Motion Simulator.

This invention relates to using machined spheres to form "spherical ball-joints" and additionally, ball screws, ball nuts, low voltage motors and a counter reactive mechanical device to achieve the inventions practical application as a motion simulator providing 120 degrees of movement in the two major axis of "Pitch and Roll", 45 degrees of "Yaw" and allowing "6-directions of freedom" hereinafter termed "6-DOF".

Generally and whilst the qualified Commercial Pilot (CPL) undertakes higher training such as Airline Transport Pilot (ATPL) ₁ the airline industry introduces motion simulators in order to evaluate, monitor and assess certified and pre- certified personnel, their capabilities without risk to "man and machine". These "high-end" simulation machines provide "6-DOF" with motion derived through hydraulic forces, cylinders, pumps, electromagnetic solenoid valves thus the associated complexity of design and high financial costs, do not allow introduction of these motion simulation machines into the initial, primary assessment of abilities, capabilities of prospective Private Pilots (PPL) in General Aviation or indeed those undertaking initial training and assessments as Commercial Pilots (CPL).

This invention does not require the usage of complex and expensive hydraulic or pneumatic components to achieve "6-DOF" thus the invention allows for 'low cost" assessment of prospective pilots, their physical abilities, aptitude and mental-status prior to their or family's significant financial investment in course fees and airborne training.

The invention proposes a motion simulation machine having "6-DOF" and 120 degrees of movement about its central spherical pivot, employing low voltage motors to achieve controlled rotation of ball screws within captive ball nuts, whilst allowing the ball screws to longitudinally self-centre. The invention allows proportionality usually associated with electronic gearing through usage of "spherical ball-joints", their counter rotational forces being restricted. Motor control is achieved through a programmable controller with voltage inputs in the form of "signals" being through a Human Interface Device (HID) namely a "joystick".

The invention uses an additional motor, independently controlled and devoid of any relationship to the aforementioned major axis of "Pitch & Roll", to achieve 45 degrees of "Yaw" within any such degrees of arc the major axis may take.

The bearing plates encasing the central spherical pivot and those encasing the upper and lower "spherical ball-joints" contain such re-moveable plates that allow eradication of frictional wear as would occur from time to time.

Additionally and as per necessity, the bearing plates are individually "matched marked" to their respective sphere thus interchangeable as full assemblies only.

The invention allows the upper bearing plates to "tilt" proportionally upon and to any increase or decrease in the free distance between the lower "spherical ball- joints" and that of the ball nuts encased in the upper "spherical ball-joints".

The spheres forming the "spherical ball-joints" within the upper and lower bearing plates, allow their respective ball screw or ball nut, angular freedom within the bearing plates thus assuring proportionality of movement within the invention.

Within the bearing plates, the invention uses a counter reactive "hardened peg", "bearing" and track" to restrict rotation of the sphere within the "spherical ball- joint" that would naturally occur upon motor rotation.

The invention uses another motor through a conventional "rack & pinion" arrangement to vertically lift and lower the central spherical pivot.

The invention will now be described by reference to the accompanying drawings and by explanation of how the invention may be performed.

Figure No 1 shows a cross sectional view of the bearing plates encasing an upper "spherical ball-joint" the central location of the re-moveable plates, ball nut and that of the counter reactive "hardened peg", "bearing" and "track" sunken into the surface of the sphere.

Figure No 2 shows the frontal view of the bearing plates encasing an upper "spherical ball-joint" and the elliptical shape of the "track" as sunken into the surface of the sphere.

Figure No 3 shows an upper "spherical ball-joint" assembled into a set of "slotted arms". The invention requires two sets of "slotted arm" assemblies to be mounted at 90 degrees apart, secured to and extending from the bearing plates encasing the central spherical pivot.

95 Figure No 4 show a cross sectional view of an upper "spherical ball-joint" within a set of "slotted arms".

Figure No 5 shows a cross sectional view of a lower "spherical ball-joint", its 100 internal components and bearing plates thereof. The invention uses two of these assemblies being opposed at 90 degrees, to secure the low voltage motors and their coupling to the ball screws which in turn transfer their rotational force to the ball nuts encased within the upper "spherical ball-joints".

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Figure No 6 is the cross sectional view showing the central spherical pivot, its support, upper and lower bearing plates and the inventions mechanism to achieve 45 degrees of "Yaw" independently of the invention's other major axis of "Pitch & Roll" and that of "Lift & Descend".

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Figure No 7 shows the inventions general arrangement, it's directions of movement around the central spherical pivot and the location of the low voltage motors. 115

In Figure No 1 the configuration of the upper "spherical ball-joint" for which there are two of per invention opposed at 90 degrees, allows for the encasement and captivation of a ball nut (6) whilst allowing and retaining its ability to turn through

120 an included angle of 120 degrees after which physical contact occurs between the internal edges of the bearing plates (1 & 3) and ball screw's (12) outer circumference. The bearing plates (1 & 3) replicate the outer radius of the sphere allowing for clearances measurable in microns, upon these clearances becoming excessive then the invention allows for the removal of plates (2) thus the

125 elimination of frictional wear which may occur from time to time.

There is a necessity for the bearing plates (1 & 3) and their corresponding sphere (13) to be "matched marked" hence two of dowels (5) are located 180 degrees apart, between the spherical ball (13) and the barrel bolts (4) securing the assembly. The ball nut (6) firmly secured by cap-head screws (11) converts the

130 ball screw's (12) rotary motion into linear motion and thus the subsequent rise or fall of the bearing plates (1 & 3) within the invention. In order to oppose the rotary movement induced into the sphere (13) a "hardened peg" (9) is inserted through the bearing plates (1 & 3) internally securing a "bearing" (7) sunk into a designed, elliptical "track"

135 (10). The bearing (7) does not have contact with the sub-surface of the "track" (10) but acts upon the elliptical edge of the "track-way" corresponding to the position of the sphere (13) thus the angle of the ball screw (12). The "hardened peg" (9) is retained by a plate (8) and two of cap-screws.

In Figure 2 the frontal view of a "spherical ball-joint" is depicted as is the elliptical "track-way" (10) and "bearing" (7) which counters and oppose the rotational force applied to the sphere through the ball nut's (6) conversion of the ball screw's rotary motion into linear motion.

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In Figure No 3 an upper "spherical ball-joint" has been assembled into a set of "slotted arms" (14 & 15) with these "slotted arms" subsequently being securely fitted to the upper bearing plates encasing the invention's central spherical pivot.

150 Four of roller bearings (17) have now been fitted to "axles". (18) sunken into the sides of the bearing plates (1 & 3) thus allowing the complete assembly free movement along the arm's internal slot's (16).

With the usage of four roller bearings (17) and providing them free movement within the internal "slots" (16) the upper "spherical ball-joint" can achieve

155 longitudinal travel thus the "arc" at which the tip or uppermost point of the ball screw (12) travels during rotation is radically reduced whilst maintaining proportionality of movement within the invention.

160 In Figure No 4 it will be seen that the addition of four roller bearings (17) within the "slotted arms" has no effect on the position of the ball nut (6) within the sphere (13) hence included angular movement of 120 degrees remains.

In Figure No 5 it will be noted that basic construction and principle of a lower

165 "spherical ball-joint" follows that of an upper "spherical ball-joint" as described at Figures 1 & 2. The sphere (19) is retained by bearing plates (22 & 24) machined internally to replicate the sphere's outer circumference. Both upper and lower bearing plates (22 & 24) are "matched marked" through the usage of two dowels (25) at 180 degrees apart, positioned between the plate's six of cap head screws

170 (20) securing the assembly and the joint (19). Removable plates (23) allow for eradication of frictional wear between sphere (19) and bearing plates (22 & 24) whilst four of drillings (21) allow the assembly to be firmly "bolted" to a set of arms affixed to the support of the central spherical pivot. Notwithstanding, this sphere (19) encases the outer-race of ball screw's bearings

175 (26) but allows free-rotation of the ball screw (12) now being attached to it's upper coupling (31). A bi-directional low voltage motor (29) along with its corresponding free-rotating coupling (30) is fitted against a machined mounting plate (27) which also serves to retain the ball screw' bearings (26) and restrict the screw's end-float during rotation. The machined mounting plate, which secures

180 the motor through bolts (28), is itself secured within the sphere through sunken cap head screws (36) with this feature thus allowing for adjustment to the bearing's (26) pre-load and air-gap between the two halves of the motor coupling.

In order to counter rotation of the sphere (19) and as principally used within the 185 upper "spherical ball-joints", a plate along with cap head screws (32) secures a "hardened peg" (33), inserted through the bearing plates (22 & 24), internally securing a "bearing" (34) sunken into a designed, elliptical "track" (35). The "bearing" (34) does not have contact with the "tracks" (35) sub-surface but acts upon the elliptical edge of the "track-way" corresponding to the position of the 190 sphere thus the angle of the ball screw.

In Figure No 6 it will be noted that the general arrangement of the captive but not constrained sphere (49) termed "central spherical pivot", between two bearing plates (47 & 50) is as that previously described but obviously larger than, all of

195 those in the aforementioned figures of 1 to 5 inclusive. Notwithstanding and as unique to the central spherical pivot, there is no requirement nor necessity to employ any counter reactive device such as a "hardened peg" or "bearing" within an elliptical "track" or "track-way". Above and directly through the vertical centre passing through the support (48)

200 and central spherical (49), is a raised "king-post" (37) or otherwise known as "centre-post", mounted to the upper and lower bearing plates (47 & 50) at a distance and clear of the central sphere's upper surface. This "king-post" allows for fitment of a roller bearing (38) at the centre of a plate (40) hereinafter termed the "Yaw-plate", thus and when outwardly supported in the horizontal by a thrust

205 bearing (41), rotational movement around the "king-post" is achieved in any arc or "tilt" the bearing plates (47 & 50) may encounter upon their movement around the central sphere (48) - the pivot point.

As established, the newly termed "Yaw-plate" (40) is "free to rotate". Hence and once the central bearing (38) is made captive by an adjustable nut (39) and with

210 a low voltage motor (42) being assembled upon the "Yaw-plate, it can now provide the inventions source of controlled rotation; that of 45 degrees of "Yaw" upon the motor being fitted with a "pinion" (45) that subsequently engages with and into a matching radial "rack" (46). A machined housing (43) provides stability upon pinion rotation and provides

215 "lands" to affix the pinions lower bearings (44).

At the lower of Figure No 6 is the inventions mechanism that achieves "Lift & Descent" that being a conventional "rack" (51) and "pinion" (54). Rotation of the pinion is achieved through the usage of a controllable low voltage motor (55) whilst counter rotation of the spheres support (48) is averted by insertion of a key

220 (53) into a key-way (52) constrained within the supports (48) outer casing.

In Figure No 7 the inventions movement, 6-DOF around the central spherical pivot is depicted by the "block arrows". The low voltage motor depicted at the 225 lower-right and to the forefront, provides the bi-directional rotary force allowing the inventions 120 degrees of "Pitch" whilst the other bi-directional motor (29), mounted rearwards and set opposed by 90 degrees, provides the rotary force for 120 degrees of "Roll". Low voltage motor (42) provides the rotary force for 45 degrees of "Yaw" whilst motor (55) provides "lift and descent".