Connecticut Corsair Senior Design Simulator Refurbishment EE Design Team 194

2 Connecticut Corsair Senior Design Problem Statement Summary In interdisciplinary team of mechanical, computer and electrical engineering students are reengineering the base of an outdated flight simulator to have movements characteristics akin to that of a Corsair F4U-4 aircraft.

3/15 Connecticut Corsair Senior Design Previous Work Pros/Cons of Induction vs. Servo Motors SERVO MOTORSINDUCTION MOTORS SmallLarge Integrated EncoderEncoder Separate Low Run TemperatureHigh Run Temperature Easier to PrototypeHard to Develop Prototype EfficientLess Efficient ExpensiveCheaper Servo drives are expensiveVFDs are less expensive Arduino compatible

4/15 Connecticut Corsair Senior Design Previous Work Ideal Motor Specifications OLD SPECIFICATIONSNEW SPECIFCATIONS RPM: 26RPM: 65 Torque Out: 1212 in-lbsTorque Out: in-lbs Gear Ratio: 63:1Gear Ratio: 21:1 **4.7hp non-standard. 5hp required.**

5/15 Connecticut Corsair Senior Design Current Work: Second Design Semester Motor Purchase and Installation - Induction motors mounted, relays built - Existing VFDs wired to motors - Servo purchased and being shipped Electronics Interfacing Components include... - Motor, - Arduino - VFDs - Protective circuitry, i.e: relays - Computer - Joystick inputs Arduino Sketch development - Function documentation and specifications

Connecticut Corsair Senior Design Current Work: Existing Motor Rebuild and Servo Integration -Initial Design: three servo motors -Redesign: single servo, two induction! -More compliant with budget -Small simulator load makes this possible -Induction motor damage update -Motor stator housings replaced

7/15 Connecticut Corsair Senior Design Current Work: Second Design Semester

Given the previous design team’s wiring… Wiring modifications were made Parts of existing setup cut out New wiring allows for variable frequency input Old schematics didn’t provide Arduino pin numbers Connecticut Corsair Senior Design Current Work: Rewire VFDs

Connecticut Corsair Senior Design Current Work: Wire Schematics

Reads Joystick(Pots) inputs to move motors at variable speeds using PWM. Easy to write analog output with simple math. Only at half capacity, will be solved with circuit elements. Encoder code is being developed for the AS25 Gurley Absolute Encoder. Connecticut Corsair Senior Design Current Work: Arduino Sketch Development Thus Far

Interfacing with Servo drive shipment estimated between 3/14 and 3/22 Actual position controlled induction motors. Connecticut Corsair Senior Design Current Work What’s Next?

Provides absolute position information to Arduino controller 16 bit resolution - very accurate Synchronous serial data communication between encoders and Arduino High speed: ~1 microsecond response time Connecticut Corsair Senior Design Current Work Absolute Encoder

Lockheed Martin’s Prepar3D Academic v Used for both entertainment and training Immersive cockpit with real-life airports and environments Mission Design, capable of entertainment and training purposes SimConnect Developer SDK Add-ons can be written in C, C++, C#.net or VB.net Add gauge processing, replace events processing, record/monitor flights, create custom missions, weather manipulation, enable hardware with Prepar3D, control additional views and/or AI aircraft F4U-4 Corsair Plane Model Import via A2A A2A is a software add-on company “Aircraft Factory” Line Fine distinction: use software to control machine Future application: 3D immersive LCD screen Connecticut Corsair Senior Design Current Work Simulation Software: Prepar3D

Connecticut Corsair Senior Design Timeline 2/24/20143/3/20143/10/20143/17/20143/24/20143/31/20144/7/20144/14/20144/21/2014 Zach Mosch Run VFD's and Induction motors with Joystick Absolute encoder feedback Position controlled Induction Motors See previous Servo's hopefully? Transfer Arduino code to servo drive See previousTesting David Tartaglino Complete VFD and Induction motor wiring Finalize wirings and mount to simulator. Make new wiring diagrams and schematics See previous Unpack and start working on servo motor installation Complete servo and drive wiring Make servo wiring diagrams and schematics Testing Amanda Sweat Contact Lockheed customer support for installation issues Purchase A2A simulation Corsair model Corsair model imported using client server. Model joystick control Outline how encoder feedback inputs are imported into software Create logfiles of positions from Prepar3D Integrate logfiles with existing Arduino code Answer: Can environment outputs be processed to affect flight simulator? Write up on machine + Prepar3d integration. Computer wired. Manipulate machine and software for simulation Randy Bertrand Find usable code for Prepar3d outputs Absolute encoder feedback Link motors to Prepar3d position outputs See previousServo motors Help with servo setup Incorporate servo position info with encoder feedback from other motors Testing

Connecticut Corsair Senior Design High Level Joystick Motor Diagram

Connecticut Corsair Senior Design ME Contributions Drive motor Analysis and Replacement Free body Diagrams Torque Requirements and Comparison Nonlinear Linkages Analysis Scissor Arm Analysis and Redesign Determined failure scenarios ANSYS analysis CAD models Motor Mount Redesign Gearbox designs ANSYS analysis CAD models

17 Connecticut Corsair Senior Design Questions?