Motion simulation system and method

Abstract

Various embodiments described herein include methods, devices, and systems for motion simulation. In one aspect, a motion simulation system includes a load-bearing actuator and a positioning actuator assembly. The load-bearing actuator includes a cylinder defining a cavity and a piston rod disposed at least partially in the cavity of the cylinder. The first end of the piston rod and the cavity of the cylinder define a volume of the cylinder, and the volume of the cylinder is configured to be pressurized to support a weight of a load. The positioning actuator assembly includes a positioning actuator having a stator and a rotor, and a connecting rod. The connecting rod is connected with the rotor. The rotor is configured to rotate to translate the link and position a load supported by the load-bearing actuator.

Description

[0001] Citation of Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 308,421, filed on February 9, 2022, the disclosure of which is hereby incorporated by reference herein. Technical Field

[0003] The present disclosure relates to motion simulation systems, including but not limited to motion simulation systems including a platform assembly and configured to move in multiple degrees of freedom. Background Art

[0004] Motion simulation systems include multiple platforms used to support and enable physical motion for participants in amusement rides and simulation products (e.g., video games). Such systems are designed to provide physical motion to participants in movies or computer simulation / gaming activities. The Stewart platform (or hexapod platform) is a well-known simulator that enables the platform to move relative to a base.

[0005] In some applications, the hexapod platform includes six linear actuators that are arranged to move the platform relative to the base in six degrees of freedom, specifically three linear degrees of freedom and three rotational degrees of freedom, depending on which actuators are used in combination. The translational degrees of freedom are typically referred to as sway (horizontal motion along the direction of travel), sway (horizontal motion perpendicular to the direction of travel), and heave (vertical motion). The rotational degrees of freedom are referred to as roll (rotation about an axis parallel to the direction of travel), pitch (rotation about a horizontal axis perpendicular to the direction of travel), and yaw (rotation about a vertical axis).

[0006] In some applications, the hexapod platform may have a limited workspace, which is defined by the maximum and minimum excursions of the platform and further defined by the travel limitations of the actuators. For large workspaces that require further platform motion in any given degree of freedom, some systems use longer actuators, but such longer actuators may significantly increase the cost of the simulator and may also reduce the inherent stiffness of the simulator. In addition, some existing motion simulation systems may use expensive industrial-grade components, further increasing the cost of the simulator. In some applications, the main cost driver of existing motion simulation systems is the motion actuator subsystem, which includes the drive elements (servomotors), associated gear reduction elements, and associated feedback and control systems. Summary of the invention

[0007] Therefore, there is a need for a motion simulation system that has improved motion control and capabilities (eg, higher frequency response) while also having a lower manufacturing cost.

[0008] The present disclosure describes a motion simulation system for initiating physical motion for entertainment and simulation purposes. In some embodiments, the motion simulation system includes one or more load bearing actuators and one or more positioning actuator assemblies.

[0009] The motion simulation system includes a plurality of load-bearing actuators and a plurality of positioning actuator assemblies. In various embodiments, the motion simulation system may include twice the number of positioning actuator assemblies as the load-bearing actuators. In some embodiments, the motion simulation system may include three load-bearing actuators and six positioning actuator assemblies. In some embodiments, one end of a load-bearing actuator may be adjacent to one end of the first and second positioning actuator assemblies. The motion simulation system may allow six degrees of freedom.

[0010] The motion simulation system may include a platform that may be connected to a load-bearing actuator and a positioning actuator assembly.

[0011] In some embodiments, the load-bearing actuator may include a buffer tank. The buffer tank may provide or define a dead volume. The buffer tank may be in fluid communication with the cylinder. The buffer tank may increase the dead volume of the load-bearing actuator. For example, the dead volume may be approximately 100%-500% of the swept volume of the cylinder. In some embodiments, the cylinder may be filled by swinging the piston rod.

[0012] In some embodiments, the positioning actuator assembly includes a crank pivotally connected to the rotor and the connecting rod. The crank may be integrally formed with the rotor.

[0013] In some embodiments, the load-bearing actuator and the positioning actuator assembly are at least partially disposed within a linear drive housing. A connecting rod of the positioning actuator assembly may be connected to a piston rod of the load-bearing actuator. In some embodiments, one end of the connecting rod is pivotally connected to the piston rod between the first end and the second end of the piston rod.

[0014] In some embodiments, the motion simulation system includes a controller for controlling the operation of the load-bearing actuator and the positioning actuator. In various embodiments, the controller is capable of detecting the current consumption of the positioning actuator. In some embodiments, the controller is configured to pressurize the volume of the cylinder to a pressure to minimize the current consumption of the positioning actuator. In various embodiments, the controller is configured to control the operation of the positioning actuator at a frequency close to about 1000 Hz.

[0015] In various embodiments, the controller of the motion simulation system can compare the rotational position of the positioning actuator with the desired rotational position of the positioning actuator to perform closed-loop control of the motion simulation system. In some embodiments, the controller can adjust the gain factor based on the comparison of the rotational position of the positioning actuator with the desired rotational position of the positioning actuator.

[0016] In some embodiments, the motion simulation system includes an electrical energy storage device for receiving energy generated by the positioning actuator and deploying the energy into the motion simulation system.

[0017] As previously mentioned, some traditional motion simulation systems can be expensive and can have relatively low frequency response and inherent stiffness. The present disclosure includes embodiments that can improve motion control, increase frequency response, and increase inherent stiffness while providing lower component and manufacturing costs. Embodiments of the present disclosure can use a direct drive actuator arrangement and eliminate gear reduction elements. In addition, embodiments of the present disclosure can use rotary or linear encoders to provide additional control for non-servo motors. In addition, embodiments of the present disclosure can allow forced ventilation of the actuator to increase cooling.

[0018] In one aspect, some embodiments include a motion simulation system comprising a load-bearing actuator and a positioning actuator assembly. The load-bearing actuator includes a cylinder defining a cavity and a piston rod at least partially disposed in the cavity of the cylinder, wherein a first end of the piston rod and the cavity of the cylinder define a volume of the cylinder, and the volume of the cylinder is configured to be pressurized to support the weight of a load. The positioning actuator assembly includes a positioning actuator, the positioning actuator including: a stator, a rotor configured to rotate relative to the stator, and a connecting rod connected to the rotor, wherein the rotor is configured to rotate to translate the connecting rod and position the load supported by the load-bearing actuator.

[0019] On the other hand, some embodiments include a motion simulation system, the motion simulation system comprising: a base; a platform movable relative to the base and configured to support a load; a plurality of load-bearing actuators; and a plurality of positioning actuator assemblies. Each load-bearing actuator includes: a cylinder pivotally connected to the base, wherein the cylinder defines a cavity; and a piston rod having a first end and a second end, wherein the first end is at least partially disposed in the cavity of the cylinder to define a volume of the cylinder, and the second end is pivotally connected to the platform, and the volume of the cylinder is configured to be pressurized to support the platform. Each positioning actuator assembly includes: a positioning actuator connected to the base, the positioning actuator including: a stator and a rotor configured to rotate relative to the stator; and a connecting rod including a first end pivotally connected to the rotor and a second end pivotally connected to the platform, wherein the rotor is configured to rotate to translate the connecting rod and position the load supported by the plurality of load-bearing actuators.

[0020] On the other hand, some embodiments include a method for operating a motion simulation system, the method comprising: applying pressure to a plurality of load-bearing actuators to support a platform relative to a base; and moving the platform by rotating a plurality of positioning actuators of a corresponding plurality of positioning actuator assemblies, wherein each positioning actuator assembly is pivotally connected to the platform via a corresponding connecting rod of the plurality of positioning actuator assemblies.

[0021] In another aspect, some embodiments include an apparatus for performing any of the methods described herein. In another aspect, some embodiments include a non-transitory computer-readable storage medium storing one or more programs, wherein the one or more programs include a plurality of instructions that, when executed by a system, enable the system to perform any of the methods described herein.

[0022] Thus, systems and methods are provided for simulating motion with more efficient motion control while reducing component and manufacturing costs, thereby improving the performance of these systems and devices and reducing the overall cost of these systems and devices. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] For a better understanding of the various embodiments described, reference will be made to the following detailed description taken in conjunction with the following drawings, wherein like reference numerals refer to corresponding parts throughout.

[0024] Figure 1 is a perspective view of a motion simulation system with a load, according to some embodiments.

[0025] Figure 2 is a perspective view of a motion simulation system according to some embodiments.

[0026] Figure 3According to some embodiments Figure 2 A perspective view of the load-bearing actuator of the motion simulation system in FIG.

[0027] Figure 4 According to some embodiments Figure 2 Cross-sectional view of the load-bearing actuator of the motion simulation system in FIG.

[0028] Figure 5 According to some embodiments Figure 2 A perspective view of a positioning actuator assembly of a motion simulation system in FIG.

[0029] Figure 6 According to some embodiments Figure 5 A stereoscopic view of a positioning actuator of a positioning actuator assembly in FIG.

[0030] Figure 7 According to some embodiments Figure 5 A perspective view of a positioning actuator of a positioning actuator assembly in FIG.

[0031] Fig. 8A is a perspective view of a motion simulation system according to some embodiments.

[0032] Figure 8B According to some embodiments Fig. 8A Side view of the positioning actuator assembly of the motion simulation system.

[0033] Figure 8C is a perspective view of a motion simulation system according to some embodiments.

[0034] Fig.8D According to some embodiments Figure 8C Side view of the positioning actuator assembly of the motion simulation system.

[0035] Fig. 8E is a perspective view of a positioning actuator assembly according to some embodiments.

[0036] Fig. 9 is a perspective view of a motion simulation system with a load, according to some embodiments.

[0037] Fig.10 is a perspective view of a motion simulation system according to some embodiments.

[0038] Figures 11A-11G are perspective views of a motion simulation system according to some embodiments.

[0039] Fig.12 is a perspective view of a motion simulation system according to some embodiments.

[0040] Fig.13 According to some embodiments Fig.12 A perspective view of the integrated linear actuator unit of the motion simulation system.

[0041] Fig.14 yes Fig.13 Side view of the integrated linear actuator unit in.

[0042] Fig.15 According to some embodiments Fig.13 A perspective view of a load-bearing actuator with an integrated linear actuator unit.

[0043] Fig.16 is a perspective view of a motion simulation system according to some embodiments.

[0044] Fig.17 is a perspective view of a haptic device according to some embodiments.

[0045] Fig.18 yes Fig.17 Side view of the haptic device in. DETAILED DESCRIPTION

[0046] The present disclosure describes various embodiments of motion simulation systems. In some embodiments, the motion simulation system includes a plurality of load-bearing actuators and a plurality of positioning actuators, such that the load-bearing actuators support the weight of the load, thereby minimizing the weight that the positioning actuators need to support. In some applications, the use of load-bearing actuators allows the use of direct-drive positioning actuators. Advantageously, by minimizing the weight that the positioning actuators must support, embodiments of the motion simulation system are able to use smaller and cost-effective actuators that provide the desired range of motion and degrees of freedom (e.g., six degrees of freedom) while providing improved motion control and high frequency response (up to 1000 Hz in some embodiments).

[0047] Figure 1 is a perspective view of a motion simulation system 100 with a load 10 according to some embodiments. Figure 2 is a perspective view of a motion simulation system 100 according to some embodiments. Figure 1 and Figure 2, the motion simulation system 100 supports and / or positions a load 10 relative to a base 110 to provide motion information, signals or other feedback to a user. In some embodiments, the load 10 may include, but is not limited to, a user, a seat, and / or hardware. In some embodiments, the hardware device may include, but is not limited to, automotive simulation hardware (e.g., a steering wheel and multiple pedals), aviation simulation hardware or other suitable hardware devices. In some applications, the load 10 may exceed 100 kilograms. Although various embodiments of the motion simulation system may carry or move heavier loads than some traditional motion simulation systems, the load capacity of an embodiment of the motion simulation system may vary with the size and configuration of the motion simulation system.

[0048] As shown, the platform 120 is capable of supporting and positioning the load 10 relative to the base 110. In the example shown, the platform 120 includes one or more legs 122, which are shaped, bent or otherwise configured to receive, cradle or otherwise support the load 10. Portions of the load 10 can be attached or fixed to the plurality of legs 122 of the platform 120. The legs 122 or other features of the platform 120 can be suitable for any suitable load 10. In some embodiments, the platform 120 can be of any suitable shape or configuration. For example, the platform 120 can have a planar shape, such as a disk, to allow a flat surface to support the load 10. In some embodiments, the shape of the platform 120 can be symmetrical or asymmetrical, and can be varied in other ways.

[0049] In the example shown, the base 110 is capable of supporting the weight of the platform 120 and the load 10, as well as other components of the motion simulation system 100. As shown, the base 110 can have a generally hexagonal shape. In some embodiments, the shape of the base 110 can be symmetrical or asymmetrical, and can vary in other ways.

[0050] As described herein, one or more load bearing actuators 130 can support the weight of the platform 120 and the load 10 relative to the base 110. Additionally, one or more positioning actuator assemblies 140 can move or position the platform 120 and the load 10 relative to the base 110.

[0051] Figure 3 According to some embodiments Figure 2 A perspective view of a load-bearing actuator of the motion simulation system 100 in FIG. Figure 4 According to some embodiments Figure 2 A cross-sectional view of a load-bearing actuator of the motion simulation system 100 in FIG. Figure 1-4Each load bearing actuator 130 is capable of supporting the platform 120 and the load 10 in a desired posture relative to the base 110. In the illustrated example, during normal operation, the load bearing actuators 130 support the platform 120 and the load 10 without affecting the position of the platform 120.

[0052] In the illustrated example, a load bearing actuator 130 is connected to the platform 120 and the base 110. As shown, one end of the load bearing actuator 130 is connected to the base 110 and the opposite end 136 of the load bearing actuator 130 is connected to the platform 130. In some embodiments, the end 136 can be connected to the end 124 of the leg 122 or other suitable part of the platform 120. In some embodiments, the position of the joint, connector or end 136 of the load bearing actuator 130 relative to the platform 120 and / or the base 110 can be coplanar, non-coplanar, symmetrical, asymmetrical, or can vary in other ways. In some embodiments, the end 136 can be pivotally connected to the base 120 and the platform 120. The end 136 can include a ball joint.

[0053] Before the motion simulation system 100 operates normally, the load-bearing actuator 130 can be extended to a desired length to act as a leg or otherwise support the platform 120 and the load 10 in a desired posture. In the example shown, the load-bearing actuator 130 is a pneumatic actuator that uses air pressure to extend and support the platform 120 and the load 10 in a desired posture. In some embodiments, the pneumatic actuator includes a piston rod 134 that is movable relative to the cylinder 132.

[0054] As shown, the first end of the piston rod 134 is at least partially disposed in the cavity of the cylinder 132 to define a cylinder volume 133. During operation, the cylinder volume 133 can be pressurized to advance the piston rod 134 and support the platform 120. As described herein, the pressure of the cylinder volume 133 can be adjusted to adjust the position of the piston rod 134 relative to the cylinder 132 and to support various load weights, platform heights and / or postures. In some embodiments, the second end 136 of the piston rod 134 is connected to the platform 120. In some embodiments, the second end 136 of the piston rod 134 can have a stroke of about 100mm-200mm. In addition, in some embodiments, the diameter of the piston rod 134 is about 30mm-50mm, and a force of about 500-1500N can be applied.

[0055] In some embodiments, the cylinder 132 can be pressurized by a pneumatic control circuit. The pneumatic control circuit may include a compressor for pressurizing the cylinder volume 133 to a desired pressure through port 139. The pneumatic control circuit can introduce, release, or otherwise control the pressure in the cylinder volume 133 through port 139. In some embodiments, the motion simulation system 100 can be capable of self-pressurizing the pneumatic actuator by using the piston rod 134 as a pump element. During self-pressurization or without a compressor, the positioning actuator assembly 140 can move the platform through a series of suitable postures (e.g., vibrating the platform 120 along a vertical axis or a heave axis) and selectively drive the control elements of the pneumatic control system to vibrate the piston rod 134 connected to the platform 120, thereby pressurizing the cylinder volume 133 to a desired pressure. In some embodiments, the cylinder 132 may include a one-way valve to allow air to enter the cylinder volume 133 and be compressed through the piston rod 134 during self-pressurization without escaping the cylinder volume 133.

[0056] In some applications, the state or extension of the weight bearing actuators 130 for supporting the platform 120 and the load 10 in a desired attitude relative to the base 110 may be determined by a calibration process. For example, the calibration process may determine and provide the required pressure of the cylinder volume 133 of each weight bearing actuator 130 to support the platform 120 and the load 10 in a desired attitude relative to the base 110. In some embodiments, the weight bearing actuators 130 may be calibrated to support the platform 120 and the load 10 in an attitude that allows the motion simulation system 100 to move the platform 120 through a desired range of motion, which attitude may be located at the center of the motion envelope of the motion simulation system 100. In some embodiments, the weight bearing actuators 130 may be calibrated to support the platform 120 in an attitude that is offset from the center of the motion envelope of the motion simulation system 100. For example, the weight bearing actuators 130 may be calibrated to support the platform 120 at a position above or below the center of the motion envelope of the motion simulation system 100.

[0057] In some embodiments, the calibration process may begin by placing the platform 120 in static equilibrium in a pre-selected pose, which may be referred to as a zero position pose, using the positioning actuator assembly 140. As described herein, the controller may determine the weight of the platform 120 and the supported load 10 by detecting the load borne by the positioning actuator assembly 140. In some embodiments, the load on the positioning actuator assembly 140 may be determined by a current feedback signal analyzed by the controller.

[0058] After determining the weight of the platform 120 and any supported load 10, the cylinder volume 133 of each corresponding load bearing actuator 130 can be pressurized to minimize the load experienced by the positioning actuator assembly 140. In some embodiments, the minimum value of the current signal from the positioning actuator assembly 140 can be used as feedback for closed-loop control of the pressurization of the load bearing actuator 130. As described herein, the load bearing actuator 130 can be pressurized using a pneumatic circuit (i.e., a compressor) or can be self-pressurized through vibration of the platform 120.

[0059] In some embodiments, after the calibration process, the pressure of the cylinder volume 133 of each corresponding load-bearing actuator 130 is constructed as a balanced pressure to support the platform 120 and the load 10 in the desired posture. Similarly, the stroke of the piston rod 134 relative to the cylinder 132 of each corresponding load-bearing actuator 130 can be constructed as a balanced distance or stroke to support the platform 120 and the load 10 in the desired posture. The balanced pressure and stroke can be varied between each load-bearing actuator 130. After calibration, each load-bearing actuator 130 can be separated from the pneumatic circuit gas. Advantageously, since the weight of the platform 120 and the load 10 is supported or offset by the load-bearing actuator 130, the calibrated load-bearing actuator allows the motion simulation system 100 to maintain a zero position posture with minimal torque (and power) from the positioning actuator assembly 140.

[0060] In some applications, some pneumatic actuators may apply different forces based on the position of the piston rod within the variable volume or swept volume of the actuator. For example, without considering the effects of temperature, some pneumatic actuators may apply a smaller driving force when the piston rod is extended because the cylinder volume increases and the pressure decreases, and apply a larger driving force when the piston rod is retracted because the cylinder volume decreases and the pressure increases. In some pneumatic actuators, the force applied by the actuator may be inversely proportional to the piston position.

[0061] In some embodiments, the load bearing actuator 130 can provide a relatively large non-variable volume or dead volume compared to the variable working volume of the cylinder 132 and the piston rod 134 to minimize the pressure change and thus the change in the driving force when the piston rod 134 passes through its stroke. In the illustrated example, the load bearing actuator 130 includes a buffer tank 138, which is in fluid communication with the cylinder 132 to provide additional dead volume for the cylinder 132. As shown, the dead volume of the buffer tank 138 can be in fluid communication with the cylinder volume 133 through port 139. Advantageously, because the dead volume of the buffer tank 138 is significantly larger than the variable volume of the cylinder volume 133, the overall pressure change of the load bearing actuator 130 is minimized (i.e., the total volume of the buffer tank 138 and the cylinder volume 133) when the cylinder volume 133 changes, and similarly, the change in the force provided by the load bearing actuator 130 is also minimized. In some embodiments, the dead volume of the surge tank 138 is 100%-500% of the variable working volume of the cylinder volume 133 .

[0062] In some embodiments, the weight bearing actuator 130 can provide mechanical damping between the moving and fixed parts of the motion simulation system 100. In some embodiments, the magnitude of the damping effect can be adjusted by controlling the air flow rate between the buffer tank 138 and the extension chamber of the cylinder 132 and / or between the retraction chamber of the cylinder 132 and the environment. In some embodiments, the air flow rate can be adjusted during operation to dynamically adjust the magnitude of the damping effect provided by the weight bearing actuator 130. In addition, the weight bearing actuator 130 can act as a spring to recover and / or restore energy from the platform 120 and the load 10.

[0063] In some embodiments, the load-bearing actuator 130 can be an active or passive device, and other types of actuators can be used, including but not limited to gas struts, gas springs, elastic ropes, linear springs, coil springs and / or rotational springs. As described herein, the force applied by the load-bearing actuator 130 is adjustable. For example, certain load-bearing actuators may include adjustable or programmable springs. In some embodiments, the programmable spring may include a series elastic actuator (SEA), which includes an actuator connected to a load via an elastic element (e.g., one or more springs) and a sensor for measuring the degree of force transmitted by the elastic element. A control loop can be programmed to produce a system that can apply a specified force to a load and cause the actuator to act like a spring with a desired stiffness.

[0064] In some embodiments, the force applied by the load bearing actuator 130 may be pre-set or not easily adjustable. For example, some load bearing actuators 130 may be configured to hold a load and may be initially adjusted or manufactured to provide an appropriate load bearing force. In some embodiments, some load bearing actuators 130 may be configured to hold a load and may be initially adjusted or manufactured using a calibration process similar to that described herein.

[0065] As described herein, the weight bearing actuators 130 may be arranged or otherwise disposed in any suitable arrangement relative to the base 110 and the platform 120. For example, the motion simulation system 100 may include twice as many positioning actuator assemblies 140 as weight bearing actuators 130. As shown, the motion simulation system 100 may include three weight bearing actuators 130. The weight bearing actuators 130 may be arranged at equal intervals.

[0066] Figure 5 According to some embodiments Figure 2 A perspective view of the positioning actuator assembly 140 of the motion simulation system 100 in FIG. Figure 5 , each positioning actuator assembly 140 can move or position the platform 120 and the payload 10 in a desired attitude relative to the base 110. In the illustrated example, the positioning actuator assemblies 140 can collectively or cooperatively position the platform in any six-dimensional attitude with respect to surge, sway, heave, yaw, pitch, and roll in the motion space envelope of the motion simulation system 100.

[0067] In the illustrated example, the positioning actuator assembly 140 is connected to the platform 120 and the base 110. As shown, the positioning actuator 150 can be connected to the base 110, and one end 148 of the connecting rod 146 can be connected to the platform 120. In some embodiments, one end 148 of the connecting rod 146 can be connected to the end 124 of the leg 122 or other suitable parts of the platform 120. In some embodiments, the position of the corresponding positioning actuator assembly 140 relative to the end 148 of the platform 120 can be coplanar, non-coplanar, symmetrical, asymmetrical, or can be changed in other ways. In some embodiments, the end 148 of the connecting rod 146 can be pivotally connected to the platform 120 and the positioning actuator 150. The end 148 can include a ball joint. In some embodiments, the position of the positioning actuator 150 of the corresponding positioning actuator assembly 140 relative to the base 110 can be coplanar, non-coplanar, symmetrical, asymmetrical, or can be changed in other ways.

[0068] During operation of the motion simulation system 100, the positioning actuator assembly 140 may extend, retract, translate, or otherwise move the various links 146 to position the platform 120 and the payload 10 in a desired attitude. In the illustrated example, the positioning actuator assembly 140 includes a positioning actuator 150 that is used to manipulate the links 146 and thereby (in conjunction with other positioning actuator assemblies 140) position the platform 120 in a desired attitude.

[0069] In the illustrated example, the positioning actuator 150 rotates the rotor 142 to adjust the position of the connecting rod 146, particularly the position of the connecting rod end 148 pivotally connected to the platform 120. As shown, a connecting rod mechanism, such as a crank 144 connected to the rotor 142, can move or translate the opposite connecting rod end 148 pivotally connected to the crank 144 as the rotor 142 rotates. The rotation of the crank 144 can move or translate the connecting rod 146, and in turn move or translate the connecting rod end 148 connected to the platform 120. In some embodiments, the length or geometry of the crank 144 can be varied to adjust the relationship between the rotation of the rotor 142 and the movement of the connecting rod 146. In addition, in some embodiments, the positioning actuator can include a linear actuator.

[0070] Advantageously, the direct attachment or connection of the connecting rod 146, crank 144, and rotor 142 of the positioning actuator 150 allows a direct drive mechanism or device to adjust the position of the platform 120. In addition, the lack of an indirect or intermediate machine or power transmission element allows the weight and inertia of the platform 120 and load 10 to be directly and immediately transferred to the positioning actuator 150 and improves system stiffness and response, thereby allowing the motion simulation system 100 to reject or overcome both static external disturbances (e.g., when an axis maintains position or velocity) and dynamic external disturbances (e.g., when an axis follows a position or velocity trajectory).

[0071] In certain conventional applications, the use of a direct drive mechanism may require that a conventional positioning actuator directly bear the weight of the platform and load. Thus, in certain applications, even during static balancing, conventional actuators are required to apply a constant torque to balance the weight of the platform and load, increasing energy consumption and actuator requirements. Advantageously, the use of a load-bearing actuator 130 to support the weight of the platform 120 and load 10 enables the use of a direct drive positioning actuator assembly 140 that does not need to directly or continuously bear the weight of the platform 120 and load 10. The use of a load-bearing actuator 130 allows for the use of smaller, lighter, less expensive actuators and other components in the positioning actuator 140 while achieving desired performance, and allows for reduced energy consumption.

[0072] Figure 6 According to some embodiments Figure 5A stereoscopic view of the positioning actuator 150 of the positioning actuator assembly 140 in FIG. Figure 7 According to some embodiments Figure 5 A perspective view of the positioning actuator 150 of the positioning actuator assembly 140 in FIG. Figure 5-7 , the positioning actuator 150 rotates the rotor 142 relative to a stator disposed in a housing of the positioning actuator 150. In some embodiments, the positioning actuator 150 includes a rotary encoder 152 for determining the rotational position of the rotor 142 relative to the stator or other static part of the positioning actuator 150. Generally, the signal from the rotary encoder 152 can be used as feedback for closed-loop control of the positioning actuator assembly 140 and the motion simulation system 100. In some embodiments, the positioning actuator 150 can include a fan 156 for actively cooling the components of the positioning actuator 150. The fan 156 can draw in cool air and exhaust heat through a fan housing 154 formed in the positioning actuator 150.

[0073] As described herein, embodiments of the positioning actuator assembly may include a connecting rod having a ball joint end that allows the connecting rod to pivot or rotate relative to the positioning actuator and the platform while allowing the positioning actuator to control the position of the platform. In some applications, certain ball joints may have a limited rotation angle, potentially limiting the movement of the connecting rod, and thus the movement of the positioning actuator assembly, which may result in limiting the motion envelope of the motion simulation system. For example, certain ball joints may have a rotation angle range of approximately ±10 degrees, ±15 degrees, or ±20 degrees.

[0074] In addition, in some applications, some positioning actuator assemblies are configured so that the motion simulation system cannot use the full range of rotation angles of the ball joint, thereby possibly limiting the motion envelope of the motion simulation system within a given range of rotation angles of the ball joint. For example, some positioning actuator assemblies may be configured so that when the motion simulation system is in a preselected, stationary or zero position attitude, the ball joint end of the corresponding connecting rod is disposed at or located at a midpoint that deviates from the respective rotation angle range. Therefore, in some applications, the ball joint end can rotate more in one direction and less in another direction relative to the zero position attitude. In some applications, the reduced rotation stroke relative to the zero position attitude may limit the overall motion envelope of the motion simulation system.

[0075] Fig. 8A is a perspective view of a motion simulation system 200a according to some embodiments. Figure 8B According to some embodiments Fig. 8A2 is a side view of a positioning actuator assembly 240a of a motion simulation system 200a in FIG. In some embodiments, one or more positioning actuator assemblies 240a are configured to increase the range of motion or motion envelope of the motion simulation system 200a compared to certain conventional motion simulation systems. In some embodiments, the motion simulation system 100 can use actuator assemblies or actuators of other types, configurations, or configurations, as shown in their implementation in other systems.

[0076] In some embodiments, one or more positioning actuator assemblies 240a can be positioned or arranged to avoid limiting or otherwise increase the available range of motion of the connecting end 248a, thereby increasing the range of motion of the positioning actuator assembly 240a and the motion envelope of the motion simulation system 200a. In the illustrated example, the positioning actuator assembly 240a can be positioned so that when the motion simulation system 200a is in a preselected, static or zero position attitude, the ball joint end 248a of the corresponding connecting rod 246a is set or positioned at a position approximately located at or near the midpoint of the respective rotation angle range. In some applications, when the load-bearing actuator 230a is set in a balanced configuration or position, the ball joint end 248a can be configured to be approximately located at or near the midpoint of the respective rotation angle range. By allowing the ball joint end 248a to be set at a position approximately located at or near the midpoint of the respective rotation angle range when the motion simulation system 200a is in the zero position attitude, the ball joint end 248a can rotate an equal amount in all directions relative to the zero position attitude. Advantageously, substantially equal rotational travel relative to the zero-position attitude may maximize the overall motion envelope of the motion simulation system 200a for a given ball joint end 248a.

[0077] In certain embodiments, for a given position or attitude, the position of the ball joint end 248a within the rotation angle range can be adjusted by changing the angle between the horizontal plane and the motor shaft of the positioning actuator 250a, and this angle can also be referred to as the motor dihedral. In the illustrated example, the motor dihedral of the positioning actuator 250a can be adjusted so that when the motion simulation system 200a is in the zero position attitude, the ball joint end 248a can be roughly located at or close to the midpoint of the respective swing angle range. In some applications, the motor dihedral of the positioning actuator 250a can be adjusted so that under the desired attitude, the ball joint end 248a is located at another desired position of the respective rotation angle range. As shown in the figure, the motor dihedral of the positioning actuator 250a can be non-zero and positive. In certain embodiments, the motor dihedral of the positioning actuator 250a can be between about 0.1 degree and about 20 degree.

[0078] In some embodiments, for a given position or attitude, the position of the ball joint end 248a within the rotation angle range can be adjusted by changing the angle between the platform 220 base surface and the ball joint end 248a axis, which angle can also be referred to as the platform dihedral. In the example shown, the platform dihedral of the platform 220a can be adjusted so that when the motion simulation system 200a is in the zero position attitude, the ball joint end 248a can be approximately located at or close to the midpoint of the respective rotation angle range. In some applications, the platform dihedral of the platform 220a can be adjusted so that the ball joint end 248a is located at another desired position of the respective rotation angle range under the desired attitude. As shown in the figure, the platform dihedral of the platform 220a can be non-zero and positive. In some embodiments, the platform dihedral of the platform 220a can be between about 0.1 degrees and about 20 degrees. In some applications, the motor dihedral and the platform dihedral can be identical, similar or complementary. In some applications, the motor dihedral and the platform dihedral can be different.

[0079] Figure 8C is a perspective view of a motion simulation system 200b according to some embodiments. Fig.8D According to some embodiments Figure 8C 2. A side view of a positioning actuator assembly 240b of a motion simulation system 200b. In some embodiments, the motor dihedral angle of the positioning actuator 250b can be non-zero and negative. In some embodiments, the motor dihedral angle of the positioning actuator 250b can be between about 0.1 degrees and about 20 degrees.

[0080] In some embodiments, the platform dihedral angle of platform 220b can be non-zero and negative. In some embodiments, the platform dihedral angle of platform 220a can be between about 0.1 degrees and about 20 degrees.

[0081] In some applications, the motor dihedral angle and the platform dihedral angle can be the same, similar, or complementary. In some applications, the motor dihedral angle and the platform dihedral angle can be different. In addition, in some embodiments, the motor dihedral angle and the platform dihedral angle of certain portions of the motion simulation system can be positive or negative, or non-zero. In some applications, the use of non-zero motor dihedral angles and platform dihedral angles can make the base and the entire motion simulation system smaller in profile.

[0082] Fig. 8E is a perspective view of a positioning actuator assembly 240c according to some embodiments. Fig. 8E, the motion simulation system 100 can use a positioning actuator assembly 240c (replacing the positioning actuator assembly 140 or combining with the positioning actuator assembly 140) including a crank 244c, which is integrated with the rotor 242c. As shown, the crank 244c can extend axially from the surface of the rotor 242c so that the connecting rod 246c can be directly attached or connected to the rotor 242c. During operation, the crank 244c can rotate with the rotor 242c to move or translate the connecting rod, thereby adjusting the position of the platform 120.

[0083] As shown, positioning actuator assembly 240c can have a non-zero motor dihedral angle and / or platform dihedral angle to maximize the rotation range of ball joint end 248c relative to the zero position attitude. In some embodiments, positioning actuator assembly 240c can have a negative motor dihedral angle and / or platform dihedral angle.

[0084] As described herein, the positioning actuator assembly 140 can be arranged relative to the base 110 and the platform 120 in any suitable arrangement or otherwise provided. In the illustrated example, the positioning actuator assembly 140 can be arranged to allow the motion simulation system 100 to move in six degrees of freedom. As shown, the motion simulation system 100 can include six positioning actuator assemblies 140. The six positioning actuator assemblies 140 can be arranged equidistantly. For example, the positioning actuator assemblies 140 can be spaced 500 mm to 1200 mm apart. In some embodiments, the positioning actuator assembly 140 can be arranged in a "rotating hexapod" arrangement.

[0085] In some applications, the position of the positioning actuator assembly 140 can be changed relative to the weight bearing actuator 130. As previously described, the motion simulation system 100 can include twice as many positioning actuator assemblies 140 as weight bearing actuators 130. In some embodiments, each weight bearing actuator 130 can be located between two positioning actuator assemblies 140, forming three "leg sets" arranged around the base 110 and connected to the platform 120. In addition, in some embodiments, the end of the piston rod 134 of the weight bearing actuator 130 connected to the platform 120 can be set between the connecting rod ends 148 of the two positioning actuator assemblies 140.

[0086] During operation, the motion simulation system 100 can use the positioning actuator assembly 140 to place the platform 120 and the load 10 in a desired posture or a series of postures in response to the position input. In the example shown, the controller of the motion simulation system 100 can receive a position input as a series of posture vectors. These posture vectors can be received at a streaming frequency. In some embodiments, the controller of the motion simulation system 100 can receive and / or process posture vectors at a streaming frequency of about 1000 Hz. In addition, in some embodiments, the positioning actuator assembly 140 can place the platform 120 in various postures at a streaming frequency of about 1000 Hz. In some applications, the positioning actuator assembly 140 can be driven synchronously using specific features, including but not limited to a parallel architecture with a synchronization signal.

[0087] In the pre-processing stage, each received attitude vector may be converted or scaled. In addition, each received attitude vector may be processed with reference to the kinematic state of the system (e.g., to limit the maximum acceleration and / or velocity of the motion simulation system 100). In addition, each received attitude vector may be verified according to the physical mechanical limitations of the motion simulation system 100. In some embodiments, the motion simulation system 100 may have a minimum travel limit of about -100 mm to -50 mm, a maximum travel limit of about 50 mm to 100 mm, and a span of about 100 mm to 200 mm on the sway, swing, and heave axes. In some embodiments, the motion simulation system 100 may have a minimum travel limit of about -15 degrees to -5 degrees, a maximum travel limit of about 5 degrees to 15 degrees, and a span of about 10 degrees to 20 degrees on the heading / yaw, attitude / pitch, and roll / roll axes.

[0088] In the example shown, the effective attitude vector is then converted into a position vector of each corresponding positioning actuator assembly 140, and the position vector is commanded to each corresponding positioning actuator assembly 140. In some embodiments, the controller of the motion simulation system 100 uses inverse kinematics to control the position of the platform 120. For example, the controller processes the attitude vector to provide an effective position vector, which can be the desired rotation angle of the corresponding positioning actuator 150. Therefore, the aforementioned series of input attitude vectors can cause highly controllable motion of the platform 120. In some embodiments, the motion control system 100 can control the action of at least six positioning actuator assemblies 140 to provide six degrees of freedom. In some embodiments, the motion control system 100 can be "overdriven" and can include more positioning actuator assemblies 140 than required degrees of freedom. In some applications, the motion simulation system 100 can use "forward" or joint space control (i.e., each positioning actuator assembly 140 is controlled separately), "inverse" or model space control (i.e., the motion control of the platform 120 as a system), or a hybrid system that can switch between joint space control and model space control in different situations. In some applications, the motion simulation system 100 may control the position of the platform 120 using forward kinematics and / or inverse dynamic control.

[0089] In some embodiments, the motion simulation system 100 can perform independent closed-loop control of each positioning actuator assembly 140 while the controller of the motion simulation system 100 can collectively or cooperatively provide an effective position vector to each positioning actuator assembly 140 to provide a desired attitude of the platform 120. For example, in some embodiments, the motion simulation system 100 can use the position information or other operational information of the positioning actuator 150 to provide closed-loop feedback, adjustment, or control of the input signal to the positioning actuator 150 to provide a desired position or attitude.

[0090] As described herein, each positioning actuator 150 may include a rotary encoder 152 for providing position information to the motion simulation system 100. In some embodiments, the positioning actuator may include a linear actuator having a linear encoder for providing position information to the motion simulation system 100. The motion simulation system 100 may compare the position information from the rotary encoder 152 with the desired position provided by the effective position vector to adjust the signal or current provided to the positioning actuator 150, thereby controlling the positioning of the positioning actuator 150. In addition, in some embodiments, the motion simulation system 100 may adjust the current through the motor coil of the positioning actuator 150, recognizing that the current is proportional to the torque output of the rotor 142. The current sensor may provide a feedback signal to allow closed-loop control of the torque output and operation of the positioning actuator 150. In some embodiments, the feedback signal described herein may be processed by a multi-order control loop of the motion simulation system 100 to produce an appropriate control system response.

[0091] Optionally, the response of the control loop of one or more positioning actuator assemblies 140 can be configured by selecting and adjusting one or more gain factors. In some embodiments, the gain factors of each positioning actuator assembly 140 can be independently or individually set and can be dynamically modified during system operation. Therefore, the positioning actuator assembly 140 and the motion simulation system 100 can generally be configured to respond in a variety of ways, depending on any suitable combination of available and selectable drivers. Advantageously, the performance of the motion simulation system 100 can be optimized under a variety of conditions, including but not limited to motion operation requirements, load 10 and load mass distribution, and the position of the platform 120. In some embodiments, before normal operation, the gain factor for controlling the position of the positioning actuator assembly 140 can be initialized according to the motion operation requirements, load 10 and load mass distribution, and the position of the platform 120.

[0092] Advantageously, in some applications, the motion simulation system 100 can recover or recycle energy for later use due to the direct drive arrangement of the positioning actuator assembly 140. In some embodiments, the positioning actuator 150 can recover kinetic energy and / or potential energy from the platform 120. During operation, the movement of the platform 120 can excite or back-drive the positioning actuator 150, generating electrical energy.

[0093] The electrical energy generated by the positioning actuator 150 can be stored in the form of electrical potential energy. In some embodiments, the electrical energy can be stored in an energy storage device, such as an ultracapacitor, a supercapacitor, a capacitor, a battery or other suitable energy storage device, or a combination thereof. In some embodiments, the energy storage device can store energy from multiple recovery events. The energy stored in the energy storage device can be redeployed to the motion simulation system 100 as needed. The energy storage device can be connected in parallel with the power supply of the motion simulation system 100. During operation, the energy storage device can quickly deploy electrical energy to respond to high peak current requirements that may exceed the capabilities of certain power supplies. Advantageously, the capture, storage and deployment of electrical energy can supplement the capabilities of the power supply of the motion simulation system 100, allowing the demand for power to be reduced. Advantageously, by reducing the power demand on the power supply, the size of the power supply can be reduced without losing the kinematic performance of the motion simulation system 100. In some applications including battery energy storage devices, the motion simulation system may include components or control systems for maintaining battery health and integrity.

[0094] Fig. 9 is a perspective view of a motion simulation system 100a with a load 10 according to some embodiments. Fig.10 is a perspective view of a motion simulation system 100a according to some embodiments. Fig. 9 and 10 , the motion simulation system 100a includes some features similar to those of the motion simulation system 100. Therefore, some features of the motion simulation system 100a that are similar to those of the motion simulation system 100 are identified by similar reference numerals.

[0095] In the example shown, the motion simulation system 100a includes a curved platform 120a for supporting a load 10. In the example shown, the platform 120a includes one or more curved legs 122a, which are shaped to hold or otherwise support the load 10. In some embodiments, these curved legs 122a can be bent vertically and / or horizontally. Optionally, these curved legs 122a can define a compound curve in multiple planes. As shown, in some embodiments, the curved legs 122a can be configured to support or hold up a car seat. Portions of the load 10 can be attached or fixed to the legs 122a of the platform 120a. Other features of the legs 122a or the platform 120a can be applicable to any suitable load 10.

[0096] In some embodiments, one end of the load bearing actuator 130 can be connected to the middle portion 124a of the leg 122a or other suitable parts of the platform 120a. In addition, in some embodiments, one end of the positioning actuator assembly 140 can be connected to the middle portion 124a of the leg 122a or other suitable parts of the platform 120a.

[0097] Figures 11A-11G are perspective views of motion simulation systems 300a - 300g , respectively, according to some embodiments. Figures 11A-11G Different embodiments of motion simulation systems using positioning actuator assemblies 340 and load-bearing actuators 330 according to the present disclosure are shown. In some applications, the positioning actuator assemblies 340 and load-bearing actuators 330 described here can be replaced by any other acceptable positioning actuator assemblies and load-bearing actuators, including the components described here. In addition, a mixture of different types of positioning actuator assemblies 340 and / or load-bearing actuators 330 is also possible. In some applications, a six-degree-of-freedom motion simulation system can use a minimum of six positioning actuator assemblies 340. However, in some embodiments, a six-degree-of-freedom motion simulation system can be "overdriven" and include more than six positioning actuator assemblies 340. Similarly, the number of load-bearing actuators 330 can also vary. In some applications, the arrangement and configuration of the positioning actuator assemblies 340 and load-bearing actuators 330 described here can be implemented using any other suitable motion simulation system described here.

[0098] In some embodiments, the arrangement and position of the positioning actuator assembly 340 and / or the load bearing actuator 330 can be symmetrical or asymmetrical. The arrangement and position of the load bearing actuator 330 relative to the positioning actuator assembly 340 can also vary. In addition, the shape of the base 310 and the shape of the platform 320 can vary, and these shapes can be symmetrical or asymmetrical. The arrangement and position of the joint relative to the base 310 and / or the platform 320 can vary, such as being coplanar or non-coplanar, symmetrical or asymmetrical, etc.

[0099] like Figures 11A-11G As shown, in some embodiments, the motion simulation system may use a circular platform 320 and a circular base 310. Fig.11A An embodiment of the motion simulation system 300 a includes six positioning actuator assemblies 340 and three load-bearing actuators 330 , and each load-bearing actuator 330 is disposed between two adjacent positioning actuator assemblies 340 .

[0100] exist Fig. 11BIn one embodiment of the motion simulation system 300b, nine positioning actuator assemblies 340 and three bearing actuators 330 are included. The nine positioning actuator assemblies 340 are grouped into three positioning actuator assemblies 340, and each bearing actuator 330 is disposed between separate groups.

[0101] exist Fig. 11C In one embodiment of the motion simulation system 300c, six positioning actuator assemblies 340 and three bearing actuators 330 are included. Two positioning actuator assemblies 340 form a group, and each bearing actuator 330 is disposed between separate groups.

[0102] exist Fig.11D In one embodiment of the motion simulation system 300d, six positioning actuator assemblies 340 and three load-bearing actuators 330 are included, wherein two positioning actuator assemblies 340 form a group, and each load-bearing actuator 330 is disposed at a more central position on the base 310, thereby supporting a more central position of the platform 320.

[0103] exist Fig.11E In one embodiment of the motion simulation system 300e, there are six positioning actuator assemblies 340 and six load-bearing actuators 330, wherein each two positioning actuator assemblies 340 form a group, a load-bearing actuator 330 is arranged between each individual group, and the other three load-bearing actuators 330 are arranged at a more central position on the base 310, thereby supporting a more central position of the platform 320.

[0104] exist Fig.11F In one embodiment of the motion simulation system 300f, there are six positioning actuator assemblies 340 and nine load-bearing actuators 330, wherein each two positioning actuator assemblies 340 form a group, a load-bearing actuator 330 is arranged between the two positioning actuator assemblies 340 of each group and between each individual group, and the other three load-bearing actuators 330 are arranged at a more central position on the base 310, thereby supporting a more central position of the platform 320.

[0105] exist Fig.11G In one embodiment of the motion simulation system 300g, there are seven positioning actuator assemblies 340 and three load-bearing actuators 330, each load-bearing actuator 330 is disposed between two adjacent positioning actuator assemblies 340, and the seventh positioning actuator assembly 340 is disposed at a more central position on the base 310, thereby supporting a more central position of the platform 320.

[0106] Fig.12is a perspective view of a motion simulation system 400 according to some embodiments. Fig.13 According to some embodiments Fig.12 A perspective view of an integrated linear actuator unit 460 of the motion simulation system 400 in FIG. Fig.14 yes Fig.13 Side view of the integrated linear actuator unit 460 in . Fig.15 According to some embodiments Fig.13 A perspective view of a load-bearing actuator 430 of an integrated linear actuator unit 460 in FIG. Figure 12-15 , the motion simulation system 400 uses an integrated linear actuator unit 460 to support and position a load relative to a base 410 to provide motion information, signals, or other feedback to a user.

[0107] As shown in the text, the platform 420 can support and position the load relative to the base 410. In some embodiments, the platform 420 can include one or more legs 422 to form a space frame for receiving, holding or otherwise supporting the load. Portions of the load can be attached or fixed to the legs 422 of the platform 420. The legs 422 or other features of the platform 420 can be suitable for any suitable load. In some embodiments, the platform 420 can be any suitable shape or structure. In some embodiments, the platform 420 can be symmetrical or asymmetrical, and can be varied in other ways. Fig.16 is a perspective view of a motion simulation system 400a according to some embodiments. Fig.16 As shown, for the motion simulation system 400a, in some embodiments, the platform 420a can have a flat or planar shape. In some embodiments, the platform 420a can have a generally circular or disc-shaped shape.

[0108] In the example shown, the base 410 can support the weight of the platform 420 and the load, as well as other components of the motion simulation system 400. As shown, the base 410 can have a generally circular or disc-shaped shape. In some embodiments, the shape of the base 410 can be symmetrical or asymmetrical, and can vary in other ways.

[0109] As described herein, the platform 420 and any loads may be supported and positioned in a desired posture relative to the base 410 by one or more integrated linear actuator units 460. In the illustrated example, each integrated linear actuator unit 460 includes a load-bearing actuator 430 for supporting the weight of the platform 420 and any loads and a positioning actuator assembly 440 for positioning the platform 420 and any loads, both of which are at least partially disposed in a common housing 462 of the integrated linear actuator unit 460.

[0110] In the illustrated example, an integrated linear actuator unit 460 is connected to the platform 420 and the base 410. As shown, one end of the load-bearing actuator 430 of the integrated linear actuator unit 460 can be connected to the base 410, and the other end 436 of the load-bearing actuator 430 can be connected to the platform 420. In some embodiments, the end 436 can be connected to the end of the leg 422 or other suitable part of the platform 420. In some embodiments, the position of the joints, connections or ends of these integrated linear actuator units 460 relative to the platform 420 and / or the base 410 can be coplanar, non-coplanar, symmetrical, asymmetrical, or can vary in other ways. In some embodiments, the end 436 can be pivotally connected to the base 410 and the platform 420. The end 436 can include a ball joint.

[0111] Before the motion simulation system 400 operates normally, the integrated linear actuator unit 460 can be extended to a desired length to act as a leg or otherwise support the support platform 420 and the load in a desired posture. As shown, each integrated linear actuator unit 460 includes a load-bearing actuator 430 to support the platform 420 and any load in a desired relative posture relative to the base 410.

[0112] In the example shown, during normal operation, the load bearing actuator 430 supports the platform 420 and the load without affecting the position of the platform 420. The load bearing actuator 430 is connected to the housing 462 of the integrated linear actuator unit 460. As shown, the piston rod 434 of the load bearing actuator 430 extends out of the housing 462. In addition, one end 436 of the load bearing actuator 430 extends out of the opposite side of the housing 462.

[0113] In the example shown, during normal operation, the load bearing actuator 430 is a pneumatic actuator that uses gas pressure to extend and support the platform 420 and the load in a desired posture. In some embodiments, the load bearing actuator 430 may include features similar to those of the load bearing actuator 130 and / or operate in a manner similar to the operation of the load bearing actuator 130. Unless otherwise specified, similar reference numerals may be used for features of the load bearing actuator 430 that are similar to the features of the load bearing actuator 130. In some embodiments, the load bearing actuator 430 may use other types of actuators, including but not limited to gas struts, gas springs, elastic cords, linear springs, helical springs, and / or rotary springs.

[0114] In the illustrated example, the load bearing actuator 430 includes one or more buffer tanks 438 in fluid communication with the cylinder 432 to provide additional dead volume for the cylinder 432. In some embodiments, the one or more buffer tanks 438 can be connected to the body of the cylinder 432. It can be appreciated that the use of multiple buffer tanks 438 can allow for a desired dead volume while allowing for flexibility or configurability of the housing of the load bearing actuator 430. In some embodiments, the use of multiple buffer tanks 438 can allow for a relatively compact design while allowing for a desired dead volume, such that the cylinder 432 and buffer tanks 438 are disposed in a housing 462 of an integrated linear actuator unit 460.

[0115] During operation of the motion simulation system 400, the integrated linear actuator unit 460 can be extended to a desired length to position the platform 420 and the load in a desired posture. As shown, each integrated linear actuator unit 460 includes a positioning actuator assembly 440 for moving or positioning the platform 420 and the load in a desired posture relative to the base 410.

[0116] In the illustrated example, the positioning actuator assembly 440 can apply force or otherwise act on the load-bearing actuator 430 of the same integrated linear actuator unit 460 to position the platform 420 (in combination or cooperation with other integrated linear actuator units 460) in any six-dimensional posture in the motion space envelope of the motion simulation system 400 with respect to surge, sway, heave, yaw, pitch, and roll. As shown, the positioning actuator assembly 440 is connected to the load-bearing actuator 430 and the housing 462 of the integrated linear actuator unit 460. In some embodiments, one end 448 of the connecting rod 446 is pivotally connected to the piston rod 434 of the load-bearing actuator 430 at a joint 464. As shown, the joint 464 between the connecting rod 446 and the piston rod 434 can be disposed between the cylinder 432 and one end of the piston rod 434. In some embodiments, the joint 464 can be disposed in the housing 462 of the integrated linear actuator unit 460. Furthermore, the body of the positioning actuator may be connected to the housing 462 of the integrated linear actuator unit 460 .

[0117] In the example shown, the positioning actuator assembly 440 includes a positioning actuator that is used to operate a connecting rod 446, which in turn moves the piston rod 434 of the load-bearing actuator 430, and ultimately positions the platform 420 at a desired posture. In some embodiments, the positioning actuator assembly 440 may include features similar to those of the positioning actuator assembly 140 and / or operate in a manner similar to that of the positioning actuator assembly 140. Unless otherwise specified, similar reference numerals may be used for features of the positioning actuator assembly 440 that are similar to those of the positioning actuator assembly 140.

[0118] As described herein, the integrated linear actuator units 460 may be arranged or otherwise disposed relative to the base 410 and the platform 420 in any suitable arrangement. In the illustrated example, the integrated linear actuator units 460 may be arranged to allow the motion simulation system 400 to move in six degrees of freedom. As shown, the motion simulation system 400 may include six integrated linear actuator units 460. The six integrated linear actuator units 460 may be arranged at equal intervals. In some embodiments, the integrated linear actuator units 460 may be arranged in a "linear hexapod" arrangement.

[0119] During operation, the motion simulation system 400 can place the platform 420 and the load into a desired attitude or a series of attitudes in response to a position input using the integrated linear actuator unit 460. In the illustrated example, the controller of the motion simulation system 400 can receive a position input as a series of attitude vectors. In some applications, the implementation of the integrated linear actuator unit 460 can simplify the mathematical complexity of the kinematic equations that convert the position input into the resulting motion of the motion simulation system 400.

[0120] In addition, the present disclosure describes various embodiments of a human machine interface (HMI). In some embodiments, the human machine interface can use a direct drive actuator to receive motion input from an operator and position the input portion of the interface to provide tactile feedback. The human machine interface or tactile device can receive input with six degrees of freedom and provide tactile feedback with six degrees of freedom. In some applications, the human machine interface may include the features, structures and / or configurations of the motion simulation system described herein. In some embodiments, such as in certain small mass applications, the human machine interface may include or may not include a load-bearing actuator.

[0121] Fig.17 is a perspective view of a haptic device 500 according to some embodiments. Fig.18 yes Fig.17 FIG. 5 is a side view of a haptic device 500. Fig.17 and 18 The haptic device 500 receives motion input from an operator through an input unit 502, and provides motion or tactile information, signals, or other feedback to the user through the same input unit 502. In some embodiments, the input unit 502 may be a knob, a joystick, a mouse, or any other suitable input device or structure.

[0122] As shown, the platform 520 can support, position, and move the input 502 relative to the base 510. In the example shown, the platform 520 is shaped or configured to accommodate or otherwise support the input 502. Parts of the input 502 can be attached or fixed to the platform 520. In some embodiments, the platform 520 can have a planar shape, such as a disk shape, to support the input 502 through a flat surface. In some embodiments, the shape of the platform 520 can be symmetrical or asymmetrical, and can be varied in other ways.

[0123] In the example shown, the base 510 can support the weight of the platform 520, the input portion 502, and other components of the haptic device 500. As shown, the base 510 can have a generally triangular shape. In some embodiments, the shape of the base 510 can be symmetrical or asymmetrical, and can vary in other ways.

[0124] In some applications, one or more load bearing actuators 530 can support the weight of platform 520, input 502, and the weight applied by an operator relative to base 510. In some embodiments, load bearing actuator 530 can include features similar to features of the load bearing actuators described herein, and can operate or be implemented in a manner similar to the operation of the load bearing actuators described herein, including but not limited to load bearing actuator 130 and / or load bearing actuator 430.

[0125] Before the haptic device 500 operates normally, the load-bearing actuator 530 can be extended to a desired length to act as a leg or otherwise support the platform 520 and the input part 502 in a desired posture. In some embodiments, the load-bearing actuator 530 for the haptic device 500 can use other types of actuators, including but not limited to gas struts, gas springs, elastic ropes, linear springs, helical springs, and / or rotational springs.

[0126] As described herein, the load bearing actuators 530 can be arranged or configured in any suitable layout relative to the base 510 and the platform 520. For example, the haptic device 500 can include twice the number of positioning actuator assemblies 540 as the load bearing actuators 530. As shown, the haptic device 500 can include three load bearing actuators 530. These load bearing actuators 530 can be arranged at equal intervals. In some embodiments, such as in low-mass applications, the haptic device 500 can use one or more positioning actuator assemblies 540 to support the weight of the platform 520, the input portion 502, and the weight applied by the operator relative to the base 510 without using load bearing actuators.

[0127] In the illustrated example, the haptic device 500 includes one or more positioning actuator assemblies 540 capable of receiving motion input from an operator and positioning the platform 520 and the input portion 502 relative to the base 510. In the illustrated example, the positioning actuator assembly 540 can receive motion input from the operator and position the platform 420 in any six-dimensional pose with respect to surge, sway, heave, yaw, pitch, and roll within the motion space envelope of the haptic device 500. In some embodiments, the positioning actuator assembly 540 can include features similar to those of the positioning actuator assemblies described herein, and can operate or be implemented in a manner similar to the operation of the positioning actuator assemblies described herein, including but not limited to the positioning actuator assembly 140 and / or the positioning actuator assembly 440.

[0128] As described herein, the positioning actuator assembly 540 can be arranged or set relative to the base 410 and the platform 420 in any suitable layout. In the illustrated example, the positioning actuator assembly 540 can be arranged to allow the haptic device 500 to receive position input and / or move in six degrees of freedom. As shown in the figure, the haptic device 500 may include six positioning actuator assemblies 540. These six positioning actuator assemblies 540 can be arranged at equal intervals. As shown in the figure, these six positioning actuator assemblies 540 can be arranged in three "leg sets" arranged around the base 510 and connected to the platform 520. In some embodiments, these positioning actuator assemblies 540 can be arranged in a "rotating six-foot" layout.

[0129] Advantageously, direct attachment or connection between components of the positioning actuator assembly 540 allows for implementation of a direct drive mechanism or device. In addition to the performance advantages described herein, the direct drive device of the positioning actuator assembly 540 allows an operator to provide motion or other input via the input 502 and / or the platform 520 to provide the operator's position input to other devices such as a computer. During operation, motion of the input 502 and / or the platform 520 can excite or back-drive the positioning actuator assembly 540 to generate a signal responsive to the operator's position input.

[0130] In the illustrated example, the control of the haptic device 500 may receive position input from the operator via signals received from the positioning actuator assembly 540. During operation, the controller of the haptic device 500 may convert or transform the signals of the positioning actuator assembly 540 into signals that can be used as position input signals by a connected device (e.g., a computer). In some embodiments, the controller of the haptic device 500 may provide the desired position input signals to the connected device using a suitable method (e.g., forward kinematics).

[0131] In addition, as described herein with respect to other embodiments, the haptic device 500 can use the positioning actuator assembly 540 to place the platform 520 and the input portion 502 in a desired posture or series of postures in response to the position input to provide tactile feedback to the operator. In the example shown, the controller of the haptic device 500 can receive the tactile or position input as a series of posture vectors. In some embodiments, the controller of the haptic device 500 can include features similar to those of the controllers described herein, and can operate or be implemented in a manner similar to the operation of the controllers described herein, including but not limited to the controller of the motion simulation system 100.

[0132] It should also be understood that although in some cases, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first valve can be referred to as a second valve, and similarly, a second valve can be referred to as a first valve without departing from the scope of the various embodiments described. The first valve and the second valve are both valves, but unless explicitly stated, they are not the same valve.

[0133] The terms used in the description of various embodiments herein are only used to describe specific embodiments and are not intended to be limiting. As used in the description of the various embodiments described and in the appended claims, the singular forms "one", "an" and "the" are intended to also include plural forms, unless the context clearly states otherwise. It should also be understood that the term "and / or" used herein refers to and encompasses any and all possible combinations of one or more related listed items. It should also be understood that when the terms "include" and / or "comprising" are used in this specification, the presence of the features, integers, steps, operations, elements and / or components is specified, but the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof is not excluded.

[0134] As used herein, the term “if” may alternatively be interpreted as “when…” or “at…” or “in response to determining…” or “in response to detecting…” or “in accordance with determining…”, depending on the context. Similarly, the phrase “if it is determined” or “if [the condition or event] is detected” may alternatively be interpreted as “upon the determination” or “in response to the determination” or “upon detecting [the condition or event]” or “in response to detecting [the condition or event]” or “in accordance with the determination of detecting [the condition or event]”, depending on the context.

[0135] The above description with reference to specific embodiments is for the purpose of explanation. However, the above illustrative discussion is not intended to be exhaustive or to limit the scope of the claims to the precise forms disclosed. In light of the above teachings, many modifications and variations may be made. These embodiments were selected in order to best explain the basic principles of the claims and their practical application, thereby enabling others skilled in the art to best use the embodiments with various modifications suitable for the specific use contemplated.

Claims

1. A motion simulation system, comprising: Load bearing actuator, comprising: a cylinder defining a cavity; and a piston rod at least partially disposed within the cavity of the cylinder, wherein a first end of the piston rod and the cavity of the cylinder define a volume of the cylinder, and wherein the volume of the cylinder is configured to be pressurized to support the weight of a load; and A positioning actuator assembly comprising: a positioning actuator comprising a stator and a rotor configured to rotate relative to the stator; and A connecting rod is connected to the rotor, wherein the rotor is configured to rotate to translate the connecting rod and position the load supported by the load-bearing actuator.

2. The motion simulation system according to claim 1, further comprising: A second positioning actuator assembly, wherein the second positioning actuator assembly is configured to cooperate with the positioning actuator assembly to position a load supported by the load bearing actuator.

3. The motion simulation system according to claim 1, further comprising: a plurality of additional load-bearing actuators and a plurality of additional positioning actuator assemblies, wherein the plurality of additional load-bearing actuators are configured to be pressurized to cooperate with the load-bearing actuators to support the weight of the load, and the plurality of additional positioning actuator assemblies are configured to cooperate with the positioning actuator assembly to position the load supported by the load-bearing actuators and the plurality of load-bearing actuators.

4. The motion simulation system according to claim 3, wherein: The plurality of additional load bearing actuators includes two additional load bearing actuators and the plurality of additional positioning actuator assemblies includes five additional positioning actuator assemblies.

5. The motion simulation system according to claim 1, further comprising a platform, wherein: The platform is connected to the second end of the piston rod and the connecting rod, and the platform is configured to support the load.

6. The motion simulation system according to claim 1, wherein: The load bearing actuator includes a surge tank defining a dead volume in fluid communication with the volume of the cylinder.

7. The motion simulation system according to claim 6, wherein: The range of motion of the first end of the piston rod relative to the cavity of the cylinder defines a working volume, and the dead volume is about 100% to about 500% of the working volume.

8. The motion simulation system according to claim 1, wherein: The volume of the cylinder is pressurized by vibrating the first end of the piston rod relative to the cylinder.

9. The motion simulation system according to claim 1, wherein: The detent actuator assembly includes a crank pivotally coupled to the rotor and the connecting rod.

10. The motion simulation system according to claim 9, wherein: The crank is formed integrally with the rotor.

11. The motion simulation system according to claim 1, further comprising a linear actuator housing, wherein: The load bearing actuator and the positioning actuator assembly are at least partially disposed within the linear actuator housing.

12. The motion simulation system according to claim 11, wherein: One end of the connecting rod is pivotally connected to the piston rod between the first end and the second end of the piston rod.

13. The motion simulation system of claim 1, further comprising a controller configured to control operation of the load-bearing actuator and the positioning actuator.

14. The motion simulation system according to claim 13, wherein: The controller is configured to pressurize the volume of the cylinder to a pressure to minimize current consumption by the positioning actuator.

15. The motion simulation system according to claim 13, wherein: The controller is configured to control operation of the positioning actuator at a frequency of up to about 1000 Hz.

16. The motion simulation system of claim 1, further comprising an electrical energy storage device for receiving energy generated by the positioning actuator.

17. A motion simulation system comprising: Pedestal; a platform movable relative to the base and configured to support a load; A plurality of load-bearing actuators, wherein each load-bearing actuator comprises: a cylinder pivotally connected to the base, wherein the cylinder defines a cavity; and a piston rod having a first end and a second end, wherein the first end is at least partially disposed in the cavity of the cylinder to define a volume of the cylinder, the second end is pivotally connected to the platform, and the volume of the cylinder is configured to be pressurized to support the platform; and A plurality of positioning actuator assemblies, wherein each positioning actuator assembly comprises: a positioning actuator connected to the base, the positioning actuator comprising a stator and a rotor configured to rotate relative to the stator; and A link includes a first end pivotally connected to the rotor and a second end pivotally connected to the platform, wherein the rotor is configured to rotate to translate the link and position the load supported by the plurality of load-bearing actuators.

18. The motion simulation system according to claim 17, wherein: The number of positioning actuator assemblies in the plurality of positioning actuator assemblies is twice the number of weight-bearing actuators in the plurality of weight-bearing actuators.

19. The motion simulation system according to claim 18, wherein: The plurality of load-bearing actuators include three load-bearing actuators, and the plurality of positioning actuator assemblies include six positioning actuator assemblies.

20. The motion simulation system according to claim 18, wherein: The second end of the piston rod of the first load-bearing actuator of the plurality of load-bearing actuators is disposed proximate to the second end of the connecting rod of the first positioning actuator assembly and the second end of the connecting rod of the second positioning actuator assembly of the plurality of positioning assemblies.

21. The motion simulation system according to claim 17, wherein: The platform is movable in six degrees of freedom relative to the base.

22. The motion simulation system according to claim 17, wherein: The platform comprises a plurality of legs, wherein the second end of the piston rod of each of the plurality of load bearing actuators is connected to a corresponding one of the plurality of legs of the platform.

23. The motion simulation system according to claim 22, wherein: Each of the plurality of weight bearing actuators includes a surge tank defining a dead volume in fluid communication with the volume of the cylinder.

24. The motion simulation system according to claim 23, wherein: The range of motion of the first end of the piston rod relative to the volume of the cylinder defines a working volume, and the dead volume is about 100% to about 500% of the working volume.

25. The motion simulation system according to claim 17, wherein: The volume of the cylinder of each of the plurality of load bearing actuators is pressurized by vibrating the first end of the piston rod relative to the cylinder.

26. The motion simulation system according to claim 17, wherein: Each of the plurality of positioning actuator assemblies includes a crank pivotally connected to the rotor and the connecting rod.

27. The motion simulation system according to claim 26, wherein: The crank is formed integrally with the rotor.

28. The motion simulation system of claim 17, further comprising a plurality of linear actuator housings, wherein: A respective one of the plurality of load bearing actuators and a respective one of the plurality of positioning actuator assemblies are at least partially disposed in a common one of the plurality of linear actuator housings.

29. The motion simulation system according to claim 28, wherein: One end of the connecting rod of the corresponding positioning actuator assembly is pivotally connected to the piston rod of the corresponding load-bearing actuator between the first end and the second end of the piston rod.

30. The motion simulation system of claim 17, further comprising a controller configured to control operation of the plurality of load bearing actuators and the plurality of positioning actuator assemblies.

31. The motion simulation system according to claim 30, wherein: The controller is configured to pressurize the volume of each respective cylinder of the plurality of load bearing actuators to a pressure to minimize current consumption of each respective detent actuator of the plurality of detent actuator assemblies.

32. The motion simulation system according to claim 30, wherein: The controller is configured to control operation of each of the plurality of detent actuator assemblies at a frequency of up to about 1000 Hz.

33. The motion simulation system of claim 17, further comprising an electrical energy storage device for receiving energy generated by the positioning actuator.

34. A method of operating a motion simulation system, the method comprising: pressurizing a plurality of load-bearing actuators to support the platform relative to the base; The platform is moved by driving a plurality of positioning actuators of a corresponding plurality of positioning actuator assemblies, wherein each positioning actuator assembly is pivotally connected to the platform via a corresponding link of the plurality of positioning actuator assemblies.

35. The method of claim 34, further comprising: detecting a current consumption of each of the plurality of detent actuator assemblies; as well as The plurality of load bearing actuators are pressurized to a desired pressure to minimize current consumption by each of the plurality of positioning actuator assemblies.

36. The method of claim 34, further comprising: Prior to pressurizing the plurality of load bearing actuators, the platform is supported by a plurality of positioning actuators.

37. The method of claim 34, further comprising: The plurality of load bearing actuators are vibrated to stress each respective load bearing actuator.

38. The method of claim 34, further comprising: The platform is moved continuously in response to a sequence of gesture vectors at a flow frequency of up to about 1000 Hz.

39. The method of claim 34, further comprising: determining a respective rotational position of each of the plurality of detent actuator assemblies; and A gain factor for each detent actuator assembly is adjusted based on a comparison of the respective rotational position of each of the plurality of detent actuator assemblies with a desired rotational position of each of the plurality of detent actuator assemblies.

40. The method of claim 34, further comprising: generating electrical energy from movement of the plurality of positioning actuator assemblies; storing the electrical energy from the plurality of positioning actuator assemblies in an electrical energy storage device; as well as Deploy the electrical energy in the electrical energy storage device.

41. A non-transitory computer-readable storage medium storing instructions configured to cause a processor of a device to at least perform: detecting a current draw of each of the plurality of detent actuator assemblies; The plurality of load bearing actuators are pressurized to a desired pressure to minimize current consumption by each of the plurality of positioning actuator assemblies.

42. The instructions of claim 41 , further configured to cause a processor of the device to at least perform: The plurality of positioning actuator assemblies are continuously driven at a flow frequency of up to about 1000 Hz in response to a series of attitude vectors.

43. The instructions of claim 41 , further configured to cause a processor of the device to at least perform: determining a respective rotational position of each of the plurality of detent actuator assemblies; comparing the respective rotational position of each of the plurality of detent actuator assemblies to a desired rotational position of each of the plurality of detent actuator assemblies; and A gain factor for each detent actuator assembly is adjusted based on a comparison of the respective rotational position of each of the plurality of detent actuator assemblies with a desired rotational position of each of the plurality of detent actuator assemblies.

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