Movement System

Abstract

The present invention relates to the field of motion systems, particularly for simulating motion, such as driving or flying. In particular, but not exclusively, the present invention relates to a motion generator, a motion system including the motion generator, and a method for utilizing the motion generator or motion system, for example, as a vehicle simulator. One aspect of the present invention relates to a primary motion generator that is a parallel manipulator capable of moving a primary payload (14) of 80 kg or more over a surface (12) utilized in a motion simulator. The primary motion generator includes a primary frame or platform (11) supporting the primary payload (14) of 80 kg or more; three elongated linear guides (21, 22, 23) arranged at angles to one another in a planar array below the frame; and at least one actuator (31, 32, 33) positioned per linear guide (21, 22, 23) on the surface, controllable to move the linear guides (21, 22, 23) to move the primary payload of 80 kg or more with at least three degrees of freedom.

Description

[Technical field]

[0001] The present invention relates to the field of motion systems, in particular for simulating motion, such as driving or flying. In particular, but not exclusively, the present invention relates to a motion generating device, a motion system including said motion generating device, and a method of using the motion generating device or the motion system, for example as a vehicle simulator. [Background technology]

[0002] A motion generator has the ability to apply motion, force, and acceleration to a payload in one or more directions of degrees of freedom (or "DOF"). The payload may be, for example, a human undergoing a simulated experience in a motion simulator. Alternatively, the payload may be another motion generator considered in series with the first motion generator. The motion generators are used by the motion system under the control of the control system.

[0003] Motion generators are used in a variety of applications, including motion simulation (e.g., flight simulators, driving simulators, vehicle simulators, etc.), robotics, 3D printing, and vibration and earthquake simulation. Currently, the most common type of motion system used for motion simulation is the Stewart Platform (or "hexapod"). It is a type of parallel manipulator with six actuators. The six actuators are typically mounted in pairs at three locations on the platform's base plate and intersect at three mounting locations on the platform's top plate (or end effector). The device or payload - usually a human user placed on the platform in the form of a cockpit, driver's area, or model vehicle - can be moved in the six degrees of freedom in which a free-suspended body can move - three linear motions x, y, z (lateral, longitudinal, and vertical) and three rotations (pitch, roll, and yaw). Typically, in a parallel manipulator, multiple computer-controlled actuators are arranged to operate in parallel to support the payload. In this context, "parallel" means that there is only one actuator in each independent load path that exists between the payload and the base plate. On the other hand, in a serial manipulator, one or more of the possible load paths existing between the payload and the base plate includes at least two actuators.

[0004] A motion simulator is a mechanism that incorporates at least one motion generator that can give the occupant the effect or sensation of being in a moving vehicle. Motion simulators are used in driving and flight simulators to train drivers and pilots as professionals, respectively. Motion simulators are also used industrially as vehicle simulators to create, design, and test vehicles. Professional motion simulators used in driving and flight simulators typically synchronize visual displays, such as projection systems and associated screens, and audio signals with the movement of the carriage (or chassis) in which the driver or pilot rides, to enhance the feeling of motion effects. The advent of virtual reality (VR) head-mounted displays (HMDs) has made the immersive simulation aspect of current motion systems less expensive, allowing virtual reality applications to be provided for leisure use, such as passive driving, first-person rides, and flying vehicle rides in amusement parks and arcades, as well as active games in which one or more players have some control over the driving, riding, flying, and first-person game experience.

[0005] The payloads of motion generators used in motion simulations, such as chassis and cockpits, are therefore relatively heavy, often on the order of several hundred kilograms. Motion generators used in motion simulations need to accurately control such relatively heavy payloads over large movements, such as a meter or more.

[0006] Hexapods used for human motion simulation typically have a relatively low bandwidth, up to around 20Hz. This means that such hexapods can create constant amplitude oscillatory motion or vibrations at frequencies up to 20 times per second, but above that frequency the amplitude of the motion decreases. This is sufficient to replicate the suspension movement of most automobiles, but it cannot transmit the frequency content associated with engine vibrations, tire vibrations, road noise, or sharp curbs on a race track. The low bandwidth also means that the signal is delayed, meaning the driver cannot react as quickly.

[0007] Current motion systems, especially those intended for high-end applications such as military and commercial flight instruction and training, are typically very large, heavy, complex and expensive, and their complexity requires extensive programming and maintenance, further increasing the burden on users.

[0008] Motion systems specific to driving simulators have been developed by companies such as McLaren / MTS Williams / ABD and Ansible, but they tend to be very mechanically complex and therefore expensive, using precisely machined custom parts and expensive linear motors. These simulator-specific motion systems are more responsive than hexapods when moving in some directions, but are still limited in other directions. The use of ball screws in such systems, while excellent for position determination, suffers from impaired force transmission and low bandwidth. This results in a less natural experience for the human user.

[0009] US Patent No. 5,399,633 discloses an interactive racing car simulator. The simulator includes a primary motion generator having a simple arrangement of superimposed rectangular frames - called "X-frame and Y-frame" - arranged to move in the X- and Y-directions, respectively, on linear guides under pneumatic control. The simple arrangement of the X- and Y-frames provides good motion in the X- and Y-directions, but the vertical size of the motion generator is not reduced because the X- and Y-frames are stacked on top of each other. Furthermore, the motions in the X- and Y-directions are not particularly precise and have a relatively narrow bandwidth. The simulator is not a parallel manipulator type device. US Patent No. 5,399,633 discloses another XY-frame device. A further XY device is disclosed in US Patent No. 5,399,633.

[0010] In the above prior art motion generators, the X-axis and the Y-axis are arranged in series with each other. If the X-axis were attached to the ground, the force associated with the Y-axis motion would need to be transferred to the ground via the X-axis. Such an indirect load path necessarily introduces compliance, thereby reducing the responsiveness and bandwidth of the known motion generators.

[0011] In US Pat. No. 5,399,436, an example of a primary motion generator with a payload including other motion generators is given. US Pat. No. 5,399,436 discloses a 3-DOF motion generator and a 6-DOF motion generator. The 3-DOF and 6-DOF motion generators can sustain large motions in the horizontal plane using the primary motion generator while simultaneously achieving maximum vertical motion with the secondary motion generator. Thus, by placing two motion generators in series, a combination of motions with different degrees of freedom can be achieved that would not be possible with a hexapod of the same size. However, to achieve this, the primary motion generator described above uses a very large, heavy, and complex planar bearing system that relies on a precisely machined metal base plate and magnetically preloaded air bearings. This requires extensive construction work to incorporate the driving simulator into any building, and difficult and time-consuming setup to ensure flatness. The metal base plate has a large surface area and must be precisely machined to ensure flatness, which is costly. The air bearing unit has a complex structure that requires an air supply and a fail-safe mechanism to ensure that the permanent magnets do not permanently bind to the metal base plate.

[0012] US Patent No. 5,399,633 discloses a motion system that includes a cable / actuator controlled platform that can slide on a large, low friction fixed base, allowing large horizontal movements of the platform. The cables and actuators are arranged around the periphery of the large base, allowing large horizontal movements of the platform. In addition, a hexapod-based secondary motion generator is mounted on the platform to support the model cockpit, providing additional cockpit movement. This system is not compact and has low bandwidth.

[0013] US Patent No. 5,399,633, by the same applicant as US Patent No. 5,399,633, discloses a further cable-controlled motion generator. The motion generator's cables are driven by a large pulley system to move a central effector. The high inertia of the pulleys precludes high bandwidth operation. This system requires large, expensive and complex planar bearing surfaces, whereas the motion generator of the present invention has load-bearing capabilities built into its own mechanism. [Prior art documents] [Patent documents]

[0014] [Patent Document 1] U.S. Patent No. 5,919,045 [Patent Document 2] British Patent Publication No. 2474279A [Patent Document 3] French Patent No. 2677155A [Patent Document 4] European Patent Publication No. 2810268A [Patent Document 5] U.S. Patent Application Publication No. 2017 / 0053548A [Patent Document 6] International Publication No. 2017 / 021323 Summary of the Invention [Problem to be solved by the invention]

[0015] It is an object of the present invention to provide improved motion generating devices and motion systems, as well as other implementations, such as motion simulators, that incorporate such motion generating devices. [Means for solving the problem]

[0016] According to one aspect of the invention, there is provided a primary motion generator suitable for use in or mounted within a motion simulator and capable of moving a primary payload of 80 kg or more across a surface, the primary motion generator being a parallel manipulator comprising: a) a primary frame or platform (14) supporting said primary payload of 80 kg or more, b) three elongated linear guides arranged at angles to each other in a planar array below said frame, and c) at least one actuator arranged on said surface per linear guide that is controllable to move said linear guides to move said primary payload of 80 kg or more in at least three degrees of freedom.

[0017] The primary motion generator of the present invention provides three degrees of freedom of motion. The primary motion generator of the present invention may be more rigid, i.e. less elastic, than known motion generators, in particular those based on the X-frame and Y-frame arrangements described above. The primary motion generator of the present invention may provide relatively large motions in the longitudinal / front-back, lateral / left-right, and up-down directions. For example, the primary motion generator of the present invention may have a minimum radius of motion of about 0.5 m. That is, the platform of the primary motion generator may be capable of moving about 0.5 m in both the X and Y directions simultaneously. For example, the primary motion generator of the present invention may have a minimum radius of motion of about 0.49-0.6 m. A preferred primary motion generator of the present invention may have a minimum radius of motion of about 0.5-1 m or more, more preferably 1.5 m or more. Thus, the primary motion generator of the present invention is very suitable for land vehicle / driving simulations, since it has a sufficiently large travel distance in forward / backward, left / right and up / down motions, while the heave, pitch and roll degrees of freedom can be provided by a gentler secondary motion generator in series with the primary motion generator in the motion system. This allows the motion system of the present invention to be much smaller in the vertical direction than a hexapod-based motion generator, which results in easier installation, storage and use. On a typical hexapod-based motion generator for a driving simulator, the driver or pilot is more than 1 m above the ground, whereas in the motion system of the present invention, it is less than 0.5 m. Being a 6-DOF parallel manipulator, the motion functions of the hexapod are strongly coupled in each degree of freedom. For example, if the hexapod-based motion generator is fully forward longitudinal, it cannot generate a heave motion without introducing other unintended motions. Such unintended motions can be avoided with the primary motion generator described below or the combination of the present invention.

[0018] Although described as a "primary" motion generating device, the primary motion generating device of the present invention may in some applications be used in series with other motion generating devices, which may in some cases be of the same design as the primary motion generating device, and thus are secondary motion generating devices.

[0019] In the present invention, the payload of the primary motion generator is typically greater than 80 kg. The primary payload may include a human user or a vehicle or a model of part or all of a vehicle. Thus, the payload may typically be greater than about 80 kg, or greater than about 250 kg, or greater than about 500 kg, or greater than about 2 tonnes (e.g., a full vehicle chassis).

[0020] The elongated linear guides may form a star-shaped array, for example a three-point star array, or may extend radially and / or outward from a common central point. Typically, each guide makes an angle of 120° with the other guides, as this is optimal in most cases, but this is not required.

[0021] In the motion generating device according to any claim, the linear guides are parallel to a common base plate. At least two, preferably three, of the linear guides may be adjacent to or coupled to each other. The linear actuators may be linear motors, rack and pinion, belt drive, cable drive, or ball screw systems. There may be more than four linear actuators. For example, there may be six linear actuators. The linear actuators may be arranged in a substantially triangular array. Preferably, the linear actuators are arranged in a planar array. The linear actuators may move the primary frame by applying a motive force to a carriage connected to the linear actuators and the linear guides and movable along the linear guides. The motive force is transferred from the actuators through the carriage and linear guides to the primary frame by applying a force that includes a normal component - i.e. a component perpendicular to the axis of motion of the linear guides. As a result, a force applied at one linear guide is transferred through the primary frame to move the other linear guide along the axis of motion of the other linear guide. A linear actuator may be connected to a carriage of a corresponding linear guide by a joint, bearing, revolute joint, spherical joint, or thrust bearing. Preferably, the or each linear actuator is connected to a corresponding carriage associated with a linear guide by a spherical joint. Hexapods and other motion generators typically generate motion by utilizing ball screw actuators that have inherently high internal friction. This friction manifests itself as a step force input to the system as the system passes through zero speed. Such interference limits the band over which the system can be controlled. The primary motion generator of the present invention is therefore advantageous over such ball screw based motion generators. All or part of the linear actuator may be mounted on a surface.

[0022] The motion generating device of the present invention is advantageous because of low friction in the moving parts, especially in the linear guides, the actuators (even if not of the ball screw type) and the joints.

[0023] In contrast to the system of, for example, U.S. Patent No. 5,399,633, the primary motion generator of the present invention eliminates the need for complex planar air bearing arrangements and instead utilizes a set of linear bearings that are inexpensive components readily available on the market.

[0024] Furthermore, the system of the above-mentioned US Pat. No. 6,399,633 also has separate bearings and drive mechanisms, whereas in the primary motion generating device of the present invention, the bearings and drive mechanisms are combined, thus simplifying the system and further reducing costs.

[0025] The primary motion generator of the present invention is suitable for a wide range of actuator technologies in addition to ball screw actuators, allowing the motion system to be controlled with higher bandwidth and lower latency. Such actuator technologies include linear motors and belt drives.

[0026] The actuator technology available in the present invention also allows the motion system to be driven in the opposite direction. This has useful applications in entertainment and training scenarios, where the user can move his body or apply forces to the primary generator and / or motion generator for the purpose of providing input to the simulation experience. For example, in a skiing simulation using the primary motion generator of the present invention in a motion system, the motion of the user's body applies forces to the motion generator platform, which changes the position, velocity, and / or acceleration that can be measured by the control system and used as input for the position of the skis, which input affects the skiing simulation in the virtual environment. Thus, the platform may represent, for example, skis, a surfboard, or a skateboard. The primary motion generator may have at least one safe end stop that limits the progression of the frame or platform. The at least one safe end stop includes one or more elongated straps that limit the motion of the platform or frame between the platform or frame and the surface. Preferably, there are three or more straps that limit the motion of the frame. At least one, and preferably all, of the straps are rigidly fixed at one end and directly connected to a shock absorber, spring, or damper at the other end.

[0027] According to another aspect of the invention there is provided a combination comprising a motion generating device according to the first aspect of the invention as a primary motion generating device and a secondary motion generating device mounted on the primary motion generating device as a payload for the primary motion generating device, preferably for use as a base for a motion system.

[0028] The primary motion generator may be used in series with a secondary motion generator to provide additional degrees of freedom in the vertical / heave, roll, and pitch directions.

[0029] While the primary motion generator of the present invention generally has a higher bandwidth than conventional primary motion generators, such as those described in US Pat. No. 5,399,633 and US Pat. No. 5,599,663, when used in series with a secondary motion generator, it generally has a lower bandwidth than the secondary motion generator, since the primary motion generator of the present invention must move a relatively heavy primary frame. It is therefore advantageous to have a six degree of freedom secondary motion generator, since the six degree of freedom secondary motion generator allows motion in a horizontal degree of freedom and provides vertical motion capability through an additional degree of freedom. During use of the combination according to the present invention, the primary motion generator may operate at a lower bandwidth than the secondary motion generator. For example, the primary motion generator may operate at about 5 Hz to about 20 Hz, and the secondary motion generator may operate at about 30 Hz to about 100 Hz or more.

[0030] Thus, for example, a motion system used as a high performance driving simulator may have a secondary motion generator with 6 degrees of freedom, while a more relaxed entertainment focused motion based system may have a secondary motion generator with 6 degrees of freedom.

[0031] A motion system according to the invention may comprise a primary motion generator according to the invention and a secondary motion generator in series, the combination being under the control of a control means, i.e. a control system. The motion system may thus generate a full range of vertical motion, regardless of horizontal orientation. Furthermore, the primary motion generator may allow a much larger radial range of motion at different yaw angles than is possible with a hexapod platform. This is very useful in land vehicle simulations, since vehicles are usually subject to lateral or longitudinal accelerations that are comparable to the yaw direction. It is therefore advantageous to be able to generate lateral or longitudinal accelerations that require lateral or longitudinal motions of the primary motion generator that are comparable to the yaw accelerations that require yaw motions.

[0032] Preferably, the secondary motion generator used in combination with a primary motion generator in a combination according to the invention has three or more degrees of freedom - i.e. 3, 4, 5, 6. In one embodiment, the secondary motion generator has six degrees of freedom, providing the required three more degrees of freedom (heave, pitch, and roll) while also providing three redundant degrees of freedom (surge, sway, and yaw already provided by the primary motion generator). In some situations, this redundancy can be useful. For example, the combination can allow for an increased range of motion produced by the primary motion generator. The combination can also allow for a wider bandwidth in the redundant degrees of freedom than the primary motion generator allows.

[0033] The primary motion generator of the present invention used in series with a secondary motion generator is well suited for land vehicle simulation and is superior to ball screw hexapods in these applications for some or all of the following reasons: First, the primary motion generator of the present invention used in series with said secondary motion generator can be more compact to operate within a workspace optimized for land vehicle simulation. Second, during operation, the primary motion generator of the present invention used in series with said secondary motion generator has less unintended cross-coupling between degrees of freedom, i.e., the primary motion generator of the present invention used in series with said secondary motion generator mitigates the restriction of unintended motion in one direction (e.g., sway) when the system is already extended in another direction (e.g., yaw) that may be associated with hexapod-based motion generators as described above. Third, the primary motion generator of the present invention used in series with said secondary motion generator has higher bandwidth and lower latency than similar conventional motion generators and can be driven in reverse.

[0034] According to another aspect of the invention there is provided a primary motion generator according to the invention or a combination comprising said primary motion generator, a motion system according to the invention or a vehicle simulator comprising a motion system according to the invention and a cockpit or a chassis and / or other vehicle simulator parts, said vehicle simulator may comprise means for simulating an environment comprising at least one of a display device, a virtual reality device, a projection device and software means for modelling the virtual environment and the vehicle model.

[0035] In other aspects of the invention there is provided a method of manufacturing a motion generating device or combination according to the invention or a method of designing a vehicle or part of a vehicle, either method comprising use of a motion generating device according to the invention, a combination according to the invention or a vehicle simulator according to the invention. Further aspects of the invention are set out in the claims and in the detailed description below and include a games device. [Brief description of the drawings]

[0036] A motion generator, motion system and driving simulator according to the present invention, and their operation and manufacture, will now be described, by way of example only, with reference to the accompanying Figures 1 to 37. [Figure 1] FIG. 1 is a perspective view of a motion system including a primary motion generator according to the present invention with a base. [Diagram 2] FIG. 2 is a bottom view of the exercise system of FIG. 1 without the bottom in a neutral state. [Diagram 3] FIG. 2 is a detailed schematic diagram of the motion system of FIG. 1 without the bottom showing the primary motion generator. [Figure 3A] FIG. 2 is a further detailed view of the primary motion generator of the motion system of FIG. 1 without the bottom. [Figure 4] FIG. 2 is a perspective view of the motion system of FIG. 1 showing the bottomless primary motion generator in a surge forward state. [Diagram 5] FIG. 5 is a bottom view of the exercise system shown in FIG. 4 without the bottom. [Figure 6]FIG. 2 is a perspective view of the motion system of FIG. 1 showing the bottomless primary motion generator in a surge state. [Figure 7] FIG. 7 is a bottom view of the exercise system shown in FIG. 6 without the bottom. [Figure 8] FIG. 2 is a perspective view of the motion system of FIG. 1 without the bottom showing the primary motion generator in a sway right state. [Figure 9] FIG. 9 is a bottom view of the exercise system shown in FIG. 8 without the bottom. [Figure 10] FIG. 2 is a perspective view of the motion system of FIG. 1 without the bottom showing the primary motion generator in a sway left state. [Figure 11] FIG. 11 is a bottom view of the exercise system shown in FIG. 10 without the bottom. [Figure 12] FIG. 2 is a perspective view of the motion system of FIG. 1 showing a bottomless primary motion generator that is in a counterclockwise yaw direction. [Figure 13] FIG. 13 is a bottom view of the exercise system shown in FIG. 12 without the bottom. [Figure 14] FIG. 2 is a perspective view of a secondary motion generator used in a motion system according to the present invention in a neutral state and without a bottom. [Figure 15] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 without the bottom. [Figure 16] FIG. 15 is a front view of the secondary motion generator shown in FIG. 14 without the bottom. [Figure 17] FIG. 15 is a more detailed left side view of a portion of the secondary motion generator shown in FIG. [Figure 18] FIG. 15 is a bottom perspective view of the secondary motion generator shown in FIG. 14 without the bottom. [Figure 19] FIG. 15 is another perspective view of the secondary motion generating device shown in FIG. 14 without the bottom in a neutral state. [Figure 20] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless surge advance configuration. [Figure 21] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless surge retracted state. [Figure 22]FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless sway-left configuration. [Diagram 23] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless sway-right configuration. [Figure 24] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless heave up configuration. [Diagram 25] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless heave down configuration. [Figure 26] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless roll-right-down configuration. [Figure 27] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless roll-upright configuration. [Figure 28] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless pitch nose down configuration. [Figure 29] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless pitch nose up configuration. [Diagram 30] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless yaw nose leftward configuration. [Diagram 31] FIG. 15 is a bottom view of the secondary motion generator shown in FIG. 14 in a bottomless yaw nose right-facing configuration. [Diagram 32] FIG. 2 is a top perspective view of another motion system according to the present invention including a primary motion generator and a secondary motion generator. [Diagram 33] FIG. 33 shows a plan view of the motion system of FIG. 32. [Diagram 34] FIG. 33 is a detailed schematic diagram of a portion of a secondary motion generator within the motion system of FIG. 32. [Diagram 35] 1 shows a top perspective view of another motion system according to the present invention comprising a primary motion generating device and a secondary motion generating device different from the primary motion generating device. [Diagram 36] 1 is a perspective view of a driving simulator incorporating a motion system according to the present invention; [Figure 37] FIG. 1 illustrates a control system for use with a motion generator, motion system, or motion simulator in accordance with the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] The following describes, by way of example only, embodiments of motion generators, motion systems, and vehicle / driving simulators according to the present invention, and methods for their use and manufacture. Those skilled in the art will appreciate that many further embodiments may be realized within the scope of the present invention.

[0038] [Primary motion generator] The motion system 1 shown in Figure 1 includes a primary motion generator 10 according to a first aspect of the present invention. The motion generator 10 includes a support frame 11 arranged for movement over a surface 12. The surface 12 is generally flat.

[0039] The frame 11 is made of a lightweight material such as aluminum or carbon fiber and presents a triangular perimeter in the illustrated embodiment. Other frame shapes are possible, for example rectangular or circular. The frame 11 supports a chassis 14, which here reproduces a part of a passenger car. The chassis 14 constitutes the payload of the motion generator and weighs about 1000 kg, to which any user may add. Other types of chassis known to those skilled in the art may be used. For example, the chassis of a saloon body optimized for a simulator weighs about 500 kg, whereas a user-type car weighs about 2 tonnes. A racing car chassis is generally made of carbon fiber and weighs around 250 kg, including the driver. The movement of the frame 11 is brought about by the interaction of elongated linear guides 21, 22, 23 arranged in a three-star shape below the frame 11 (as shown in particular in FIG. 2), linear actuators 31, 32, 33 attached to the surface 12, and respective linear actuator carriages 41, 42, 43 to which the frame 11 is attached. The linear actuator carriages 41, 42, 43 are driven by linear actuators 31, 32, 33, respectively. The linear guides 21, 22, 23, which are attached to a common bottom surface, are precisely formed from metal such as aluminum, steel, etc. The simulator actuators 31, 32, 33 in this embodiment are belt driven units, but may be, for example, linear motors or ball screw driven actuators.

[0040] The carriages 41, 42, 43 are arranged to move in either linear direction driven by their respective linear actuators 31, 32, 33 under direction from a primary motion generator control system (shown in FIG. 37 and described in more detail below). Each carriage 41, 42, 43 includes an upper carriage part or bearing race (41U, 42U, 43U, respectively) that engages with an associated linear guide 21, 22, 23. The bearing race is connected by a revolute joint to a lower carriage part or bearing race (41L, 42L, 43L, respectively) that is fixed to the associated linear actuator 31, 32, 33, respectively. For example, as shown in FIG. 3A, the carriage 41 includes an upper carriage part 41U and a lower carriage part 41L interconnected by a revolute joint 41RJ having an axis perpendicular to a common bottom plane. The revolute joint may be replaced by a self-aligning or spherical bearing to accommodate slight lack of planarity in the three linear guides or three actuators.

[0041] Surface 12 may be the floor of the building in which motion-generating device 10 is located, or may be a particular supporting surface member attached to such a floor. As noted above, the primary motion-generating device of the present invention is advantageous in that it does not require the precision-machined metal floor surface required by some prior art motion-generating devices.

[0042] The primary motion generator 10 is shown in a neutral state in Figures 1 to 3. In this state, the positions of the upper and lower carriage parts of the carriages 41, 42, 43 are as follows: [Table 1]

[0043] [Operation of the primary motion generator] The primary motion generating device 10 operates as described in relation to FIGS. 4-13 under the control of a control system (not shown in FIGS. 4-13, but shown, for example, in FIG. 37).

[0044] Figures 4 and 5 show the motion generating device of Figure 1 in the surge advance state. In this state the positions of the upper and lower carriage parts of carriages 41, 42, 43 are as follows: [Table 2]

[0045] Figures 6 and 7 show the motion generator 10 of Figure 1 in a surge retract condition. In this condition, the positions of the upper and lower carriage parts of carriages 41, 42, 43 are as follows: [Table 3]

[0046] Figures 8 and 9 show the motion generating device of Figure 1 in a sway right state. In this state, the positions of the upper and lower carriage parts of carriages 41, 42, 43 are as follows: [Table 4]

[0047] Figures 10 and 11 show the motion generator of Figure 1 in a sway left state. In this state, the positions of the upper and lower carriage components of carriages 41, 42, 43 are as follows: [Table 5]

[0048] Figures 12 and 13 show the motion generator of Figure 1 yawing counterclockwise. In this state, the positions of the upper and lower carriage components of carriages 41, 42, 43 are as follows: [Table 6]

[0049] Conversely, when the carriages are yawing clockwise, the positional relationship between the upper and lower carriage portions of the carriages 41, 42, and 43 is as follows: [Table 7]

[0050] [Secondary motion generator] 14-31 show a secondary motion generator 48 intended for use in combination with a primary motion generator (not shown in FIGS. 14-31) in accordance with the present invention to form a motion system.

[0051] The secondary motion generator 48 has a triangular frame 49 of generally similar construction to the primary motion generator support frame 11 described above. A downwardly extending forward frame section 50 and a rearward rigid tubular or dense frame section 52 are each fixed to a chassis 114 or an intermediate platform or frame to which the chassis 114 is mounted. It will be appreciated that in this example the chassis 114, which constitutes the payload of the secondary motion generator, represents a racing car and weighs approximately 250 kg. Elongated suspension sections 54, 55, 56 are attached at one end to the forward frame section 50 or the rigid rearward frame section 52 and at their other ends to rigid upwardly extending mounting sections 58, 59, 60 which extend from the frame 49 to suspend the chassis 114. The mounting sections 58, 59, 60 may be fixed to the frame 49 or may be integral with the frame 49.

[0052] A series of pairs of linear actuators 62, 63; 64, 65; and 66, 67 are disposed within the periphery of the frame 49. In this embodiment, the linear actuators 62-67 are belt driven. Other low moving mass actuators are contemplated, such as linear motors. As shown in FIG. 18, a corresponding pair of elongated tensile members 72, 73; 74, 75; and 76, 77 are fixed at one end to linear actuator carriages 62C, 63C, 64C, 65C, 66C, 67C and at the other end to the chassis 114 or intermediate platform or frame. In use, the linear actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are linearly driven in either longitudinal direction by the linear actuators 62-67, respectively, as directed by a secondary motion generator control system (e.g., as shown in FIG. 37) to move the suspended chassis 114 with a high bandwidth of motion.

[0053] Next, a description will be given of the movement of chassis 114 with six degrees of freedom by the operation of secondary motion generating device 48 and the movement of the actuator carriage according to instructions from the control system. The operation in the neutral state shown in Figs. 14 to 20 will be described.

[0054] In the surge forward state shown in FIG. 21, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows: [Table 8]

[0055] In the surge retract state shown in FIG. 22, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows. [Table 9] In the sway left state shown in FIG. 23, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, and 67C are as follows. [Table 10]

[0056] In the sway right state shown in FIG. 24, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows: [Table 11]

[0057] In the heave down state shown in FIG. 25, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, and 67C are as follows. [Table 12]

[0058] Conversely, in a heave-up state, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, and 67C are as follows: [Table 13]

[0059] In the roll, right side down configuration shown in FIG. 26, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows: [Table 14]

[0060] In the roll, right side up configuration shown in FIG. 27, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows: [Table 15]

[0061] In the pitch nose down configuration shown in FIG. 28, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows: [Table 16]

[0062] In the pitch nose-up configuration shown in FIG. 29, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, 67C are as follows: [Table 17]

[0063] In the yaw nose leftward state shown in FIG. 30, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, and 67C are as follows. [Table 18]

[0064] In the yaw nose rightward state shown in FIG. 31, the positions of the actuator carriages 62C, 63C, 64C, 65C, 66C, and 67C are as follows. [Table 19]

[0065] In practice, in the motion system of the present invention, the secondary motion generator 48 is disposed between the primary motion generator (e.g., 100) and the chassis (e.g., 114) and, when operated, provides additional or alternative (i.e., redundant) motion to the motion produced by the primary motion generator 100 and imparted to the chassis 114.

[0066] 32 to 35, a motion system according to the present invention is shown having a primary motion generator and a different secondary motion generator configuration.

[0067] [Primary motion generator and 6DOF secondary motion generator motion system] A motion system 80 according to the present invention, including a primary motion generator 82 according to a first embodiment of the present invention and a 6DOF secondary motion generator 84, is shown in Figures 32 to 34. The motion system 80 is mounted on a surface 86.

[0068] Primary motion generator 82 is as described above, for example in FIG. 1, except that secondary motion generator 84 and chassis 88 replace chassis 14 as the payload of the primary motion generator.

[0069] The chassis 88 is suspended from a triangular support frame 89 by elongated elastic members 90, 91, 92. A pair of elongated tension members or struts 96a, 96b; 97a, 97b and 98a, 98b are connected at one end to the chassis 88 and at the other end to outwardly directed rockers 96rf, 96rr; 97rl, 97rr; and 98rr, 98rf, respectively. This arrangement is shown in more detail in FIG. 34. As can be seen in FIG. 34, the right rocker 98rr, 98rf of the secondary motion generator is free to swing in a horizontal plane and is further connected by a toothed belt 98br, 98bf which engages with a corresponding toothed capstan 98cr, 98cf of an actuator located along the inside of the frame 89 (omitted from FIG. 34 for clarity). Each belt 98br, 98bf, connected at one end to a respective elongated tension member 98a, 98b, extends around a respective capstan 98cr, 98cf and is connected to a respective passive tension member 98tmr, 98tmf, such as a spring or bungee, that is secured to the support frame (omitted from FIG. 34 for clarity). A similar pair of elongated tension members, rockers, toothed belts, toothed capstans and passive tension members is provided on the other side of the triangular frame 89 and operates in a corresponding manner.

[0070] The rotational position of the actuator capstan (e.g., 98cr, 98cf) is commanded by a control system (e.g., as shown in FIG. 37). Thus, the movement of the actuator capstan (e.g., 98cr, 98cf) drives the movement of the belt (e.g., 98br, 98bf) which resists or follows the tension applied by the passive tension member (e.g., 98tmr, 98tmf) to change the position of the associated rocker (98rr, 98rf) which in turn changes the position of the elongated tension member (98a, 98b) which is associated with the rocker (98rr, 98rf). Such rocker movement results in six degrees of freedom movement of the chassis 88. High bandwidth can be achieved with this secondary motion generator design. Furthermore, advanced combinations of primary and secondary motion generators can result in advanced motions / configurations.

[0071] The primary motion generator 82 is capable of generating large amplitude displacements but has limited bandwidth. The secondary motion generator 84, on the other hand, is capable of generating only small amplitude displacements but has a much higher bandwidth. This series configuration facilitates the combination of large amplitude and high frequency motion as follows: For high frequency motion, the secondary motion generator 84 applies the necessary acceleration forces to the payload and responds against the inertia of the primary motion generator, thereby propelling the payload in the desired direction, while responding to the primary motion generator 82, which actually pushes it in the opposite direction. Thus, the force of the response from the secondary motion generator 84 to the primary motion generator 82 actually drives the primary motion generator 82 back in the opposite direction to the direction the payload 88 was moving. This is no problem for high frequency motion. In the case of low frequency motion, the secondary motion generator 84 applies a driving force to the payload 88 while the primary motion generator 82 simultaneously applies an acceleration force to the secondary motion generator 84, causing a response force to continue to be exerted from the payload 88 and secondary motion generator 84 to the ground. In this case, the relative movement of the secondary motion generator 84 with respect to the payload 88 is very small, and instead the primary motion generator 82 can be driven with a motion profile (i.e., a series of movements performed by the motion generator over a period of time) that closely resembles the horizontal movement required of the payload.

[0072] [Movement system using a primary motion generator and a 3DOF secondary motion generator] Another motion system 101 according to the invention is shown in FIG. 35. The motion system comprises a primary motion generator 102 according to the first embodiment of the invention, for example as described above in relation to FIG. 1, and a relatively simple 3DOF motion generator 104 for supporting a payload such as a chassis 106. In this motion system, motion is provided by vertical actuators 110, 112, 114 (not shown). For example, the vertical actuators 110, 112, 114 may be D-box type actuators. Other types of actuators are also contemplated, such as hydraulic jacks and linear actuators. The secondary motion generator 104, together with any chassis (e.g. 106) mounted thereon, becomes the payload of the primary motion generator, and although it only has three degrees of freedom of movement, it may be relatively low cost (due to its relative simplicity) compared to other secondary motion generators contemplated for use in the motion system of the invention. A restraint system (not shown) is required to maintain the position of the chassis relative to the primary frame in the three horizontal degrees of freedom not controlled by the 3DOF system.

[0073] [Control System] Figure 37 illustrates a control system 501 for use in controlling the operation of a motion-generating device in accordance with the present invention. In connection with Figure 37, the motion-generating device is referred to as 502, however, the control system 501 is applicable to other motion-generating devices, motion systems, and motion simulators and associated simulation environments 503 described herein.

[0074] The control system 501 comprises a motion controller 504 that executes - preferably deterministically or in real time - a computer program that receives motion demand inputs 505 from a simulation environment 503 or a demand generator such as a setpoint generator 506. The motion controller calculates the positions, accelerations and / or forces 507 required to be generated by each actuator 509 to generate the requested motion profile 505. The control system 501 also comprises servo drives 508 that provide precisely controlled electrical currents 510 to drive the actuators 509.

[0075] In operation, the motion controller sends a demanded position or force 507 to each servo drive 508. The actuators 509 have motion measurement devices 511, such as encoders, that provide motion feedback 512, optionally via the servo drives, to the motion controller. The motion controller compares the demanded motion profile 505 with the measured motion profile 512 and updates the actuator demands 507 accordingly.

[0076] FIG. 37 also shows a control system with a simulated vehicle and a simulation environment 503, such as a driving simulation, where the physics of the environment, such as a race track or city road, are calculated. In this embodiment, the control system 501 receives motion requests from the simulation environment 503, which represent the motion of a virtual vehicle. A computer program determines the motion of the vehicle in the virtual world 514 and then applies a motion cue algorithm 513 (MCA, also known as a washout filter) to convert the motion of the simulated vehicle into one that can be represented by a motion generation device. These calculated motions are then provided to the control system as motion requests 505. The MCA 513 can be part of the simulation environment 503 or the control system 501, or can be separate to both. The simulation environment 503 may receive input signals 515 from a control device 516, such as steering, throttle or brake inputs. A human user, such as a computer program driver, passenger or pilot, uses the input signals 515 to control the virtual vehicle in the simulation environment. The operator is considered to be a passenger of the motion generation device 502. These inputs 515 may be fed back to the simulated environment via the control system or directly. The computer program environment may also generate output on a visual display 517 for a driver, passenger, or other user operator. The simulated environment may also require additional data 518 from the control system, such as related to the position of the motion generating devices, and input signals for the controllers.

[0077] [Driving simulator] A driving simulator 200 incorporating a motion system 202 consisting of a combination of primary and secondary motion generators according to the present invention is shown in FIG. 36. The motion system 202 is under the control of a control system 205 (e.g. as shown in FIG. 37) to reproduce the motion and faces a projection system 204 in which the driving environment is simulated. An additional sound system (also not shown) provides an immersive experience for the user (i.e. the "driver"). The driver interacts with the simulated driving environment through an actuation steering system that measures the driver's steering input angle and provides torque feedback to the wheels through a steering actuation system or steering motors. In addition, the driver can provide input to the simulated driving environment through pedals and other switches, rotary knobs, and touch screen devices to control the vehicle in the simulation. A computer program representing a vehicle model that replicates the physical characteristics of a real vehicle also forms part of the simulation and interfaces with the control system.

[0078] [Manufacture of motion generators, motion systems, and driving simulators] The motion generating devices and motion systems according to the present invention may be assembled in a conventional manner from a combination of custom and standard components to produce the novel motion generating devices and motion systems of the present invention. Control means suitable for controlling the operation of the motion generating devices and motion systems according to the present invention may likewise be manufactured in a conventional manner.

Claims

1. 1. A primary motion generator that is a parallel manipulator capable of moving a primary payload of 250 kg or more over a surface utilized in a motion simulator, a) a primary frame or platform for supporting said primary payload of 250 kg or more; b) three elongated linear guides arranged at angles to one another in a planar array below said frame; c) at least one actuator arranged on the surface per linear guide, controllable to move the linear guide to move the primary payload of 250 kg or more in at least three degrees of freedom; A primary motion generating device comprising:

2. 2. The primary motion generating device according to claim 1, wherein the elongated linear guide portion protrudes and converges to a single point.

3. 3. A primary motion generating device as claimed in claim 1 or 2, wherein the elongated linear guides are arranged in a star-shaped array, extending outwards from a common central point.

4. 4. The primary motion generating device according to claim 1, wherein at least two of the linear guides are adjacent to each other.

5. 5. The primary motion generating device according to any one of claims 1 to 4, wherein there are six actuators.

6. 6. The primary motion generating device according to claim 1, wherein the actuator is a linear actuator selected from a linear motor, a rack-and-pinion actuator, a belt-driven actuator, or a cable-driven actuator.

7. 7. The primary motion generating device of claim 6, wherein the linear actuators are arranged in a generally triangular array.

8. 8. A primary motion generating device according to claim 6 or 7, wherein the linear actuators are arranged in a planar array.

9. The primary motion generating device according to any one of claims 6 to 8, the linear actuator moves the primary frame by applying a motive force to a carriage connected to the linear actuator and movable along the linear guide; the motive force is transferred from the actuator through the carriage and linear guides to the primary frame by applying a force having a normal / vertical component, such that a force applied at one linear guide is transferred through the primary frame to propel the other linear guide along its axis of motion; Primary motion generator.

10. 10. A primary motion generating device according to any one of claims 6 to 9, wherein the linear actuator is connected to a carriage of a corresponding linear guide by a joint, a bearing, a revolute joint, a spherical joint, or a thrust bearing.

11. A primary motion generating device according to any one of claims 6 to 10, wherein the linear actuator is connected to a corresponding carriage associated with a linear guide by a spherical joint.

12. A primary motion generating device according to any one of claims 6 to 11, wherein the linear actuator is mounted on the surface.

13. 13. The primary motion generating device of any one of claims 1 to 12, wherein the primary payload is greater than about 500 kg.

14. 14. A primary motion generating device according to any preceding claim, wherein the primary payload comprises a vehicle or a model of part or all of a vehicle.

15. 15. A primary motion generator according to any one of claims 1 to 14, comprising at least one safe end stop limiting travel of the frame or platform; the at least one safe end stop comprises one or more elongated straps that limit movement of the platform or frame between the platform or frame and the surface; Primary motion generator.

16. A primary motion generating device according to any one of claims 1 to 15, comprising three or more straps for restricting the movement of the frame.

17. A primary motion generating device as described in any one of claims 1 to 16, wherein at least one strap is rigidly fixed at one end and directly connected to a shock absorber, spring or damper at the other end.

18. A combined motion generating device including a primary motion generating device according to any one of claims 1 to 17 as an internal primary motion generating device, and a secondary motion generating device connected to the primary motion generating device as a payload of the primary motion generating device, In use, the secondary motion generator is controllable to move a secondary payload of at least 250 kg in one or more degrees of freedom relative to the primary motion generator or platform, i.e., relative to the surface. Combinatorial motion generator.

19. 20. A combined motion generator according to claim 18, wherein, in use, the secondary motion generator is controllable to move the secondary payload relative to the primary frame in at least three degrees of freedom.

20. 20. A combined motion generator as claimed in claim 18 or 19, wherein, in use, the secondary motion generator is controllable to move the secondary payload in six degrees of freedom relative to the primary frame.

21. A combined motion generator according to any one of claims 18 to 20, wherein, in use, the primary motion generator operates at a lower band than the secondary motion generator.

22. The combined motion generating device according to any one of claims 18 to 21, at least one actuator of the primary motion generator operates at a frequency of about 5 Hz to about 20 Hz; at least one actuator of the secondary motion generator operates at a frequency of at least about 30 Hz; Combinatorial motion generator.

23. A combined motion generating device according to any one of claims 18 to 22, wherein the linear actuators and / or linear guides of the secondary motion generating device are mounted on the primary frame of the primary motion generating device.

24. A combined motion generating device according to any one of claims 18 to 23, wherein the secondary payload comprises a human user.

25. 25. The combined motion generator of any one of claims 18 to 24, wherein the secondary motion generator comprises a hexapod based motion generator, a linear motor based motion generator, a ball screw based motion generator, a linear actuator based motion generator, a cable action motion generator, or a lever action motion generator, or a combination thereof.

26. An exercise system comprising: a motion generating device according to any one of claims 1 to 17; and a control means for controlling the operation of the motion generating device.

27. 27. A motion system according to claim 26, wherein the control means receives inputs representing a required position, velocity and / or acceleration of the frame relative to an origin fixed relative to the surface.

28. 28. A motion system as claimed in claim 26 or 27, wherein the control means receives inputs representing a required position, velocity and / or acceleration of the frame relative to an origin fixed relative to a payload of the secondary motion generator.

29. 29. An exercise system according to any one of claims 26 to 28, wherein the control means controls the operation of at least one actuator.

30. A motion system according to any one of claims 26 to 29, wherein the control means controls the position, the velocity and / or the acceleration of at least one carriage.

31. A motion system according to any one of claims 26 to 30, wherein the control means utilises feedback from a measurement device to control the position, velocity and / or acceleration of the frame or carriage.

32. A vehicle simulator comprising a motion generation device according to any one of claims 1 to 17, a motion system according to any one of claims 26 to 31, and a cockpit or a chassis and / or other vehicle simulation parts.

33. 33. A vehicle simulator as claimed in claim 32, comprising means for simulating an environment including at least one of a display device, a virtual reality device and a projection device, and software means for modelling the virtual environment and the vehicle model.

34. 34. A vehicle simulator as claimed in claim 32 or 33, wherein the motion of the or each motion generating device is controlled to simulate or replicate the motion of a vehicle simulated in a virtual environment or computer simulation.

35. A domestic or commercial gaming device comprising a motion generation device according to any one of claims 1 to 17 and a motion system according to any one of claims 26 to 31.

36. 36. A gaming device according to claim 35, comprising a control system.

37. 37. A gaming device as claimed in claim 36, comprising means for simulating an environment including at least one of a display device, a virtual reality device and a projection device, and software means for modelling the virtual environment.

38. 38. The gaming device according to claim 37, further comprising a platform on the frame, in use, movement of a user on the platform applies a force to the primary motion generator that causes a measurable change in position, velocity, and / or acceleration of the platform; the measurable change is detectable by the control system and used as an input regarding a state of the platform; The input affects a simulation in the virtual environment. Gaming device.

39. 40. The gaming device of claim 38, wherein the platform represents a set of skis, a surfboard, or a skateboard.

40. 35. A method for designing a vehicle or vehicle part, comprising the use of a motion generation device according to any one of claims 1 to 17, a motion system according to any one of claims 26 to 31, or a vehicle simulator according to any one of claims 32 to 34.

41. A method for manufacturing a motion generating device according to any one of claims 1 to 25, comprising the steps of: disposing three elongated linear guides at angles to one another below the frame; providing at least one linear actuator; positioning the linear actuator above the surface at an angle relative to a linear guide; The method of manufacturing the motion generating device, comprising:

42. A method for manufacturing a primary motion generating device according to any one of claims 18 to 25, comprising the steps of: Manufacturing a motion generating device according to the method of claim 40 or 41; attaching a secondary motion generating device to the primary motion generating device; The method according to claim 1,

43. 40. A method of manufacturing a gaming device according to claim 38 or 39, comprising the steps of: - manufacturing a primary motion generating device by a method according to claim 40 or providing a motion generating device according to any one of claims 1 to 17; connecting said primary motion generating device to a control system; The method according to claim 1,

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