1、Griffon TechnologiesPROJECT TITLE: Design and development of a helicopter flight simulation demonstration facilitySUBMITTED TO: Boeing Defense and Space Group, Helicopter Div.ADDRESS: Penn State Rotorcraft Center233 Hammond BuildingCONTACT: Dr. Joe Horn, Assistant Professor of Aerospace EngineeringT
2、ELEPHONE: (814) 865-6434EMAIL: joehornpsu.eduSUBMITTTED BY: Aaron StutzmanDavid OechsleinRaymond FongSean HanleyTEAM CONTACT: Raymond FongADDRESS: 721 Beaver HallUniversity Park, PATELEPHONE: (814) 862-6888EMAIL: rkf114psu.eduDATE: 六月 14, 2018EXECUTIVE SUMMARYThe Boeing Company has proposed the task
3、 of building a realistic active control stick. The task requires one to build an active force feedback system into the existing control stick. The force feedback system will ultimately provide the pilot with important force feel cues given by the simulated helicopter during its operation. Through th
4、e use of a series of actuators one should be able to implement a force feed back system into the control stick. Before implementation, the numerical forces found in a UH-60 during flight would need to be known in order to purchase the correct type and size of actuator. INTRODUCTIONThe dynamics of a
5、helicopter are extremely complex. Modeling the helicopters physics and dynamics of flight has been done. Through such modeling, companies have created helicopter simulators. The simulators purpose is to give the pilot a unique and realistic experience while in the comfort of a controlled environment
6、. Simulators can provide unique training scenarios for a pilot. Whether it is flying in bad weather, damaged systems, or simply land, helicopter simulators assist the pilot in training for almost any scenario. To create an excellent simulator one must learn to blur the line between realistic and sim
7、ulated. The efficiency of the training not only depends on the pilot but on the belief that the simulated situation is real. The current project proposed by Boeing is to add a force feed back dimension to the control stick. The project will actually build off the existing flight simulator implemente
8、d in the Aerospace Department of Penn State. Although the control stick, collective, foot pedals and software are in place there is no such design for an active control stick present. The current flight software in place is called Flight Gear. It is a free open source flight simulator capable of run
9、ning multiple types of aircraft. The present project is to model the force feel dynamics of a UH-60 helicopter. Figure 1: Existing simulator hardwarePROJECT STATEMENTDesign, Test and Implement the following:1. Primary Objective: Active Control Stick - Students will design and build a control stick w
10、ith programmable force feel characteristics in order to provide enhanced cueing to the pilot.2. Secondary Objective: Simulator Motion Base - Students will design a moving platform to provide inertial cues to the pilot and thereby enhance the fidelity of the simulator. OBJECTIVES1. Research in the fo
11、llowing areas The forces that a pilot might feel in a UH-60 helicopter during flight. The type and size of actuator that may be feasible in such an application. The ability to monitor, calibrate and activate the actuators. The possibility of obtaining the actual hardware used in a UH-60.2. Implement
12、ation The actuators are to be mounted to the control stick Placement of actuators will be important in delivering the optimal forces to the pilot Once hardware has been installed the actuator will be calibrated, powered, and demonstrated.3. Constraints Group will not be responsible for software inte
13、rface to actuators. At least one actuator will power one axis and the process will be cloned when time permits. The motion base and its degrees of movement will be implemented only if time permits. PROJECT DEVELOPMENT:Time schedule information provided in Appendix ATeam qualifications provided in Ap
14、pendix C1. Planning Identify constraints, such as hardware, time, and budget Locate all necessary technical and hardware resources Recognize each Team members qualifications2. Concept Development Consider using existing control hardware or find new technologies Estimate time and cost of installing a
15、nd buying such hardware Find the numerical forces experienced on the control stick during flight Consider using pneumatic or electric driven actuators3. System-Level Design Identify suppliers of required actuators and flight sticks Generate an assembly scheme Develop Calibration methods in tandem wi
16、th assembly Record and document all data4. Detail Design Define tolerances developed from the calibration method Locate any special tools needed for assembly5. Testing and Refinement Calibration methods developed previously will define further refinement Technical sponsor determine if tolerances are
17、 acceptable6. Production Ramp-Up Produce a final technical schematic of the installed hardware Construct and assemble hardware Test and calibrate mounted hardware If time permits the process is cloned for all axis of freedom If time permits construction of motion base will begin Confirm that all del
18、iverables have been metTECHNICAL APPROACHSolution 1: Pneumatic ActuatorsIn order to produce a force-feel flight control stick for the Boeing Helicopter Flight Simulator there are two choices in deciding how to apply the needed force. Currently the flight control stick is manipulated by a series of m
19、echanical springs that do not accurately simulate actual flight operations. In order to create a more realistic control system the springs will be replaced with a linear actuator that will produce a force relative to the force applied by the pilots hand. The system will also be able to recognize a l
20、ocalized neutral position so that the pilot will not have to produce a constant force to keep flight constant in the desired direction. This will more accurately model the functions of the actual flight control system on board a UH-60 helicopter. The actuator chosen will depend upon the force that i
21、s needed to respond to the pilots force on the handle. A pneumatic actuator is very useful in applications where a quick and accurate response is needed such as in the control stick of a flight simulator. Pneumatic actuators are available for many applications and have a large range of forces. Howev
22、er the initial cost of implementing this system could be considerably different than an electromechanical system. The cost will mostly be due to having to purchase the entire pneumatic system including the actuators, valves, air lines, and where an air supply is not available a compressor will be ne
23、eded. However, the pneumatic system would be much more applicable to a system where a local neutral position is desired as the controlling involves the opening/closing of valves. One would also need to consider the power source for the actuators. Rather than using electricity to power conventional a
24、ctuators an air compressor will be needed if no air line is present in the room. Depending on the size of the compressor, noise may be obstructive to the concentration of the pilot. Load cells will be needed to calibrate the actuators. In addition a study of engineering static and dynamic study will
25、 be done to find the optimal location for mounting the actuators. A CAD schematic of the assembly will be done as well.In order to accurately depict a UH-60 flight simulator companies will be contacted that already produce simulators. One such company is L-3 Communications based out of Arlington, Te
26、xas. Also the possibility of implementing the actual control systems from a UH-60 Blackhawk helicopter will be researched. Companies that will be contacted are Boeing, Sikorsky (producer of the UH-60), and Curtiss-Wright Corporation (producer of mechanical control systems for aircraft applications).
27、 Computational Tools needed: Hardware needed:Solidworks Load Cells for calibrationEngineering Dynamics Digital Readout for load cellsFinite Element Analysis ActuatorsFigure 2: Pneumatic actuatorSolution 2: Electric Linear ActuatorIn contrast to what was stated in solution 1, electric linear actuator
28、s stand as a different approach in attacking the problem. In using an electromechanical linear actuator a few more considerations must be included. In implementing this type of actuator there are a more mechanical parts as it operates on the use of ball or Acme screws to produce force and positionin
29、g. The force able to be applied is comparable to a pneumatic actuator. The cost involved initially would be less, but the ability to control a localized neutral position would be more complex. The principle of the electromechanically actuator will be the same as that stated in solution 1 except for
30、power and precision. Power for an electric actuator will simply require a conventional outlet. No need to buy any other additional hardware for power. Noise will be significantly reduced. The actuators can be easier to fine tune in terms of precision. A computer could probably used to take care of t
31、his. On the other hand response time to the electromechanically actuators will be significantly slower than pneumatic. Load cells will still be needed to find the correct forces in terms of calibration. Engineering static and dynamic study will help determine the optimal position of the actuators. I
32、n addition a CAD drawing will be done to show exactly how and where the actuators will be mounted.Companies to contact will encompass the ones used in finding suitable electromechanical actuators found in solution 1. Computational Tools needed: Hardware needed:Solidworks Load Cells for calibrationEn
33、gineering Dynamics Digital Readout for load cellsFinite Element Analysis ActuatorsFigure 4: Electromechanical actuatorSolution 3: Buy an entire simulation systemThere are companies that are capable of delivering complete simulation systems. Force feedback systems are some of the standard features. M
34、ost can be bought with complete motion base systems that are capable of delivering realistic flight dynamics. Companies such as Advanced Simulation Systems and L-3 Communications specialize in full package simulation systems. Although this may seem like the easiest avenue to a solution the cost may
35、be too great. Such systems are extremely reliable and sophisticated. In addition, they are extremely expensive. Computational Tools needed: Hardware needed:None Full Simulation PackageFigure 4: Full simulator motion base packageFigure 5: Image of a full package simulatorDELIEVERABLES Objectives to b
36、e accomplished:Construction1. At least one axis on the control stick will be powered, calibrated, and tested Neutral point of control stick will be able to be reentered in that axis (one direction) Forces can be put on the stick but only in one direction (Appendix B) Force trim controls will be cons
37、tructed but will operate in one direction2. Will not be responsible for computer interfacing Force-feed back will be demonstrated but will not be interfaced to the computer software Force trim will not be interfaced to computer softwareDocumentation Schematics will include a CAD drawing Detailed assembly scheme will be provided (to clone the other axis(s)If Time Permits The mounting of the actuators will be cloned for all axis A motion base with pivotal movement will be constructed Actually incorporate the force feed back system into the simulationAPPENDIX A:Preliminary Gantt Chart:
