MOTION SIMULATION SYSTEM AND METHOD

Abstract

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

Description

[Technical field]

[0001] (Reference to Related Application) This application claims priority to U.S. Provisional Patent Application No. 63 / 308,421, filed February 9, 2022, the disclosure of which is incorporated herein by reference.

[0002] FIELD OF THEINVENTION The present disclosure relates generally to motion simulation systems, including, but not limited to, a motion simulation system that includes a platform assembly and is configured to move with multiple degrees of freedom. [Background technology]

[0003] Motion simulation systems include platforms for supporting and initiating physical movement for participants in amusement attractions and simulation products, such as video games. Such systems are designed to provide physical movement for participants in movies or computer simulation / game activities. The Stewart platform (or hexapod) is a well-known form of simulator that provides a moving platform relative to a base.

[0004] In some applications, the hexapod includes six linear actuators configured to move the platform with six degrees of freedom relative to the base, specifically three linear and three rotational degrees of freedom, depending on which actuators are used in combination. The translational degrees of freedom are commonly known as surge (horizontal movement in the direction of travel), sway (horizontal movement perpendicular to the direction of travel), and heave (vertical motion). The rotational degrees of freedom are known 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).

[0005] In certain applications, a hexapod may have a limited workspace defined by a maximum and minimum range of motion of the platform, which is further defined by actuator travel limitations. For larger workspaces requiring additional platform movement in any given degree of freedom, certain systems may utilize longer actuators, but such longer actuators may substantially increase the cost associated with the simulator and may also reduce the inherent stiffness of the simulator. Additionally, certain existing motion simulation systems may use expensive industrial grade components, further increasing simulator costs. In some applications, the primary cost driver of existing motion simulation systems is the motion effector subsystem, which includes the actuation elements (servo motors), associated gear reduction elements, and associated feedback and control systems. Summary of the Invention

[0006] Therefore, there is a need for a motion simulation system that can provide improved movement control and functionality (eg, greater frequency response) while having lower manufacturing costs.

[0007] This disclosure describes a motion simulation system for initiating physical movement for amusement and simulation purposes. In some embodiments, the motion simulation system includes one or more load-bearing actuators and one or more positioning actuator assemblies.

[0008] The motion simulation system can include a plurality of load-bearing actuators and a plurality of positioning actuator assemblies. In various embodiments, the motion simulation system can include twice as many positioning actuator assemblies as load-bearing actuators. In some embodiments, the motion simulation system can include three load-bearing actuators and six positioning actuator assemblies. In some embodiments, the ends of the load-bearing actuators can be adjacent to the ends of the first and second positioning actuator assemblies. The motion simulation system can enable six degrees of freedom.

[0009] The motion simulation system can include a platform, which can be coupled to a load-bearing actuator and a positioning actuator assembly.

[0010] In some embodiments, the load bearing actuator can include a buffer tank. The buffer tank can provide or define a dead volume. The buffer tank can be in fluid communication with the pneumatic cylinder. The buffer tank can increase the dead volume of the load bearing actuator. For example, the dead volume can be about 100% to 500% of the sweep volume of the pneumatic cylinder. In some embodiments, the pneumatic cylinder can be filled by oscillating a piston rod.

[0011] In some embodiments, the positioning actuator assembly includes a crank pivotally coupled to the rotor and the connecting rod. The crank may be integrally formed with the rotor.

[0012] In some embodiments, the load bearing actuator and the positioning actuator assembly are at least partially disposed within the linear actuator housing. A connecting rod of the positioning actuator assembly can be coupled to a piston rod of the load bearing actuator. In some embodiments, an end of the connecting rod is pivotally coupled to the piston rod between a first end and a second end of the piston rod.

[0013] 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 a current draw of the positioning actuator. In some embodiments, the controller is configured to pressurize a volume of the pneumatic cylinder to a pressure that minimizes a current draw of the positioning actuator. In various embodiments, the controller is configured to control the operation of the positioning actuator at a frequency of up to about 1000 Hz.

[0014] In various embodiments, a controller of the motion simulation system can compare the rotational position of the positioning actuator to a desired rotational position of the positioning actuator for closed-loop control of the motion control system. In some embodiments, the controller can adjust a gain factor in response to comparing the rotational position of the positioning actuator to the desired rotational position of the positioning actuator.

[0015] In some embodiments, the motion simulation system includes an electrical storage device for receiving energy generated by the positioning actuators and deploying the energy in the motion simulation system.

[0016] As previously discussed, certain conventional motion simulation systems can be costly and can have relatively low frequency response and inherent stiffness. The present disclosure includes embodiments that allow for improved motion control, increased frequency response, and increased inherent stiffness while providing lower component and manufacturing costs. Embodiments of the present disclosure can utilize direct drive actuator arrangements and eliminate gear reduction elements. Additionally, embodiments of the present disclosure can utilize rotary or linear encoders to provide additional control to non-servo motors. Additionally, embodiments of the present disclosure can allow forced ventilation of actuators to enhance cooling.

[0017] In one aspect, some embodiments include a motion simulation system including a load-bearing actuator including a pneumatic cylinder defining a cavity and a piston rod at least partially disposed within the cavity of the pneumatic cylinder, where a first end of the piston rod and the cavity of the pneumatic cylinder define a volume of the pneumatic cylinder, where the volume of the pneumatic cylinder is configured to be pressurized to support a weight of a payload; and a positioning actuator assembly including a positioning actuator including a stator and a rotor configured to rotate relative to the stator, and a connecting rod coupled to the rotor, where the rotor is configured to rotate to translate the connecting rod and position a payload supported by the load-bearing actuator.

[0018] In another aspect, some embodiments provide a motion simulation system including a base, a platform movable relative to the base and configured to support a payload, a plurality of load-bearing actuators, each load-bearing actuator including a pneumatic cylinder pivotally coupled to the base, the pneumatic cylinder defining a cavity, and a piston rod defining a first end and a second end, the first end being at least partially disposed within the cavity of the pneumatic cylinder to define a volume of the pneumatic cylinder, the second end being pivotally coupled to the platform, the volume of the pneumatic cylinder configured to be pressurized to support the platform. The motion simulation system includes a load-bearing actuator; and a plurality of positioning actuator assemblies, each positioning actuator assembly including a positioning actuator coupled 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 coupled to the rotor and a second end pivotally coupled to the platform, the rotor configured to rotate to translate the connecting rod and position a payload supported by the plurality of load-bearing actuators.

[0019] In another aspect, some embodiments include a method of operating a motion simulation system including pressurizing 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 respective plurality of positioning actuator assemblies, each positioning actuator assembly pivotally coupled to the platform via a respective connecting rod of the plurality of positioning actuator assemblies.

[0020] In another aspect, some embodiments include those configured to perform any of the methods described herein. In another aspect, some embodiments include a non-transitory computer-readable storage medium storing one or more programs, the one or more programs including instructions that, when executed by a system, cause the system to perform any of the methods described herein.

[0021] Thus, systems and methods are provided for simulating motion with more effective motion control while reducing component and manufacturing costs, thereby improving the performance and reducing the overall cost of such systems and devices. [Brief description of the drawings]

[0022] For a better understanding of the various described embodiments, reference should be made to the following description of the embodiments in conjunction with the following drawings, in which like reference numerals refer to corresponding parts throughout. [Figure 1] FIG. 1 illustrates a perspective view of a motion simulation system with a payload according to some embodiments. [Diagram 2] FIG. 1 illustrates a perspective view of a motion simulation system according to some embodiments. [Diagram 3] 3 is a perspective view of a load-bearing actuator of the motion simulation system of FIG. 2 in accordance with some embodiments. [Figure 4] 3 is a cross-sectional view of a load-bearing actuator of the motion simulation system of FIG. 2 in accordance with some embodiments. [Diagram 5] FIG. 3 is a perspective view of a positioning actuator assembly of the motion simulation system of FIG. 2 in accordance with some embodiments. [Figure 6] 6 is a perspective view of a positioning actuator of the positioning actuator assembly of FIG. 5 in accordance with some embodiments. [Figure 7]FIG. 6 is a perspective view of a positioning actuator of the positioning actuator assembly of FIG. 5 in accordance with some embodiments. [Figure 8A] FIG. 1 illustrates a perspective view of a motion simulation system according to some embodiments. [Figure 8B] FIG. 8B is a side view of a positioning actuator assembly of the motion simulation system of FIG. 8A in accordance with some embodiments. [Figure 8C] FIG. 1 illustrates a perspective view of a motion simulation system according to some embodiments. [Figure 8D] FIG. 8D is a side view of a positioning actuator assembly of the motion simulation system of FIG. 8C according to some embodiments. [Figure 8E] FIG. 1 illustrates a perspective view of a positioning actuator assembly according to some embodiments. [Figure 9] FIG. 1 illustrates a perspective view of a motion simulation system with a payload according to some embodiments. [Figure 10] FIG. 1 illustrates a perspective view of a motion simulation system according to some embodiments. [Figure 11A] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 11B] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 11C] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 11D] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 11E] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 11F] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 11G] 1A-1D are perspective views of a motion simulation system according to some embodiments. [Figure 12] FIG. 1 illustrates a perspective view of a motion simulation system according to some embodiments. [Figure 13] FIG. 13 is a perspective view of an integrated linear actuator unit of the motion simulation system of FIG. 12 according to some embodiments. [Figure 14] FIG. 14 is an elevational view of the integrated linear actuator unit of FIG. 13. [Figure 15] FIG. 14 is a perspective view of a load-bearing actuator of the integrated linear actuator unit of FIG. 13 according to some embodiments. [Figure 16] FIG. 1 illustrates a perspective view of a motion simulation system, according to some embodiments. [Figure 17] 1 is a perspective view of a haptic device according to some embodiments. [Figure 18] 18 is an elevational view of the haptic device of FIG. 17. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] This disclosure describes various embodiments of a motion simulation system. In some embodiments, the motion simulation system includes a load-bearing actuator and a positioning actuator, where the load-bearing actuator supports the weight of a payload and minimizes the weight that the positioning actuator must support. In some applications, the use of the load-bearing actuator can enable the use of a direct drive positioning actuator. Advantageously, by minimizing the weight that the positioning actuator must support, embodiments of the motion simulation system can utilize smaller, cost-effective actuators that provide improved movement control and high frequency response (up to 1000 Hz in some embodiments) while providing the desired range of motion and degrees of freedom (e.g., six degrees of freedom).

[0024] FIG. 1 is a perspective view of a motion simulation system 100 having a payload 10 according to some embodiments. FIG. 2 is a perspective view of the motion simulation system 100 according to some embodiments. With reference to FIGS. 1 and 2, the motion simulation system 100 supports and / or positions the payload 10 relative to a base 110 to provide motion information, signals, or other feedback to a user. In some embodiments, the payload 10 can include, but is not limited to, a user, a seat, and / or hardware. In some embodiments, the hardware can include, but is not limited to, automobile simulation hardware (e.g., steering wheel and pedals), aviation simulation hardware, or other suitable hardware. In some applications, the payload 10 can exceed 100 kilograms. Although embodiments of the motion simulation system can carry or move more payload than certain conventional motion simulation systems, the payload capacity of embodiments of the motion simulation system can vary depending on the size and configuration of the motion simulation system.

[0025] As shown, the platform 120 can support the payload 10 and be positioned relative to the base 110. In the illustrated example, the platform 120 includes one or more legs 122 that are shaped, bent, or otherwise configured to receive, support, or support the payload 10. A portion of the payload 10 can be attached or secured to the legs 122 of the platform 120. The legs 122 or other features of the platform 120 can be adapted to any suitable payload 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 payload 10. In some embodiments, the shape of the platform 120 can be symmetrical, asymmetrical, or otherwise varied.

[0026] In the illustrated example, the base 110 can support the weight of the platform 120 and payload 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, asymmetrical, or otherwise varied.

[0027] As described herein, one or more load supporting actuators 130 can support the weight of the platform 120 and payload 10 relative to the base 110. Additionally, one or more positioning actuator assemblies 140 can move or position the platform 120 and payload 10 relative to the base 110.

[0028] FIG 3 is a perspective view of the load-supporting actuator 130 of the motion simulation system 100 of FIG 2, according to some embodiments. FIG 4 is a cross-sectional view of the load-supporting actuator 130 of the motion simulation system 100 of FIG 2, according to some embodiments. With reference to FIGS. 1-4, each load-supporting actuator 130 can support the platform 120 and payload 10 at a desired attitude relative to the base 110. In the illustrated example, the load-supporting actuator 130 supports the platform 120 and payload 10 without affecting the position of the platform 120 during normal operation.

[0029] In the illustrated example, the load-bearing actuator 130 is coupled to the platform 120 and the base 110. As illustrated, one end 136 of the load-bearing actuator 130 can be coupled to the base 110 and an opposing end 136 of the load-bearing actuator 130 can be coupled to the platform 120. In some embodiments, the end 136 can be coupled to the end 124 of the leg 122 or any other suitable portion of the platform 120. In some embodiments, the location of the joints, connections, or ends 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 otherwise variable. In some embodiments, the end 136 can be pivotally coupled to the base 110 and the platform 120. The end 136 can include a ball joint.

[0030] Prior to normal operation of the motion simulator system 100, the load support actuator 130 can be extended to a desired length to act as legs or otherwise support the platform 120 and payload 10 in a desired orientation. In the illustrated example, the load support actuator 130 is a pneumatic actuator that utilizes air pressure to extend and support the platform 120 and payload 10 in a desired orientation. In some embodiments, the pneumatic actuator includes a piston rod 134 that is movable relative to a pneumatic cylinder 132.

[0031] As shown, a first end of the piston rod 134 is at least partially disposed within a cavity of the pneumatic cylinder 132, defining a cylinder volume 133. In operation, the cylinder volume 133 can be pressurized to advance the piston rod 134 to support the platform 120. As described herein, the pressure in the cylinder volume 133 can be adjusted to adjust the position of the piston rod 134 relative to the pneumatic cylinder 132 to support various payload weights, platform heights, and / or attitudes. In some embodiments, a second end 136 of the piston rod 134 is coupled to the platform 120. In some embodiments, the second end 136 of the piston rod 134 may have a travel distance of approximately 100 mm to 200 mm. Further, in some embodiments, the piston rod 134 may have a diameter of approximately 30 mm to 50 mm and may be capable of exerting a force of approximately 500 to 1500 N.

[0032] In some embodiments, the pneumatic cylinder 132 can be pressurized by a pneumatic control circuit. The pneumatic control circuit can include a compressor to pressurize the cylinder volume 133 to a desired pressure via the port 139. The pneumatic control circuit can introduce, relieve, or control pressure in the cylinder volume 133 via the port 139. In some embodiments, the motion simulation system 100 can self-pressurize the pneumatic actuator by utilizing the piston rod 134 as a pumping element. During a self-pressurization or compressor-less procedure, the positioning actuator assembly 140 can move the platform through a suitable series of attitudes (e.g., oscillating the platform 120 along a vertical or heave axis) and selectively actuate a control element of the pneumatic control system to enable oscillation of the piston rod 134 coupled to the platform 120 to pressurize the cylinder volume 133 to a desired pressure. In some embodiments, the pneumatic cylinder 132 can include a one-way valve that allows air to enter the cylinder volume 133 and be compressed by the piston rod 134 without escaping the cylinder volume 133 during a self-pressurization procedure.

[0033] In some applications, the state or extension of the load-supporting actuators 130 to support the platform 120 and payload 10 at a desired orientation relative to the base 110 can be determined by a calibration process. For example, the calibration process can determine and provide a desired pressure within the cylinder volume 133 of each load-supporting actuator 130 to support the platform 120 and payload 10 at a desired orientation relative to the base 110. In some embodiments, the load-supporting actuators 130 can be calibrated to support the platform 120 and payload 10 at an orientation that enables the motion simulation system 100 to move the platform 120 through a desired range of motion that can be located at the center of the motion envelope of the motion simulation system 100. In some embodiments, the load-supporting actuators 130 can be calibrated to support the platform 120 at an orientation that is offset from the center of the motion envelope of the motion simulation system 100. For example, the load-supporting actuators 130 can be calibrated to support the platform 120 at a position that is higher or lower than the center of the motion envelope of the motion simulation system 100.

[0034] In some embodiments, the calibration process may begin by using the positioning actuator assembly 140 to place the platform 120 in static equilibrium at a preselected attitude, which may be referred to as the zero position attitude. As described herein, the controller may determine the weight of the platform 120 and supported payload 10 by detecting the load experienced 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 that is analyzed by the controller.

[0035] After determining the weight of the platform 120 and any supported payload 10, the cylinder volume 133 of each individual load-bearing actuator 130 can be pressurized to minimize the load experienced by the positioning actuator assembly 140. In some embodiments, minimization 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 via self-pressurization due to vibration of the platform 120.

[0036] In some embodiments, after a calibration process, the pressure of the cylinder volume 133 of each individual load-bearing actuator 130 is established as an equilibrium pressure for supporting the platform 120 and payload 10 at a desired attitude. Similarly, the stroke of the piston rod 134 relative to the pneumatic cylinder 132 of each individual load-bearing actuator 130 is established as an equilibrium distance or stroke for supporting the platform 120 and payload 10 at a desired attitude. The equilibrium pressure and distance may vary between each load-bearing actuator 130. After calibration, each load-bearing actuator 130 may be pneumatically isolated from the pneumatic circuit. Advantageously, the calibrated load-bearing actuators allow the motion simulation system 100 to maintain a zero position attitude with a minimal amount of torque (and power) from the positioning actuator assembly 140, since the weight of the platform 120 and payload 10 is supported or balanced by the load-bearing actuator 130.

[0037] In some applications, a particular pneumatic actuator may apply different forces based on the position of the piston rod within the actuator's variable or swept volume. For example, without considering the effects of temperature, a particular pneumatic actuator may apply less actuation force as the piston rod extends because the cylinder volume expands and pressure drops, and more actuation force as the piston rod retracts because the cylinder volume compresses and pressure increases. In a particular pneumatic actuator, the force applied by the actuator may be inversely proportional to the piston position.

[0038] In some embodiments, the load bearing actuator 130 may provide a relatively large non-variable or dead volume compared to the variable sweep volume of the pneumatic cylinder 132 and piston rod 134 to minimize fluctuations in pressure, and therefore actuation force, as the piston rod 134 moves through its stroke. In the illustrated example, the load bearing actuator 130 includes a buffer tank 138 in fluid communication with the pneumatic cylinder 132 to provide additional dead volume to the pneumatic cylinder 132. As illustrated, the dead volume of the buffer tank 138 may be in fluid communication with the cylinder volume 133 via 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 fluctuations in pressure within the load bearing actuator 130 (i.e., the combined volume of the buffer tank 138 and the cylinder volume 133) as the cylinder volume 133 changes are minimized, which in turn minimizes changes in the force provided by the load bearing actuator 130. In some embodiments, the dead volume of the buffer tank 138 is between 100% and 500% of the variable sweep volume of the cylinder volume 133.

[0039] In some embodiments, the load support actuators 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 velocity of air flow between the buffer tank 138 and the extension chamber of the pneumatic cylinder 132 and / or between the retraction chamber of the pneumatic cylinder 132 and the environment. In some embodiments, the velocity of the air flow can be adjusted during operation to dynamically adjust the magnitude of the damping effect provided by the load support actuators 130. Additionally, the load support actuators 130 can recuperate and / or recover energy from the platform 120 and the payload 10 by acting as a spring.

[0040] In some embodiments, the load bearing actuator 130 can be an active or passive device and can utilize other types of actuators including, but not limited to, gas struts, gas springs, elastic ropes, linear springs, coil springs, and / or rotary springs. As described herein, the force applied by the load bearing actuator 130 can be adjustable. For example, a particular load bearing actuator can include an adjustable or programmable spring. In some embodiments, a programmable spring can include a series elastic actuator (SEA) that includes an actuator coupled to a load via an elastic element (e.g., one or more springs) and a sensor for measuring the degree of force transmitted through the elastic element. A control loop can be programmed to apply a specified force to a load and generate a system that can cause the actuator to behave like a spring with a desired stiffness.

[0041] In some embodiments, the force applied by the load bearing actuator 130 may be preset or otherwise not easily adjustable. For example, a particular load bearing actuator 130 may be configured for a fixed payload and may be initially calibrated or manufactured to provide an appropriate load bearing force. In certain embodiments, a particular load bearing actuator 130 may be configured for a fixed payload and may be initially calibrated or manufactured utilizing similar calibration procedures described herein.

[0042] As described herein, the load-supporting actuators 130 may be positioned or otherwise arranged relative to the base 110 and platform 120 in any suitable arrangement. For example, the motion simulation system 100 may include twice as many positioning actuator assemblies 140 as there are load-supporting actuators 130. As shown, the motion simulation system 100 may include three load-supporting actuators 130. The load-supporting actuators 130 may be spaced equidistantly.

[0043] Figure 5 is a perspective view of a positioning actuator assembly 140 of the motion simulation system 100 of Figure 2, according to some embodiments. With reference to Figure 5, each positioning actuator assembly 140 can move or position the platform 120 and payload 10 to a desired attitude relative to the base 110. In the illustrated example, the positioning actuator assemblies 140 can collectively or cooperatively position the platform 120 in any six-dimensional attitude with respect to surge, sway, heave, yaw, pitch, and roll within the operating space envelope of the motion simulation system 100.

[0044] In the illustrated example, the positioning actuator assembly 140 is coupled to the platform 120 and the base 110. As shown, the positioning actuator 150 can be coupled to the base 110, and the end 148 of the connecting rod 146 can be coupled to the platform 120. In some embodiments, the end 148 of the connecting rod 146 can be coupled to the end 124 of the leg 122 or any other suitable portion of the platform 120. In some embodiments, the arrangement of the end 148 of the individual positioning actuator assembly 140 relative to the platform 120 can be coplanar, non-coplanar, symmetrical, asymmetrical, or otherwise varied. In some embodiments, the end 148 of the connecting rod 146 can be pivotally coupled to the platform 120 and the positioning actuator 150. The end 148 can include a ball joint. In some embodiments, the arrangement of the positioning actuator 150 of the individual positioning actuator assembly 140 relative to the base 110 can be coplanar, non-coplanar, symmetrical, asymmetrical, or otherwise varied.

[0045] During operation of the motion simulation system 100, the positioning actuator assembly 140 can extend, retract, translate, or move the respective connecting rods 146 to position the platform 120 and payload 10 at a desired attitude. In the illustrated example, the positioning actuator assembly 140 includes a positioning actuator 150 for manipulating the connecting rods 146, which (in conjunction with the other positioning actuator assemblies 140) position the platform 120 at a desired attitude.

[0046] In the illustrated example, the positioning actuator 150 rotates the rotor 142 to adjust the position of the connecting rod 146, and in particular the connecting rod end 148 pivotally coupled to the platform 120. As illustrated, a linkage such as a crank 144 coupled to the rotor 142 can rotate with the rotor 142 being able to move or translate the opposing connecting rod end 148 pivotally coupled to the crank 144. Rotation of the crank 144 can move or translate the connecting rod 146, and thus the connecting rod end 148 coupled to the platform 120. In some embodiments, the length or geometry of the crank 144 can be altered to adjust the relationship between the rotation of the rotor 142 and the movement of the connecting rod 146. Additionally, in some embodiments, the positioning actuator can include a linear actuator.

[0047] Advantageously, the direct attachment or connection between the connecting rod 146, the crank 144, and the rotor 142 of the positioning actuator 150 allows for a direct drive mechanism or arrangement to adjust the position of the platform 120. Furthermore, the absence of any intervening or intermediate mechanical or power transmission elements allows the weight and inertia of the platform 120 and payload 10 to be transferred directly and immediately to the positioning actuator 150, increasing the stiffness and response of the system and allowing the motion simulation system 100 to reject or overcome static external disturbances (e.g., when an axis is holding a position or velocity) and dynamic external disturbances (e.g., when an axis is following a position or velocity trajectory).

[0048] In certain conventional applications, the use of a direct drive mechanism may require conventional positioning actuators to directly support the weight of the platform and payload. Thus, in certain applications, even during static equilibrium, conventional actuators must apply a constant torque to counterbalance the weight of the platform and payload, increasing the actuator energy consumption and demand. Advantageously, the use of a load-bearing actuator 130 supports the load of the platform 120 and payload 10, allowing for the use of a direct drive positioning actuator assembly 140 that does not need to directly or constantly support the weight of the platform 120 and payload 10. The use of a load-bearing actuator 130 allows for smaller, lighter, less expensive actuators and other components in the positioning actuator assembly 140, allowing for reduced energy consumption, while still allowing for desired performance.

[0049] FIG. 6 is a perspective view of the positioning actuator 150 of the positioning actuator assembly 140 of FIG. 5 according to some embodiments. FIG. 7 is a see-through perspective view of the positioning actuator 150 of the positioning actuator assembly 140 of FIG. 5 according to some embodiments. With reference to FIGS. 5-7, the positioning actuator 150 rotates the rotor 142 relative to a stator disposed within 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 a stator or other stationary part of the positioning actuator 150. A signal from the rotary encoder 152 can be used as feedback for closed-loop control of the positioning actuator assembly 140 and the motion control system 100 in general. In some embodiments, the positioning actuator 150 can include a fan 156 for actively cooling components of the positioning actuator 150. The fan 156 can draw in cool air or expel heat through a fan housing 154 formed in the positioning actuator 150.

[0050] As described herein, embodiments of the positioning actuator assembly may include a connecting rod with 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, a particular ball joint may have a limited pivot angle, which may limit the motion of the connecting rod and thus the positioning actuator assembly may limit the motion envelope of the motion simulation system. For example, a particular ball joint may have a pivot angle range of about ±10 degrees, ±15 degrees, or ±20 degrees.

[0051] Furthermore, in certain applications, a particular positioning actuator assembly may be positioned such that the motion simulation system is unable to utilize the full pivot angle range of the ball joints, limiting the operating envelope of the motion simulation system for a given ball joint pivot angle range. For example, a particular positioning actuator assembly may be positioned such that the ball joint ends of the individual connecting rods are located or positioned away from the midpoints of their individual pivot angle ranges when the motion simulation system is in a preselected rest or zero position orientation. As a result, in certain applications, the ends of the ball joints may pivot more in one direction and less in another direction relative to the zero position orientation. In some applications, the reduced pivot travel relative to the zero position orientation may impose limitations on the overall operating envelope of the motion simulation system.

[0052] FIGURE 8A is a perspective view of a motion simulation system 200a according to some embodiments. FIGURE 8B is a side view of a positioning actuator assembly 240a of the motion simulation system 200a of FIGURE 8A according to some embodiments. In some embodiments, one or more of the positioning actuator assemblies 240a can be configured to increase the operating range or operating envelope of the motion simulation system 200a as compared to a particular conventional motion simulation system. In some embodiments, the motion simulation system 100 can utilize other types, structures, or configurations of actuator assemblies or actuators, as illustrated by their implementation in other systems.

[0053] In some embodiments, one or more of the positioning actuator assemblies 240a can be positioned or arranged to avoid limiting or otherwise increase the available range of motion of the joint ends 248a, thereby increasing the range of motion of the positioning actuator assemblies 240a and the motion envelope of the motion simulation system 200a. In the illustrated example, the positioning actuator assemblies 240a can be positioned such that the ball joint ends 248a of the respective connecting rods 246a can be positioned or arranged at or near the approximate midpoint of the respective pivot angle range when the motion simulation system 200a is in a preselected rest or zero position attitude. In some applications, the ball joint ends 248a can be configured to be positioned at or near the approximate midpoint of the respective pivot angle range when the load bearing actuator 230a is placed in an equilibrium configuration or position. By allowing the ball joint ends 248a to be positioned approximately at or near the midpoint of their respective pivot angle ranges when the motion simulation system 200a is in the zero position pose, the ball joint ends 248a can pivot approximately equal amounts in various directions relative to the zero position pose. Advantageously, approximately equal pivot movement relative to the zero position pose can maximize the overall operating envelope of the motion simulation system 200a for a given ball joint end 248a.

[0054] In some embodiments, the position of the ball joint ends 248a within the pivot angle range for a given position or pose can be adjusted by changing the angle, also referred to as the motor dihedral angle, between the horizontal plane and the motor axis of rotation of the positioning actuator 250a. In the illustrated example, the motor dihedral angle of the positioning actuator 250a can be adjusted such that the ball joint ends 248a can be positioned at or near the approximately midpoint of their respective pivot angle range when the motion simulation system 200a is in the zero position pose. In some applications, the motor dihedral angle of the positioning actuator 250a can be adjusted such that the ball joint ends 248a are positioned at another desired position of their respective pivot range at a desired pose. As illustrated, the motor dihedral angle of the positioning actuator 250a can be non-zero and positive. In some embodiments, the motor dihedral angle of the positioning actuator 250a can range from about 0.1 degrees to about 20 degrees.

[0055] In some embodiments, the position of the ball joint end 248a within the pivot angle range for a given position or attitude can be adjusted by changing the angle, also referred to as the platform dihedral angle, between the base of the platform 220a and the axis of the ball joint end 248a. In the illustrated example, the platform dihedral angle of the platform 220a can be adjusted such that the ball joint ends 248a can be positioned at or near the approximately midpoint of their respective pivot angle range when the motion simulation system 200a is in the zero position attitude. In some applications, the platform dihedral angle of the platform 220a can be adjusted such that the ball joint ends 248a can be positioned at another desired position of their respective pivot range at a desired attitude. As illustrated, the platform dihedral angle of the platform 220a can be non-zero and positive. In some embodiments, the platform dihedral angle of the platform 220a can range from about 0.1 degrees to about 20 degrees. 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 may be different.

[0056] Figure 8C is a perspective view of a motion simulation system 200b according to some embodiments. Figure 8D is a side view of a positioning actuator assembly 240b of the motion simulation system 200b of Figure 8C according to some embodiments. 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 range from about 0.1 degrees to about 20 degrees.

[0057] In some embodiments, the platform dihedral angle of platform 220b can be non-zero and negative, hi some embodiments, the platform dihedral angle of platform 220b can be in the range of about 0.1 degrees to about 20 degrees.

[0058] In some applications, the motor dihedral angles and platform dihedral angles may be the same, similar, or complementary. In some applications, the motor dihedral angles and platform dihedral angles may be different. Additionally, in some embodiments, the motor dihedral angles and platform dihedral angles of a particular portion of the motion simulation system may be positive or negative, or non-zero. In some applications, the use of non-zero motor dihedral angles and platform dihedral angles may allow for a smaller profile of the base, as well as the overall motion simulation system.

[0059] 8E is a perspective view of a positioning actuator assembly 240c, according to some embodiments. Referring to FIG. 8E, the motion simulation system 100 can utilize a positioning actuator assembly 242c (instead of or in addition to the positioning actuator assembly 140) that includes a crank 244c integrated with the rotor 240c. As shown, the crank 244c can extend axially from a surface of the rotor 242c, allowing a connecting rod 246c to be directly attached or coupled to the rotor 242c. In operation, the crank 244c can rotate with the rotor 242c to move or translate the connecting rod to adjust the position of the platform 120.

[0060] As shown, the positioning actuator assembly 240c can have non-zero motor and / or platform dihedral angles to maximize the pivot range of the ball joint end 248c relative to the zero position orientation. In some embodiments, the positioning actuator assembly 240c can have negative motor and / or platform dihedral angles.

[0061] As described herein, the positioning actuator assemblies 140 may be arranged or otherwise positioned relative to the base 110 and platform 120 in any suitable arrangement. In the illustrated example, the positioning actuator assemblies 140 may be configured to enable the motion simulation system 100 to move in six degrees of freedom. As illustrated, the motion simulation system 100 may include six positioning actuator assemblies 140. The six positioning actuator assemblies 140 may be arranged equidistantly. For example, the positioning actuator assemblies 140 may be spaced between 500 mm and 1200 mm apart. In some embodiments, the positioning actuator assemblies 140 may be arranged in a "rotating hexapod" arrangement.

[0062] In some applications, the placement of the positioning actuator assemblies 140 may vary relative to the load-bearing actuators 130. As mentioned above, the motion simulation system 100 may include twice as many positioning actuator assemblies 140 as there are load-bearing actuators 130. In some embodiments, each load-bearing actuator 130 may be positioned between two positioning actuator assemblies 140, forming a "leg set" of three arranged around the base 110 and coupled to the platform 120. Furthermore, in some embodiments, the end 136 of the piston rod 134 of the load-bearing actuator 130 coupled to the platform 120 may be positioned between the connecting rod ends 148 of the two positioning actuator assemblies 140.

[0063] In operation, the motion simulation system 100 can utilize the positioning actuator assemblies 140 to place the platform 120 and payload 10 in a desired attitude or a streamed series of attitudes in response to a position input. In the illustrated example, a controller of the motion simulation system 100 can receive the position input as a streamed series of attitude vectors. The attitude vectors can be received at a streaming frequency. In some embodiments, the controller of the motion simulation system 100 can receive and / or process the attitude vectors at a streaming frequency of up to about 1000 Hz. Furthermore, in some embodiments, the positioning actuator assemblies 140 can position the platform 120 in various attitudes at a streaming frequency of up to about 1000 Hz. In some applications, the positioning actuator assemblies 140 can be operated simultaneously by utilizing certain features, including but not limited to a parallel architecture with synchronization signals.

[0064] During the pre-processing stage, each received attitude vector may be transformed or scaled. Additionally, each received attitude vector may be processed with respect to kinematic conditions of the system (e.g., to limit the maximum acceleration and / or velocity of the motion simulation system 100). Additionally, each received attitude vector may be verified against the physical mechanical limits of the motion simulation system 100. In some embodiments, the motion simulation system 100 may have minimum travel limits of about -100mm to -50mm and maximum travel limits of about 50mm to 100mm in the surge, sway, and heave motion axes, and a span of about 100mm to 200mm. In some embodiments, the motion simulation system 100 may have minimum travel limits of about -15 degrees to -5 degrees and maximum travel limits of about 5 degrees to 15 degrees in the heading / yaw, attitude / pitch, and bank / roll axes, and a span of about 10 degrees to 20 degrees.

[0065] In the illustrated example, the effective attitude vector is converted to a position vector for each individual positioning actuator assembly 140 that is commanded to the respective positioning actuator assembly 140. In some embodiments, the controller of the motion simulation system 100 utilizes inverse kinematics to control the position of the platform 120. For example, the controller processes the attitude vector to provide an effector position vector, which may be a desired rotation angle of the individual positioning actuators 150. Thus, a pre-described set of input attitude vectors can result in highly controlled movement of the platform 120. In some embodiments, the motion control system 100 can control the movement of at least six positioning actuator assemblies 140 to provide six degrees of freedom. In some embodiments, the motion control system 100 can be "over-actuated" and include more positioning actuator assemblies 140 than desired. In some applications, the motion simulation system 100 can utilize "forward" or joint-space control (i.e., individual control of each positioning actuator assembly 140), "reverse" or model-space control (i.e., control of the movement of the platform 120 as a system), or a hybrid system that can alternate between joint-space control or model-space control under various circumstances. In some applications, the motion simulation system 100 may control the position of the platform 120 using forward kinematics and / or inverse dynamics control.

[0066] In some embodiments, the controller of the motion simulation system 100 can collectively or cooperatively provide effector position vectors to each positioning actuator assembly 140 to provide a desired platform 120 pose, but the motion control simulation system 100 can have independent closed-loop control of each positioning actuator assembly 140. For example, in some embodiments, the motion simulation system 100 can use position information or other motion information of the positioning actuators 150 to provide closed-loop feedback, adjustments, or control of input signals to the positioning actuators 150 to provide a desired position or pose.

[0067] 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 actuators may include linear actuators having a linear encoder for providing position information to the motion simulation system. The motion simulation system 100 may compare the position information from the rotary encoder 152 to a desired position provided by the effector position vector and adjust the signal or current provided to the positioning actuator 150 to control the positioning of the positioning actuator 150. Additionally, in some embodiments, the motion simulation system 100 may adjust the current through the motor coils of the positioning actuator 150, knowing that the current is proportional to the torque output at the rotor 142. The current sensor may provide a feedback signal that enables closed-loop control of the torque output and operation of the positioning actuator 150. In some embodiments, the feedback signals described herein may be processed by a multi-stage control loop of the motion simulation system 100 to generate an appropriate control system response.

[0068] Optionally, the response of the control loop to one or more of the positioning actuation assemblies 140 can be configured by selecting and adjusting one or more gain coefficients. In some embodiments, the gain coefficients can be set independently and individually for each positioning actuator assembly 140 and can be dynamically changed during system operation. Thus, the positioning actuation assemblies 140 and the motion simulation system 100 can be configured to react in different ways in response to any suitable combination of available selectable drivers. Advantageously, the performance of the motion simulation system 100 can be optimized under different conditions, including but not limited to kinematic operating requirements, payload 10 and payload mass distribution, and platform 120 position. In some embodiments, prior to normal operation, the gain coefficients for the control of the positioning actuation assemblies 140 can be initially set according to kinematic operating requirements, payload 10 and payload mass distribution, and platform 120 position.

[0069] Advantageously, in some applications, the direct drive arrangement of the positioning actuator assembly 140 allows the motion simulation system 100 to recover or recover energy for later use. In some embodiments, the positioning actuator 150 can recover kinetic and / or potential energy from the platform 120. During operation, the movement of the platform 120 can energize or back-drive the positioning actuator 150 to generate electrical energy.

[0070] The electrical energy generated by the positioning actuator 150 can be stored in the form of 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, any 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 deployed back to the motion simulation system 100 as needed. The energy storage device may be connected in parallel with the power source of the motion simulation system 100. During operation, the energy storage device can rapidly deploy electrical energy in response to high peak current demands that may exceed the capabilities of a particular power source. Advantageously, the capture, storage, and deployment of electrical energy can complement the capabilities of the power source of the motion simulation system 100, allowing for less demand on the power source. Advantageously, by reducing the power demand on the power source, the power source can be made smaller without compromising the operational performance of the motion simulation system 100. In some applications involving a battery energy storage device, the motion simulation system can include components or control systems for maintaining the health and integrity of the battery.

[0071] Figure 9 is a perspective view of a motion simulation system 100a having a payload 10 according to some embodiments. Figure 10 is a perspective view of a motion simulation system 100a according to some embodiments. With reference to Figures 9 and 10, the motion simulation system 100a includes certain features similar to those of the motion simulation system 100. Accordingly, certain features of the motion simulation system 100a that are similar to those of the motion simulation system 100 are identified with like reference numbers.

[0072] In the illustrated example, the motion simulation system 100a includes a curved platform 120a for supporting a payload 10. In the illustrated example, the platform 120a includes one or more curved legs 122a shaped to support or support the payload 10. In some embodiments, the curved legs 122a can be curved vertically and / or horizontally. Optionally, the curved legs 122a can define a compound curve in multiple planes. As illustrated, in some embodiments, the curved legs 122a can be configured to support or support an automobile seat. A portion of the payload 10 can be attached or fixed to the legs 122a of the platform 120a. The legs 122a or other features of the platform 120a can be adapted to any suitable payload 10.

[0073] In some embodiments, ends of the load bearing actuators 130 may be coupled to the intermediate portions 122a of the legs 124a or any other suitable portion of the platform 120a. Further, in some embodiments, ends of the positioning actuator assemblies 140 may be coupled to the intermediate portions 124a of the legs 122a or any other suitable portion of the platform 220.

[0074] 11A-11G are perspective views of each of motion simulation systems 300a-300g according to some embodiments. FIGS. 11A-11G show various embodiments of motion simulation systems according to the present disclosure utilizing positioning actuator assemblies 340 and load-bearing actuators 330. In some applications, the positioning actuator assemblies 340 and load-bearing actuators 330 shown herein can be replaced with any other acceptable positioning actuator assemblies and load-bearing actuators including the components described herein. Additionally, 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 "over-actuated" and include more than six positioning actuator assemblies 340. Similarly, the number of load-bearing actuators 330 can vary. In some applications, the arrangements and configurations of the positioning actuator assemblies 340 and load-bearing actuators 330 described herein can be implemented in any other suitable motion simulation system described herein.

[0075] In some embodiments, the placement and positioning of the positioning actuator assembly 340 and / or the load bearing actuator 330 may be symmetric or asymmetric. The placement and positioning of the load bearing actuator 330 relative to the positioning actuator assembly 340 may be varied as well. Additionally, the shape of the base 310 and the shape of the platform 320 may vary in symmetric or asymmetric shapes. The placement and positioning of the joints relative to the base 310 and / or the platform 320 may vary, for example, by being coplanar or non-coplanar, symmetric or asymmetric, etc.

[0076] 11A-11G, in some embodiments, the motion simulation system may utilize a circular platform 320 and a circular base 310. With reference to FIGURE 11A, one embodiment of a motion simulation system 300a includes six positioning actuator assemblies 340 and three load-bearing actuators 330, with each load-bearing actuator 330 disposed between two adjacent positioning actuator assemblies 340.

[0077] In FIG. 11B, one embodiment of a motion simulation system 300b includes nine positioning actuator assemblies 340 and three load-supporting actuators 330, where the nine positioning actuator assemblies 340 are arranged in groups of three positioning actuator assemblies 340, with each load-supporting actuator 330 positioned between separate groups.

[0078] In FIG. 11C, one embodiment of a motion simulation system 300c includes six positioning actuator assemblies 340 and three load-supporting actuators 330, where the six positioning actuator assemblies 340 are arranged in groups of two positioning actuator assemblies 340, with each load-supporting actuator 330 positioned between a separate group.

[0079] In FIG. 11D, one embodiment of a motion simulation system 300d includes six positioning actuator assemblies 340 and three load-supporting actuators 330, where the six positioning actuator assemblies 340 are arranged in groups of two positioning actuator assemblies 340, with each load-supporting actuator 330 positioned in a more central position on the base 310 thereby supporting a more central location of the platform 320.

[0080] In FIG. 11E, one embodiment of a motion simulation system 300e includes six positioning actuator assemblies 340 and six load-supporting actuators 330, where the six positioning actuator assemblies 340 are arranged in groups of two positioning actuator assemblies 340 with a load-supporting actuator 330 positioned between each of the separate groups, and three other load-supporting actuators 330 are positioned in a more central position on the base 310 thereby supporting a more central location of the platform 320.

[0081] In FIG. 11F, one embodiment of a motion simulation system 300f includes six positioning actuator assemblies 340 and nine load-supporting actuators 330, where the six positioning actuator assemblies 340 are arranged in groups of two positioning actuator assemblies 340, with load-supporting actuators 330 positioned between the two positioning actuator assemblies 340 in each group and between each of the separate groups, and three other load-supporting actuators 330 are positioned in a more central position on the base 310, thereby supporting a more central location of the platform 320.

[0082] In FIG. 11G, one embodiment of a motion simulation system 300g includes seven positioning actuator assemblies 340 and three load-supporting actuators 330, with each load-supporting actuator 330 positioned between two adjacent positioning actuator assemblies 340, and the seventh positioning actuator assembly 340 being positioned at a more central position on the base 310, thereby supporting a more central location of the platform 320.

[0083] FIG. 12 is a perspective view of a motion simulation system 400 according to some embodiments. FIG. 13 is a perspective view of an integrated linear actuator unit 460 of the motion simulation system 400 of FIG. 12 according to some embodiments. FIG. 14 is an elevation view of the integrated linear actuator unit 460 of FIG. 13. FIG. 15 is a perspective view of a load-bearing actuator 430 of the integrated linear actuator unit 460 of FIG. 13 according to some embodiments. With reference to FIGS. 12-15, the motion simulation system 400 utilizes the integrated linear actuator unit 460 to support and position a payload relative to the base 410 and to provide motion information, signals, or other feedback to a user.

[0084] As described herein, the platform 420 can support a payload and be positioned relative to the base 410. In some embodiments, the platform 420 can include one or more legs 422 formed on a space frame configured to receive, support, or support a payload. A portion of the payload 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 adapted to any suitable payload. In some embodiments, the platform 420 can be any suitable shape or configuration. In some embodiments, the shape of the platform 420 can be symmetrical, asymmetrical, or otherwise varied. FIG. 16 is a perspective view of a motion simulation system 400a according to some embodiments. As shown in FIG. 16, with respect to 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 an approximately circular or disk-like shape.

[0085] In the illustrated example, the base 410 can support the weight of the platform 420 and payload, as well as other components of the motion simulation system 400. As shown, the base 410 can have a generally circular or disk-like shape. In some embodiments, the shape of the base 410 can be symmetrical, asymmetrical, or otherwise varied.

[0086] As described herein, the platform 420 and any payload may be supported and positioned at a desired orientation 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-supporting actuator 430 for supporting the weight of the platform 420 and any payload, and a positioning actuator assembly 440 for positioning the platform 420 and any payload, both disposed at least partially within a common housing 462 of the integrated linear actuator unit 460.

[0087] In the illustrated example, the integrated linear actuator unit 460 is coupled to the platform 420 and the base 410. As illustrated, one end 436 of the load-bearing actuator 430 of the integrated linear actuator unit 460 can be coupled to the base 410 and an opposing end 436 of the load-bearing actuator 430 can be coupled to the platform 420. In some embodiments, the end 436 can be coupled to the end 424 of the leg 422 or any other suitable portion of the platform 420. In some embodiments, the location of the joints, connections, or ends of the integrated linear actuator unit 460 relative to the platform 420 and / or the base 410 can be coplanar, non-coplanar, symmetrical, asymmetrical, or otherwise variable. In some embodiments, the end 436 can be pivotally coupled to the base 410 and the platform 420. The end 436 can include a ball joint.

[0088] Prior to normal operation of the motion simulator system 400, the integrated linear actuator units 460 can be extended to a desired length to act as legs or otherwise support the platform 420 and any payload at a desired orientation. As shown, each integrated linear actuator unit 460 includes a load-bearing actuator 430 for supporting the platform 420 and any payload at a desired orientation relative to the base 410.

[0089] In the illustrated example, the load-bearing actuator 430 supports the platform 420 and payload without affecting the position of the platform 420 during normal operation. The load-bearing actuator 430 is coupled to a housing 462 of an integrated linear actuator unit 460. As shown, a piston rod 434 of the load-bearing actuator 430 extends through the housing 462. Additionally, an end 436 of the load-bearing actuator 430 extends through the opposite side of the housing 462.

[0090] In the illustrated example, the load support actuator 430 is a pneumatic actuator that utilizes air pressure to extend and support the platform 420 and payload at a desired attitude. In some embodiments, the load support actuator 430 may include features and / or operate in a manner similar to the features and / or manner of operation of the load support actuator 130. Unless otherwise noted, like reference numbers may be used for features of the load support actuator 430 that are similar to features of the load support actuator 130. In some embodiments, the load support actuator 430 may utilize other types of actuators, including, but not limited to, gas struts, gas springs, elastic ropes, linear springs, coil springs, and / or rotary springs.

[0091] In the illustrated example, the load bearing actuator 430 includes one or more buffer tanks 438 in fluid communication with the pneumatic cylinder 432 to provide additional dead volume for the pneumatic cylinder 432. In some embodiments, the one or more buffer tanks 438 can be coupled to the body of the pneumatic cylinder 432. As can be appreciated, the use of multiple buffer tanks 438 can allow for a desired dead volume while allowing for flexibility or configurability of the envelope of the load bearing actuator 430. In some embodiments, the use of multiple buffer tanks 438 can allow for a relatively compact design that allows the pneumatic cylinder 432 and buffer tanks 438 to be located within the housing 462 of the integrated linear actuator unit 460 while allowing for a desired dead volume.

[0092] During operation of the motion simulation system 400, the integrated linear actuator units 460 can be extended to a desired length to position the platform 420 and payload at a desired attitude. As shown, each integrated linear actuator unit 460 includes a positioning actuator assembly 440 for moving or positioning the platform 420 and payload at a desired attitude relative to the base 410.

[0093] In the illustrated example, the positioning actuator assembly 440 can apply a force or otherwise act on a load-bearing actuator 430 of the same integrated linear actuator unit 460 to position the platform 420 (in conjunction or cooperation with other integrated linear actuator units 460) in any six-dimensional attitude in terms of surge, sway, heave, yaw, pitch, and roll within the motion simulation system 400's operating space envelope. As illustrated, the positioning actuator assembly 440 is coupled to the load-bearing actuator 430 and a housing 462 of the integrated linear actuator unit 460. In some embodiments, an end 448 of the connecting rod 446 is pivotally coupled to a piston rod 434 of the load-bearing actuator 430 at a joint 464. As illustrated, the joint 464 between the connecting rod 446 and the piston rod 434 may be disposed between the pneumatic cylinder 432 and the end 436 of the piston rod 434. In some embodiments, the joint 464 can be disposed within the housing 462 of the integrated linear actuator unit 460. Further, a body of the positioning actuator can be coupled to the housing 462 of the integrated linear actuator unit 460.

[0094] In the illustrated example, the positioning actuator assembly 440 includes a positioning actuator for manipulating a connecting rod 446, which positions the piston rod 434 of the load bearing actuator 430, and ultimately the platform 420, at a desired attitude. In some embodiments, the positioning actuator assembly 440 may include features and / or operate in a manner similar to the features and / or manner of operation of the positioning actuator assembly 140. Unless otherwise noted, features of the positioning actuator assembly 440 that are similar to features of the positioning actuator assembly 140 may be labeled with similar reference numbers.

[0095] As described herein, the integrated linear actuator units 460 may be disposed or otherwise arranged relative to the base 410 and platform 420 in any suitable arrangement. In the illustrated example, the integrated linear actuator units 460 may be configured to enable 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 equidistantly. In some embodiments, the integrated linear actuator units 460 may be arranged in a "linear hexapod" arrangement.

[0096] During operation, the motion simulation system 400 can utilize the integrated linear actuator unit 460 to place the platform 420 and payload into a desired attitude or a streamed series of attitudes in response to a position input. In the illustrated example, a controller of the motion simulation system 400 can receive the position input as a streamed series of attitude vectors. In some applications, the implementation of the integrated linear actuator unit 460 can simplify the mathematical complexity of the equations of motion to translate the position input into a resulting motion of the motion simulation system 400.

[0097] Additionally, this disclosure describes various embodiments of a human machine interface (HMI). In some embodiments, the human machine interface can utilize direct drive actuators to receive motion input from an operator and position the input portion of the interface to provide haptic feedback. The human machine interface or haptic device can receive input in six degrees of freedom and provide haptic feedback in six degrees of freedom. In some applications, the human machine interface can include features, structures, and / or configurations of the motion simulation systems described herein. In some embodiments, such as certain low mass applications, the human machine interface may or may not include load bearing actuators.

[0098] Fig. 17 is a perspective view of a haptic device 500 according to some embodiments. Fig. 18 is an elevational view of the haptic device 500 of Fig. 17. With reference to Figs. 17 and 18, the haptic device 500 receives motion input from an operator via an input 502 and provides motion or haptic information, signals, or other feedback to a user via the same input 502. In some embodiments, the input 502 can be a knob, a joystick, a mouse, or any other suitable input device or structure.

[0099] As shown, the platform 520 can support, position, and move the input portion 502 relative to the base 510. In the illustrated example, the platform 520 can be shaped or configured to accept or support the input portion 502. A portion of the input portion 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, to allow for a flat surface to support the input portion 502. In some embodiments, the shape of the platform 520 can be symmetrical, asymmetrical, or otherwise varying.

[0100] In the illustrated example, the base 510 can support the weight of the platform 520 and the input portion 502, as well as 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, asymmetrical, or otherwise varied.

[0101] In some applications, one or more load supporting actuators 530 may support the weight of an operator applied to the platform 520, the input 502, and the base 510. In some embodiments, the load supporting actuators 530 may include features, operate, or be otherwise implemented in a manner similar to the features and / or methods of operation of the load supporting actuators described herein, including, but not limited to, load supporting actuator 130 and / or load supporting actuator 430.

[0102] Prior to normal operation of the haptic device 500, the load-bearing actuator 530 can be extended to a desired length to act as legs or otherwise support the platform 520 and the input portion 502 in a desired position. In some embodiments, the load-bearing actuator 530 for the haptic device 500 can utilize other types of actuators, including, but not limited to, gas struts, gas springs, elastic ropes, linear springs, coil springs, and / or rotary springs.

[0103] As described herein, the load-bearing actuators 530 can be positioned or otherwise arranged relative to the base 510 and the platform 520 in any suitable arrangement. For example, the haptic device 500 can include twice as many positioning actuator assemblies 540 as there are load-bearing actuators 530. As shown, the haptic device 500 can include three load-bearing actuators 530. The load-bearing actuators 530 can be arranged equidistantly. In some embodiments, such as certain low-mass applications, the haptic device 500 can utilize one or more positioning actuator assemblies 540 to support the weight of the platform 520, the input 502, and the weight applied by the operator to the base 510 without the use of load-bearing actuators.

[0104] In the illustrated example, the haptic device 500 includes one or more positioning actuator assemblies 540 that can receive motion input from an operator and position the platform 520 and the input portion 502 relative to the base 510. In the illustrated example, the positioning actuator assemblies 540 can receive motion input from an operator and position the platform 520 to any six-dimensional attitude of 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 may include features, operate, or be otherwise implemented in a manner similar to the features and / or methods of operation of the positioning actuator assemblies described herein, including, but not limited to, the positioning actuator assembly 140, the positioning actuator assembly 240, and / or the positioning actuator assembly 440.

[0105] As described herein, the positioning actuator assemblies 540 can be positioned or otherwise arranged relative to the base 510 and the platform 520 in any suitable arrangement. In the illustrated example, the positioning actuator assemblies 540 can be arranged to allow the haptic device 500 to receive position input and / or move in six degrees of freedom. As illustrated, the haptic device 500 can include six positioning actuator assemblies 540. The six positioning actuator assemblies 540 can be arranged equidistantly. As illustrated, the six positioning actuator assemblies 540 can be arranged in three "leg sets" arranged around the base 510 and coupled to the platform 520. In some embodiments, the positioning actuator assemblies 540 can be arranged in a "rotating hexapod" arrangement.

[0106] Advantageously, the direct attachment or connection between the components of the positioning actuator assembly 540 allows for a direct drive mechanism or arrangement. In addition to the performance advantages described herein, the direct drive arrangement of the positioning actuator assembly 540 allows for motion or other input by an operator via the input 502 and / or platform 520 to provide an operator position input to another device, such as a computer. In operation, movement of the input 502 and / or platform 520 can energize or back-drive the positioning actuator assembly 540 to generate a signal corresponding to the operator position input.

[0107] In the illustrated example, the controller of the haptic device 500 can receive position input from an operator via signals received from a positioning actuator assembly 540. In operation, the controller of the haptic device 500 can convert or translate the signals of the positioning actuator assembly 540 into signals that a connected device (e.g., a computer) can utilize as position input signals. In some embodiments, the controller of the haptic device 500 can utilize an appropriate method (e.g., forward kinematics) to provide the desired position input signal to the connected device.

[0108] Additionally, as described herein with respect to other embodiments, haptic device 500 can utilize positioning actuator assembly 540 to place platform 520 and input portion 502 in a desired pose or a streamed series of poses in response to a position input to provide haptic feedback to an operator. In the illustrated example, a controller of haptic device 500 can receive haptic or position input as a streamed series of pose vectors. In some embodiments, the controller of haptic device 500 can include features, operate, or be otherwise implemented in a manner similar to the features and / or manner of operation of a controller of a motion simulation system described herein, including, but not limited to, a controller of motion simulation system 100.

[0109] Terms such as first, second, etc. are sometimes used herein to describe various elements, but it will be understood that these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first valve can be called a second valve, and similarly, a second valve can be called a first valve, without departing from the scope of various described embodiments. Although a first valve and a second valve are both valves, they are not the same valve, unless explicitly stated.

[0110] The terms used in the description of the various embodiments described herein are for the purpose of describing particular embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. As used herein, the term "and / or" will also be understood to refer to and encompass any and all possible combinations of one or more of the associated listed items. As used herein, it will be further understood that the terms "comprise," "includes," "comprises," and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0111] As used herein, the term "if" is interpreted, optionally depending on the context, to mean "when" or "upon" or "in response to determining" or "in response to detecting" or "in accordance with a determination that." Similarly, the phrase "when determined" or "if [a described condition or event] is detected" is interpreted, optionally depending on the context, to mean "upon determining" or "in response to determining" or "upon detecting [a described condition or event]" or "in response to detecting [a described condition or event]" or "in accordance with a determination that [a described condition or event] has been detected."

[0112] The foregoing description has been described with reference to specific embodiments for purposes of illustration. However, the above exemplary description is not intended to be exhaustive or to limit the claims to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. The embodiments have been selected to best explain the principles underlying the claims and their practical application, thereby enabling others skilled in the art to best utilize the embodiments with various modifications suited to the particular application contemplated.

Claims

1. A load supporting actuator; a positioning actuator assembly; The load supporting actuator includes: a pneumatic cylinder defining a cavity; a piston rod at least partially disposed within the cavity of the pneumatic cylinder; a first end of the piston rod and the cavity of the pneumatic cylinder defining a volume of the pneumatic cylinder, the volume of the pneumatic cylinder configured to be pressurized to support a weight of a payload; The positioning actuator assembly includes: a positioning actuator including a stator and a rotor configured to rotate relative to the stator; a connecting rod coupled to the rotor; The rotor is configured to rotate to translate the connecting rod to position the payload supported by the load-bearing actuator.

2. Further comprising a second positioning actuator assembly; The motion simulation system of claim 1 , wherein the second positioning actuator assembly is configured to cooperate with the positioning actuator assembly to position the payload supported by the load-bearing actuator.

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

4. the plurality of additional load supporting actuators comprises two additional load supporting actuators; The motion simulation system of claim 3 , wherein the plurality of additional positioning actuator assemblies comprises five additional positioning actuator assemblies.

5. The platform further includes: the platform is coupled to a second end of the piston rod and to the connecting rod; The motion simulation system of claim 1 , wherein the platform is configured to support the payload.

6. The motion simulation system of claim 1 , wherein the load-bearing actuator comprises a buffer tank defining a dead volume in fluid communication with the volume of the pneumatic cylinder.

7. a range of motion of the first end of the piston rod relative to the cavity of the pneumatic cylinder defines a swept volume; The motion simulation system of claim 6 , wherein the dead volume is between about 100% and about 500% of the sweep volume.

8. The motion simulation system of claim 1 , wherein the volume of the pneumatic cylinder is pressurized by oscillating the first end of the piston rod against the pneumatic cylinder.

9. The motion simulation system of claim 1 , wherein the positioning actuator assembly comprises a crank pivotally coupled to the rotor and the connecting rod.

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

11. a linear actuator housing; The motion simulation system of claim 1 , 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 of claim 11 , wherein the end of the connecting rod is pivotally coupled to the piston rod between the first and second ends of the piston rod.

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

14. The motion simulation system of claim 13 , wherein the controller is configured to pressurize the volume of the pneumatic cylinder to a pressure that minimizes current consumption of the positioning actuator.

15. The motion simulation system of 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 storage device configured to receive energy generated by the positioning actuator.

17. With the base, a platform movable relative to the base and configured to support a payload; A plurality of load supporting actuators; a plurality of positioning actuator assemblies; Each load supporting actuator is a pneumatic cylinder pivotally coupled to the base, the pneumatic cylinder defining a cavity; a piston rod defining a first end and a second end, the first end being at least partially disposed within the cavity of the pneumatic cylinder to define a volume of the pneumatic cylinder, the second end being pivotally coupled to the platform, the volume of the pneumatic cylinder being configured to be pressurized to support the platform; Each positioning actuator assembly includes: a positioning actuator coupled to the base, the positioning actuator including a stator and a rotor configured to rotate relative to the stator; a connecting rod having a first end pivotally coupled to the rotor and a second end pivotally coupled to the platform; The rotor is configured to rotate to translate the connecting rod to position the payload supported by the plurality of load supporting actuators.

18. 20. The motion simulation system of claim 17, wherein a quantity of positioning actuator assemblies among the plurality of positioning actuator assemblies is twice a quantity of load-bearing actuators among the plurality of load-bearing actuators.

19. the plurality of load supporting actuators comprises three load supporting actuators; 20. The motion simulation system of claim 18, wherein the plurality of positioning actuator assemblies comprises six positioning actuator assemblies.

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

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

22. the platform comprises a plurality of legs; The motion simulation system of claim 17 , wherein the second end of the piston rod of each load-bearing actuator of the plurality of load-bearing actuators is coupled to a respective leg of the plurality of legs of the platform.

23. 23. The motion simulation system of claim 22, wherein each load-bearing actuator of the plurality of load-bearing actuators comprises a buffer tank defining a dead volume in fluid communication with the volume of the pneumatic cylinder.

24. a range of motion of the first end of the piston rod relative to the cavity of the pneumatic cylinder defines a swept volume; 24. The motion simulation system of claim 23, wherein the dead volume is between about 100% and about 500% of the sweep volume.

25. 20. The motion simulation system of claim 17, wherein the volume of a pneumatic cylinder of each load-bearing actuator of the plurality of load-bearing actuators is pressurized by oscillating the first end of the piston rod against the pneumatic cylinder.

26. 20. The motion simulation system of claim 17, wherein each positioning actuator assembly of the plurality of positioning actuator assemblies comprises a crank pivotally coupled to the rotor and the connecting rod.

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

28. Further comprising a plurality of linear actuator housings; 20. The motion simulation system of claim 17, wherein individual load bearing actuators of the plurality of load bearing actuators and individual positioning actuator assemblies of the plurality of load bearing actuators are at least partially disposed within a common linear actuator housing of the plurality of linear actuator housings.

29. 30. The motion simulation system of claim 28, wherein an end of the connecting rod of the individual positioning actuator assembly is pivotally coupled to the piston rod of the individual load bearing actuator between the first and second ends 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. 31. The motion simulation system of claim 30, wherein the controller is configured to pressurize the volume of each individual pneumatic cylinder of the plurality of load-bearing actuators to a pressure that minimizes current consumption of each individual positioning actuator of the plurality of positioning actuator assemblies.

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

33. 20. The motion simulation system of claim 17, further comprising an electrical storage device configured to receive energy generated by the positioning actuator.

34. 1. A method of operating a motion simulation system, comprising: energizing a plurality of load-bearing actuators to support the platform relative to the base; and moving the platform by actuating a plurality of respective positioning actuators of a plurality of positioning actuator assemblies; Each positioning actuator assembly is pivotally coupled to the platform via a respective connecting rod of the plurality of positioning actuator assemblies.

35. detecting a current consumption of each of the plurality of positioning actuator assemblies; 35. The method of claim 34, further comprising pressurizing the plurality of load bearing actuators to a desired pressure to minimize the current consumption of each of the plurality of positioning actuator assemblies.

36. 35. The method of claim 34, further comprising supporting the platform via the plurality of positioning actuators prior to pressurizing the plurality of load-bearing actuators.

37. 35. The method of claim 34, further comprising vibrating the plurality of load-bearing actuators to pressurize each individual load-bearing actuator.

38. 35. The method of claim 34, further comprising continuously moving the platform in response to a series of attitude vectors at a streaming frequency of up to about 1000 Hz.

39. determining an individual rotational position of each of the plurality of positioning actuator assemblies; 35. The method of claim 34, further comprising: adjusting a gain factor of each individual positioning actuator assembly in response to comparing the individual rotational position of each of the plurality of positioning actuator assemblies to a desired rotational position of each of the plurality of positioning actuator assemblies.

40. generating electrical energy from operation of the plurality of positioning actuator assemblies; and storing the electrical energy from the plurality of positioning actuator assemblies in an electrical storage device; 35. The method of claim 34, further comprising deploying the electrical energy from the electrical storage device.

41. The device's processor must have at least Detecting a current consumption of each of a plurality of positioning actuator assemblies; pressurizing a plurality of load bearing actuators to a desired pressure to minimize current consumption of each of the plurality of positioning actuator assemblies; A non-transitory computer-readable medium storing instructions configured to cause a

42. The device's processor must have at least 42. The instructions of claim 41, further configured to sequentially actuate the plurality of positioning actuator assemblies in response to a series of attitude vectors at a streaming frequency of up to about 1000 Hz.

43. The device's processor must have at least determining an individual rotational position of each of the plurality of positioning actuator assemblies; comparing the individual rotational positions of each of the plurality of positioning actuator assemblies to a desired rotational position of each of the plurality of positioning actuator assemblies; adjusting a gain factor for each individual positioning actuator assembly in response to comparing the individual rotational position of each of the plurality of positioning actuator assemblies to a desired rotational position of each of the plurality of positioning actuator assemblies; 42. The instructions of claim 41 further configured to:

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