1. Connecticut Corsair Senior Design
School of Engineering
Simulator Refurbishment
EE Design Team 194

2. Connecticut Corsair Senior Design
School of Engineering
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In interdisciplinary team of mechanical, computer and electrical engineering students are reengineering the base of an outdated flight simulator to have movements characteristics akin to that of a Corsair F4U-4 aircraft.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. Connecticut Corsair Senior Design
School of Engineering
Current Work
Pros/Cons of Induction vs. Servo Motors
SERVO MOTORS
INDUCTION MOTORS
Small
Large
Integrated Encoder
Encoder Separate
Low Run Temperature
High Run Temperature
Easier to Prototype
Hard to Develop Prototype
Efficient
Less Efficient
Expensive
Cheaper
Servo drives are expensive
VFDs are less expensive
Arduino compatible

4. Connecticut Corsair Senior Design
School of Engineering
Current Work
Ideal Motor Specifications
OLD SPECIFICATIONS
NEW SPECIFCATIONS
RPM: 26
RPM: 65
Torque Out: 1212 in-lbs
Torque Out: in-lbs
Gear Ratio: 63:1
Gear Ratio: 21:1
𝑀𝑜𝑡𝑜𝑟 𝑠𝑝𝑒𝑒𝑑=120∗ 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 𝑝𝑜𝑙𝑒𝑠 =120∗ 60 4 =1800 𝑅𝑃𝑀
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜= 𝐼𝑛𝑝𝑢𝑡 𝑆𝑝𝑒𝑒𝑑 𝑂𝑢𝑡𝑝𝑢𝑡 𝑆𝑝𝑒𝑒𝑑 = =21.1
𝐼𝑛𝑝𝑢𝑡 𝑇𝑜𝑟𝑞𝑢𝑒= 𝑇𝑜𝑟𝑞𝑢𝑒 𝑂𝑢𝑡 𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 = =164.5 in-lb =13.7 ft-lb
𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟= 𝐼𝑛𝑝𝑢𝑡 𝑇𝑜𝑟𝑞𝑢𝑒 ∗ 𝑅𝑃𝑀 5252 =13.7∗ =4.7 𝐻𝑃**
**4.7hp non-standard. 5hp required.**

5. Connecticut Corsair Senior Design
School of Engineering
Current Work
Prototype Design
Professor Bazzi: granted access to functional servo for practice.
Top level prototype design; to be implemented on simulator after installation.
Parts include:
3D model printing
RC hobby servo motors
Arduino board
Deconstructed joystick
Data Flow Diagram
Joystick values
Mapping Function
Motor Position
Outputs
Motor Position

6. Connecticut Corsair Senior Design
School of Engineering
High Level Joystick Motor Diagram

7. Connecticut Corsair Senior Design
School of Engineering
Current Work
Coding: Arduino Sketches and Overview
Programming plan: Arduino sketch for use with controller-less motor drives.
Deconstructed joystick: potentiometers.
Position to position mapping
Non-linear relation between cam and platform
Why Ardiuno over C?
Arduino has an entire library for servo motor support.
Easy oneliners: Servo.write(speed)
To translate analog to digital signals is easier!
analogRead() vs…
Enable interrupts via registers, create interrupt functions, store values outside of interrupt sequence etc.
Writing to analog (PWM) is easier!
analogWrite(pin, value) vs…
Set registers for I/O, use loops with counters to determine cycle, etc.
Reusable code from ECE 3411

8. Connecticut Corsair Senior Design
School of Engineering
Current Work
Coding: Arduino Sketches and Overview …
V1 + V2 high, V3 low …

9. Connecticut Corsair Senior Design
School of Engineering
Future Work:
Second Design Semester
Purchase and construct prototype.
Down-scaled, 3D printed model of simulator base for demonstration.
Develop position/speed control on practice servo supplied by Dr. Bazzi.
Arduino sketch code development.
Documentation and function specifications.
Motor purchase and installation.
Electronics interfacing
Motor, controller, drive, protective power circuitry, computer, joystick/potentiometer inputs.

10. Connecticut Corsair Senior Design
School of Engineering
Timeline

11. Connecticut Corsair Senior Design
School of Engineering
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

12. Connecticut Corsair Senior Design
School of Engineering
Questions?
School of Engineering