Connecticut Corsair Senior Design

Connecticut Corsair Senior Design

Simulator RefurbishmentEE Design Team 194

2


Problem Statement SummaryIn 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engineering students are reengineering the base of an outdated flight simulator to have movements characteristics akin to that of a Corsair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


Previous WorkPros/Cons of Induction vs. Servo Motors

SERVO MOTORS INDUCTION MOTORSSmall LargeIntegrated Encoder Encoder SeparateLow Run Temperature High Run TemperatureEasier to Prototype Hard to Develop PrototypeEfficient Less EfficientExpensive CheaperServo drives are expensive VFDs are less expensiveArduino compatible Arduino compatible

4/15


Previous WorkIdeal Motor Specifications

in-lb =13.7 ft-lb

**

OLD SPECIFICATIONS NEW SPECIFCATIONS

RPM: 26 RPM: 65

Torque Out: 1212 in-lbs Torque Out: 3484.1 in-lbs

Gear Ratio: 63:1 Gear Ratio: 21:1

**4.7hp non-standard. 5hp required.**

5/15


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 InterfacingComponents include...

- Motor,- Arduino- VFDs- Protective circuitry, i.e: relays- Computer- Joystick inputs

Arduino Sketch development- Function documentation and specifications


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


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


Current Work:Rewire VFDs


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.


Current Work:Arduino Sketch Development Thus Far

• Interfacing with Servo drive

• shipment estimated between 3/14 and 3/22

• Actual position controlled induction motors.


Current WorkWhat’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


Current WorkAbsolute Encoder

• Lockheed Martin’s Prepar3D Academic v 1.4.4747.0

• 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


Current WorkSimulation Software: Prepar3D


Timeline2/24/2014 3/3/2014 3/10/2014 3/17/2014 3/24/2014 3/31/2014 4/7/2014 4/14/2014 4/21/2014

Zach MoschRun 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 previous Testing Testing

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 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 previous Servo motors Help with servo setup

Incorporate servo position info with encoder feedback from other motors

Testing Testing


High Level Joystick Motor Diagram

=Arduino Sketch


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

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Questions?

Documents

Connecticut Corsair Senior Design