Electromechanical cushioned linear actuator for dynamic simulation and associated system

Abstract

Electromechanical cushioned linear actuator for dynamic simulation and related associated simulation system characterized in that said actuators are driven by an electric motor housed in a lower body, integral with an external reference system which, by means of a transmission system and a conversion system, imparts linear motion to an upper body. An electric motor being constrained to the external reference system, it is subjected to fewer stresses during operation, ensuring less wear and maintenance needs. Said electromechanical cushioned linear actuators are also controlled by software and an input-output hardware interface separate from the input-output interfaces dedicated to the simulation software, reducing the risk of simulation program crashes and giving the user a realistic and immersive experience.

Description

[0001] “Electromechanical cushioned linear actuator for dynamic simulation and associated system”

[0002] Description

[0003] Field of the invention

[0004] The invention relates to the field of dynamic simulation of driving or control of vehicles of various kinds by means of software, with dynamic inputs which act on the user of the simulator.

[0005] Prior art

[0006] The field of simulation by means of driving or control software of vehicles such as cars, planes, trains or others is rapidly expanding thanks to the ever-improving development of support technologies and the simulation software itself. The use of such simulation systems is very vast and ranges in different levels of use, from amateur use for entertainment to professional use. Below are some examples where such use is very convenient and revolutionary.

[0007] In training aircraft pilots, given the huge operating costs of the vehicles and the economic and human risk in some of the training phases, it is preferable to use a dynamic simulator which reproduces the same experience on land and without risks for the pilot nor for the instructor or for the vehicle itself, thus resulting in obvious economic and environmental advantages and a notable reduction in risk. In the field of preparation for car races, such dynamic simulation systems are used for driver training and for simulated testing of certain configurations on the car, also bypassing some logistical problems, such as testing a specific track without physically being in such a place or the limit, imposed in many championships and competitions, of testing hours on tracks. Given the operating cost of the simulator, which is very low with respect to the operating cost of a real racing car, it is also an advantage in terms of budget, so as not to exceed the economic limits that are set increasingly often with the aim of make competitions fairer.

[0008] Lastly, mention is made of the entertainment and gaming sector, which is rapidly expanding in the market, where the use of these simulators provides an immersive and very real experience, every user can find themselves driving a vehicle which is not accessible to them in the real world, such as a Formula 1 car, and also participate in online competitions with other real users connected from different places. The success of this field is also evident from the following which some users have who stream their gaming sessions on various platforms, giving rise to a market which generates billions of euros in profits through direct and indirect revenues. Furthermore, the recent birth of e-sports makes the activity of dynamic simulation by means of software increasingly widespread and practiced at a professional level, generating the need for increasingly cutting-edge, realistic and efficient devices.

[0009] In order for the experience to be truly immersive and real, the simulation software, whatever it may be, must be supported by hardware capable of reproducing the movement, stresses and vibrations which would be expected in the real simulated situation, for example, in the case of a car the vibrations transmitted by the vehicle in contact with uneven ground or the change of position during acceleration or braking phases, or in the case of an airplane the stress due to a landing or turbulence. Such an effect in general in the technical field is obtained by means of motorized actuators, almost exclusively by means of electric motors, which return linear movements in specific zones of a structure, called electromechanical linear actuators. The literature and industrial practice have a large number of devices of this kind: one such example is patent application WO2016134389A1 which describes a car driving simulator comprising a frame and a seat fixed thereto by means of electromechanical actuators which therefore generate movements and vibrations processed by the dynamic simulation software and transmits them to the seat and therefore to the user sitting thereon, or patent CN216412426U which defines a seat moved by an electromechanical actuator adapted to simulate the movements transferred to a human body sitting thereon from an airplane in flight, take-off or landing.

[0010] In both cases mentioned, and in general in the literature found in this regard, the electromechanical actuators, driven by normal electric motors, are arranged with the motor connected to the movable part, this means that all the vibrations and movements generated by the motor are also transmitted to the motor itself, reducing the duration thereof over time, since the repeated stresses wear out the internal components such as the ball bearings and subject all the metal parts to a more accentuated fatigue phenomenon, which can lead to the failure of the piece or in any case to frequent replacement.

[0011] The object of the present patent application is therefore to describe an electromechanical actuator with a motor arranged on the side constrained to the ground, or in general to the nonmovable part with an almost total reduction in the stresses undergone, also thanks to the use of a spring. Furthermore, the aforesaid patent application aims to define a dynamic simulation system, comprising actuators made as previously described, provided with a control system of the simulator and electromechanical actuators in general, manageable by mean of dedicated software with a specific input / output control interface, separate from the derivations dedicated to the dynamic simulation software, therefore not requiring the actual simulation software to be minimized when playing on the main screen or on the main viewer, reducing the risk of simulation software crashes and providing a more realistic and immersive experience.

[0012] Description of the invention

[0013] According to the present invention, a electromechanical cushioned linear actuator is made with positioning of the electric motor on the lower side and an associated dynamic simulation system which effectively resolve the problems set out above.

[0014] The electromechanical cushioned linear actuator comprises two main parts, in relative motion with each other, with a single degree of freedom, and can therefore be diagrammed as a variable-length connecting rod, also controllable in the speed and acceleration of the extension or of the length reduction, so as to reproduce the stresses, vibrations and movements required by dynamic simulation software. The extension and reduction of the length of such an actuator occur thanks to the relative motion between the two parts which compose it. The two parts are divided into upper body and lower body. The two parts are concentric, and a coil spring is interposed therebetween, which can have variable stiffness and geometry of length and section, so as to recreate the desired dynamic response during movement. Furthermore, in an application of the invention the coil spring is constrained with rotation prevented at the two ends, thus helping to block the relative rotation between the two parts as well as absorbing a good part of the vibrations and stresses deriving from the simulation. The upper body is connected by means of a suitable constraint to a frame or to a particular component representing the simulated dynamic system, such as a movable frame hosting a seat and related steering wheel and pedals, reproducing the passenger compartment of a car. The lower body can be fixed to an external reference, such as a fixed frame or the ground by means of classic constraints such as bolting or gluing or, in the case of vertical applications of the actuator, this can simply be placed on the ground by means of an appropriate support base, keeping itself in position thanks to the weight of the dynamic simulator above. The motion is imparted by means of an electric motor, which, when powered, generates a rotary motion of a rotor, which is then transformed into linear motion: the transformation of the motion occurs thanks to a suitable conversion system, such as a recirculating ball screw or a worm screw. Taking the first case for example, we find that the flange of the recirculating ball screw is constrained and fixed to the upper body while the screw itself is constrained to the lower body as well as to the motor itself, thanks to a suitable transmission system, such as a joint. The upper body and the lower body are characterized by holes adapted to host anti-rotation bars, which, once housed with one end constrained in the hole of the upper body and one end constrained in the hole of the lower body, together with the spring prevent the relative rotation of the upper body and the lower body, thus allowing the conversion of the rotary motion of the electric motor into linear motion along the coupling axis.

[0015] Also the aforesaid electric motor and transmission system components are comprised inside the lower body. This technical choice substantially differentiates the electromechanical cushioned linear actuator described in this patent application from other similar devices, known in the literature and available on the market, since the motor and also the transmission system, being stationary, do not undergo further stresses during operation which are due to the inertial forces generated by the weight of the components themselves, while they continue to participate in the distribution of the other stresses present. This precaution allows extending the life of the components, reducing the phenomenon of material fatigue. Especially for the electric motor, a reduction in stress allows preserving the life of the rolling bearings, present therein with the aim of maintaining the alignment of the crankshaft, and allows reducing the need for maintenance of a dynamic simulation system made with the aforesaid actuators.

[0016] Such an electromechanical cushioned linear actuator is adaptable to any application, simply through different creations of variable size and excursion range.

[0017] In practice, a dynamic simulation system does not require a single actuator but a plurality thereof and a related control system which has the aim of coordinating the movement of the various actuators in the optimal and congruent manner, from which the need arises to define the system associated with the electromechanical actuator described previously.

[0018] "Control system" is intended as the set comprising simulation software and an electronic device, such as a smartphone or tablet, with related management and control app. With even more detail, the software component of the system consists of three components: simulation software such as “Assetto Corsa Competizione”, “Fl 2023”, “Dirt Rally” or others; dynamic simulation software; a management and control app, present on said electronic device, adapted to manage said actuators while leaving the simulation software screen open.

[0019] The functional advantage of being able to manage the hardware component of the invention without necessarily minimizing the simulation software is clear. It will thus also be possible to manage the dynamic simulation software from the app, as well as the operating system and any other applications already installed on the electronic device. This feature allows reducing the risk of system crashes and providing a more realistic and immersive experience for the user.

[0020] The associated system in question comprises a plurality of electromechanical cushioned linear actuators as previously described, controlled by a dynamic simulation software interface and hardware by means of which all the various settings can be managed, and a remote management and control app, installed on a portable or fixed device (such as a tablet or smartphone), which allows the user to control and manage, remotely and without interrupting the simulation in progress, any software or operating system installed on the hardware in use. A simulation system thus described is adaptable to any application, simply by using a plurality of actuators of possibly variable sizes and excursion ranges.

[0021] In a variant of the present invention the input-output interface device of the system control software, easily accessible to the user and separated from the input-output interfaces of the dynamic simulator itself, can be used to manage the operating system, other programs and software installed on the hardware, without having to interrupt the graphic reproduction of the simulation software on the main monitors, by means of a dedicated app. This reduces the risk of the simulation software crashing, does not distract the user's attention and provides a more real and immersive experience. The programs installed on the hardware can, for example, be dedicated to streaming the simulation session by means of the various available platforms such as YouTube, Twitch, or they can be instant messaging programs, or more simply the web browser. If the input-output interface of the control system is provided with at least a camera and one microphone, it is possible for users to make video calls at the same time as the gaming session, or record or stream a subjective shot of the user's reaction during a dynamic simulation or gaming session.

[0022] Furthermore, the input-output interface can be provided with cable or wireless connection systems, exploiting technologies such as Bluetooth or wi-fi, for tablets and smartphones, through which all the control software settings can be managed and also exploit the cameras and microphones of the smartphone or tablet themselves to record the user's reaction to the simulation, or in any case the simulation session, using chosen angles.

[0023] A version of the invention which is the subject matter of the aforesaid patent application comprises a system for the emission of steam or of gaseous substances in general, adapted to simulate the smoke generated by the loss of grip of the tires of a car, operated by the simulation software, according to the needs of the dynamic simulation in execution.

[0024] The advantages offered by the present invention are evident in the light of the description presented thus far and will be even clearer thanks to the attached figures and the related detailed description. Description of the figures

[0025] The invention will be described hereinafter in at least a preferred embodiment by way of nonlimiting example with the aid of the appended figures, in which:

[0026] - FIGURE 1 shows an exploded view of the electromechanical cushioned linear actuator, highlighting the upper body 102 with relative connecting flange 101 and coupling hole 110, the coil spring 103, the anti-rotation bars 104, the lower body 107 comprising the recirculating ball screw 111, the transmission system 105, the electric motor 106 connected thereto and the relative support base 108 and the electrical connections 109.

[0027] - FIGURE 2 illustrates the electromechanical cushioned linear actuator in a vertical configuration highlighting the upper body 102, the lower body 107 with the relative electrical connections 109 and the coil spring 103.

[0028] - FIGURE 3 shows a dynamic driving simulation system created with four electromechanical cushioned linear actuators 203 constrained to a movable frame 202 and an input-output hardware interface 201 adapted to manage the control software.

[0029] Detailed description of the invention

[0030] The present invention will now be illustrated by way of a purely non-limiting or binding example, resorting to the figures which illustrate some embodiments with respect to the present inventive concept.

[0031] FIG. 1 highlights the upper body 102 with the relative connecting flange 101, coupling hole 110 and three housing holes for the same number of anti -rotation bars, then the lower body is shown comprising a support base 108, the electric motor 106 and the relative electrical connections 109, and the transmission system 105. The dynamic simulation software rotates the electric motor 106, with defined speed and acceleration, which are then transmitted to the conversion system by means of the transmission system 105, in this case made with a joint. The conversion system, in the chosen configuration composed of a coil spring 103, interposed between the upper body 102 and the lower body 107, by three anti -rotation bars 104, housed with the ends in as many holes in the upper body 102 and in the lower body 107, and by a recirculating ball screw 111, does not prevent the sliding of linear motion while it does not allow the rotation of the recirculating ball screw, thanks to which the rotary motion is converted into linear displacement: linear displacement speed and linear acceleration of the upper body 102 with respect to the lower body 107, impart to the entire movable frame 202 the movements and vibrations necessary to make the simulation experience started as real as possible.

[0032] With reference to FIG. 2, the electromechanical cushioned linear actuator is shown in vertical configuration. The preferred diameter of the coil spring 103 is 90mm, the preferred diameter of the lower body 107 and the upper body 102 is 100mm. The variable lengths during the operation of the actuator are variable between 613 mm at maximum extension and 503 mm at minimum extension, for the total length of the actuator, and for the length of the coil spring 103, variable between 452 mm at maximum extension and 343 mm at maximum compression. FIG. 3 shows the chosen configuration of a dynamic driving simulation system created by means of four electromechanical cushioned linear actuators 203 in the sizes previously described, constrained by the connecting flange 101 to a movable frame 202, and placed on the ground, considered as an external reference system, by means of the support bases 108. The movable frame 202 hosts all the devices and hardware peripherals necessary to simulate the passenger compartment of a car such as: a seat, a steering wheel, pedals, bass-shakers or butt-kickers and a monitor where the simulation software reproduces the processed graphics for the simulation, i.e., the view of the road and the surrounding landscape while driving. The actuator control software is instead managed by the independent input-output hardware interface 201, fixed on the movable frame and in any case easily accessible and removable by the user sitting on the seat. This allows intervening on the settings of the dynamic simulation software without interfering with the main peripherals, as well as managing settings related to the movable frame, such as external and internal lighting, positioning of the seat, pedals and monitor, or even managing the software and interfaces of the peripherals in use on the frame such as direct-drive, steering wheel and pedals, providing a real and immersive experience and minimizing the risk of crashes of the simulation software running on the main screen. Furthermore, the input-output hardware interface 201 allows managing all the programs and applications installed on the electronic device in use, such as those for streaming the gaming session on platforms such as YouTube or Twitch, real-time communication with other connected users, web browsers, as well as consulting the telemetry in real time and being able to compare it with ideal telemetries or saved data related to the simulation session of the person who carried out the simulation or of other users, all data available from the web or from servers made available for sharing this data.

[0033] Finally, it is clear that modifications, additions or variations that are obvious to a person skilled in the art can be made to the invention described so far, without thereby departing from the scope of protection provided by the attached claims.

Claims

Claims1. Electromechanical cushioned linear actuator for dynamic simulation, characterized in that it includes at least:• an upper body (102) comprising a connecting flange (101) and a coupling hole (110);• a lower body (107) comprising a conversion system (112), connected by means of a transmission system (105) and a recirculating ball screw (111) to an electric motor (106), to generate the movements and vibrations reproducing the dynamic experience established by a dedicated simulation software, with relative electrical connections (109) and a support base (108);• a spring interposed to the lower body (107) and the upper body (102) able to contribute to the increase in the useful life and efficiency of the electric motor and the actuator itself thanks to the drastic reduction of repeated stresses during use, as well as to the generation of the desired dynamic response;• an anti-rotation bar (104) designed to prevent the relative rotation of the upper body (102) - lower body (107) assembly; said upper body (102) being connectable to a mobile / movable frame representing a dynamic system to be reproduced and said lower body (107) being linked to an external reference system considered fixed / stationary, said electric motor (106) being stationary with respect to the external reference system, increasing its useful life and efficiency thanks to the drastic reduction of the repeated stresses during use.

2. Electromechanical cushioned linear actuator for dynamic simulation, according to claim 1, characterized in that it is mounted in a vertical arrangement / configuration, with the upper body (102) constrained by the connecting flange (101) to a mobile / movable frame representing the dynamic system to be reproduced and the lower body (107) resting on the ground through the support base (108), said lower body remaining in position due to the weight of the mobile / movable frame mounted / placeable above, without the need for further constraints.

3. Dynamic simulation system characterized in that it comprises a plurality of electromechanical cushioned linear actuators for dynamic simulation according to one of the preceding claims 1 or 2, variously arranged in order to control all or only some selected degrees of freedom of a mobile / movable frame (202) representing that part of a simulated vehicle which is integral with the driver, for the purposes of dynamic simulation.

4. Dynamic simulation system according to claim 3, characterized in that it includes dedicated software and input-output hardware interface (201), separate from the software and hardware dedicated to the dynamic simulation itself, said software and input-output hardware interface (201) being suitable for controlling said cushioned electromechanical actuators.

5. Dynamic simulation system according to claim 4, characterized in that the input-output hardware interface (201) of the control software of said system is a touch screen device placed in a position accessible to a user of the dynamic simulator but not interfering with the input-output hardware interfaces dedicated to the dynamic simulation itself.

6. Dynamic simulation system according to anyone of the preceding claims 4 or 5, characterized in that said control system is realized with appropriate software and hardware components adapted to manage, at the same time as the plurality of electromechanical cushioned linear actuators, the streaming of the game session via dedicated online platforms, web browsing through specific applications, consultation and comparison of real-time telemetry, management of frame lighting and user positions within the frame itself.

7. Dynamic simulation system according to anyone of the preceding claims 4, 5 or 6, characterized in that said input-output hardware interface (201) includes at least a video camera and a microphone adapted for recording video and audio of the user’s reaction to the simulation.

8. Dynamic simulation system according to claim 7, characterized in that said control software allows the streaming, through the use of an online platform, of the audio-video recordings of the user’s reaction to the simulation.

9. Dynamic simulation system according to anyone of the preceding claims 4, 5, 6, 7 or 8, characterized in that the hardware interface of said control system is equipped with a physical connection system via cable or wireless, such as Bluetooth or Wi-Fi, to connect a tablet or smartphone to be used as an input-output interface, through an appropriate app, of the control software of the plurality of cushioned linear actuators.

10. Dynamic simulation system according to the preceding claims 7, 8 and 9 characterized in that said physical connection system via cable or wireless allows the use of the video camera and / or microphone of a connected smartphone or tablet to record audio and / or video of the user’s reaction to the simulation and possibly transmit it in streaming via an appropriate online platform.

11. Dynamic simulation system according to anyone of the preceding claims from 3 onwards, characterized in that it comprises an audio system adapted for the emission of sound effects during simulation.

12. Dynamic simulation system according to anyone of the preceding claims from 3 onwards, characterized in that it comprises a system for the emission of steam or of gaseous substances in general, adapted for simulating the smoke generated by the loss of grip of the tires of a car, operated / activated by the simulation software, according to the needs of the dynamic simulation in execution.

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