the frame and slid out from under the simulator. This arrangement has the advantage that, during operation, the simulator frame rests immobile on the lifts or on fixed supports so that the non-simulated area and the people therein are not subject to the movements imparted to the cockpit module.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a side elevation view of a conventional flight simulator in which the visual system has been partially cut away to reveal the cockpit. Figure 2 is a side elevation view similar to Figure 1 with the cab outer skin and base frame partially cut away to reveal small-amplitude motion actuators connecting the cockpit module to the base frame in which the cab is supported by a lift system not used for motion simulation.

Figure 3 is a side elevation view similar to Figure 2 in which the base frame is supported by large-amplitude motion actuators as in Figure 1 .

Figure 4 is an oblique view of a simulator cab with full-cab motion and shows a cockpit module in two positions: installed on motion actuators; and in the process of being lowered from, or lifted into, the cab structure with the aid of, in this particular illustration, a scissors-lift table. Parts of the cab structure and visual system have been cut away to better reveal the elements of interest.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Figure 1 shows a flight simulator according to one embodiment of the present invention. The simulator cab 100 is the assembly which consists of the base frame 102 and those components in and above the base frame. In Figure 1 the outer skin of the cab has been partially cut away to reveal the cockpit 1 10 and other internal features.

The simulator shown in Figure 1 comprises numerous features. For example, it includes a full-cab motion capability in which case, as shown, the entire cab is supported by an array of motion actuators, of which actuators 104, 106 and 108 appear in Figure 1 . In this particular embodiment, the cockpit is rigidly fixed to the cab structure.

The cab can contain a visual system, the purpose of which is to provide the simulated view through the cockpit windows. In the embodiment shown in Figure 1 , the visual system consists of a set of one or more computer-controlled video projectors 1 14. In the visual system shown, the light output of the projector 1 14 is reflected from fold mirror 1 16 and projected on screen 1 18. Screen 1 18, in turn, is observed by those in the cockpit 1 10 via a viewing mirror 120 to provide a wide-field visual display. Alternatively, in other visual systems (not shown), the fold mirror 1 16 can be eliminated and the projector 1 14 located to project an image directly on the screen 1 18, either from the front side of the screen or from the back. Alternatively, in yet other visual systems (not shown), the image is projected onto a projection screen (or screens) which is (are) viewed directly by those in the cockpit.

The cab can also contain a non-simulated area 1 12, the purpose of which is to provide a place and the necessary facilities to allow training personnel and other observers to control and monitor the simulated environment and conditions and to observe and monitor the behavior of the flight crew.

Figure 2 shows an alternative embodiment in which the entire cab structure, including the base frame 130, remains stationary during simulation and the cockpit module 132 moves by virtue of an array of motion actuators between the cockpit module and the cab structure, of which actuators 134 and 136 are shown. In this embodiment the simulator is equipped with actuators, of which actuators 138 and 139 are shown, which can be used to raise the cab structure to facilitate the cockpit module's removal from, or insertion into, the cab.

Figure 3 shows an alternative embodiment in which the entire cab structure, including the base frame 180, moves during simulation and the cockpit module 182 moves relative to the cab structure by virtue of an array of motion actuators between the cockpit module and the cab structure, of which actuators 184 and 186 are shown. In this embodiment the motion actuators which support the cab structure, of which actuators 187, 188 and 189 are shown, can be used to raise the cab structure to facilitate the cockpit module's removal from, or insertion into, the cab structure. Depending on the specific geometry of the cab structure and cockpit, separate actuators (not shown) can also be used for this purpose.

Figure 4 shows an alternative embodiment which uses a direct-view visual system in which the images are projected on parts of a spherical screen (not shown) which is viewed by those in the cockpit directly, rather than via a viewing mirror. In Figure 4 the outer skin of the cab has been partially cut away and the visual equipment removed to reveal the cockpit module and other internal features.

Figure 4 shows one cockpit module in two locations. The upper location 140 shows the cockpit module in its installed position mounted on its own set of six motion actuators 151 , 152, 153, 154, 155, 156. The lower location 141 shows it in the process of being lowered from, or lifted into, the cab structure with the aid of, in this particular illustration, a scissors-lift table.

In the case of the embodiment illustrated in Figure 4, the procedure to remove a cockpit module from a full-motion cab is as follows:

1 ) Power down the simulator.

2) Disconnect the electrical connectors between the cab frame and the cockpit module.

3) Support the weight of the cockpit module. (Although Figure 4 shows a scissors- lift table being used for this purpose, this can be accomplished by various other means, a forklift for example.)

4) Disconnect the links (fixed-length links or motion actuators as the case may be) connecting the cockpit module to the cab frame.

5) Lower the scissors-lift table.

6) Use the full-cab motion actuators 161 , 162, 163, 164, 165, 166 to raise the cab frame.

7) Move the cockpit module out from under the cab frame.

The removed cockpit module can be set aside or can be inserted into another simulator (not shown), either vertically or otherwise depending on the arrangement of that other simulator.

To install a cockpit module into a full-motion cab, simply reverse the above steps. While the invention has been shown and described with reference to a number of embodiments thereof, it will be recognized by those skilled in the art that various changes in form and detail may be made herein without departing from the spirit and scope of the invention as defined by the appended claims. For example:

The connection between the fixed floor and the cab may or may not allow for relative motion and the number of relative degrees of freedom may be any number up to and including six (6);

The connection between the cab and the cockpit module may or may not allow for relative motion and the number of relative degrees of freedom may be any number up to and including six (6);

One or more further levels of relative motion can exist between the main structural frame of the cockpit module and the cockpit itself and/or the seats therein;

The cockpit module, no matter how it is inserted into the cab (for example: vertically, laterally or obliquely) or whether or not other elements of the simulator (for example: parts or all of the visual system or the non-simulated area) need to be dismantled or moved out of the way during the insertion process, can be arranged so as to allow for it to move independently of the cab structure during simulation, thereby providing the consequent advantages of reduced equipment costs and reduced energy costs;

The cockpit module can contain part or all of the cockpit alone or it can also contain part or all of the non-simulated area;

Part or all of the non-simulated area can be mounted in a separate module which can move independently during simulation;

The simulator need not represent an aircraft. The simulated cockpit can represent the operator's area of a vehicle other than an aircraft - an automobile, a truck, a rail vehicle or a ship, for example.

What is claimed is:

Claims

A simulator cab comprising:

a cockpit module;

a frame having an aperture sized to allow passage of the cockpit module vertically therethrough, said cockpit module being connected to the frame.

The simulator cab of claim 1 , wherein said cockpit module is fixed to said frame.

The simulator cab of claim 1 , further comprising motion actuators connected between the cockpit module and the frame and operable to move the cockpit module supported by the frame.

The simulator cab of claim 3, wherein said actuators provide six degrees of freedom of the cockpit module for sustained acceleration cues.

The simulator cab of claim 3 or 4, wherein said motion actuators connected between the cockpit module and the frame provide a range of extension of less than 15 centimeters.

The simulator cab of any one of claims 1 to 5, further comprising motion actuators used for motion cues that support the frame relative to the ground.

The simulator cab of any one of claims 1 to 6, further comprising an enclosure covering said cockpit module and a visual display system.

8. The simulator cab of claim 7, further comprising a non-simulated area within said enclosure.

9. The simulator cab of claim 7 or 8, wherein said cockpit module represents an aircraft environment.

10. The simulator cab of any one of claims 6 to 9, wherein said plurality of motion actuators that support the frame relative to the ground have sufficient travel to lift the frame to clear of the cockpit module after the cockpit module has passed through said aperture with the cockpit module being released from the frame and supported on the ground below the frame.

1 1 . A simulator cab comprising:

a frame;

a cockpit module supported by the frame;

a non-simulated area supported by the frame;

motion actuators connected between the cockpit module and the frame and operable to move the cockpit module supported by the frame; a visual display system mounted to be fixed with respect to said frame; and

a control system configured to control the motion actuators to provide sensations of sustained accelerations, and to control images generated by the visual display system so as to remain always synchronized with the cockpit motions.

12. The simulator cab of claim 1 1 , wherein the visual display system comprises one or more projectors, one or more projection screens, and optical paths between each projector and said one or more screens, and wherein the images to be projected are kept synchronized with the cockpit motions by controlling the software generating the image stream for each projector so as to shift its field of view appropriately.

13. The simulator cab of claim 1 1 or 12, wherein the visual display system comprises one or more projectors, one or more projection screens, and optical paths between each projector and said one or more screens, and wherein the images to be projected are kept synchronized with the cockpit motions by manipulating the optical paths using one or more lenses or mirrors between each projector and said one or more screens.

14. The simulator cab of claim 1 1 , 12 or 13, wherein the visual display system comprises one or more projectors, one or more projection screens, and optical paths between each projector and said one or more screens, and wherein the images to be projected are kept synchronized with the cockpit motions by controlling the motion of each projector to move its projected image appropriately.

15. The simulator cab of any one of claims 1 1 to 14, further comprising an enclosure integrating the frame and the visual display system, the enclosure enclosing the cockpit module.

16. The simulator cab of any one of claims 1 1 to 15, wherein each said motion actuator connected between the frame and the cockpit module has a range of extension of less than 15 centimeters.

17. The simulator cab of any one of claims 1 1 to 16, wherein the non- simulated area is astern of the cockpit module.

18. The simulator cab of any one of claims 1 1 to 17, wherein said cockpit module represents an aircraft environment.

19. The simulator cab of any one of claims 1 1 to 18, wherein said frame has an aperture sized to allow passage of the cockpit module vertically therethrough.

20. The simulator cab of claim 19, further comprising motion actuators used for motion cues and connected between the frame and one or more structures fixed to ground, wherein said motion actuators connected between the said frame and the said one or more structures fixed to ground support the frame relative to the ground and have sufficient travel to lift the frame clear of the cockpit module after the cockpit module has passed through the aperture with the cockpit module being released from the frame and supported on the ground below the frame.

21 . The simulator cab of any one of claims 1 1 to 19, further comprising motion actuators used for motion cues and connected between the frame and a ground support.

22. A simulator system comprising:

a simulator cab as defined in any one of claims 1 to 9 and 19;

a lift for vertically moving said cockpit module relative to said frame through said aperture to clear said simulator cab and allow for removal and replacement of said cockpit module.

23. A method of manufacturing a simulator, the method comprising:

building a simulator cab as defined in any one of claims 1 to 9 and 1 1 to 19; selecting one of stationary frame or moving frame for said simulator cab; and

using either a set of one or more fixed ground supports or motion actuators between said frame and the floor in accordance with said selecting.

A method of operating a simulator, the method comprising:

providing a simulator cab as defined in any one of claims 1 to 10 and 19 to 20;

providing an alternative cockpit module for use with said simulator cab;

removing the cockpit module installed in said simulator cab through said aperture, and installing said alternative cockpit module in said simulator cab through said aperture; and

conducting simulation using said alternative cockpit module.