Hydraulic-Free Braking Simulator Using Mechanical Springs
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Solution Overview
Problem
Current aeronautical simulators fail to accurately simulate the dynamic behavior of foot-braking systems, particularly the hydraulic circuit pressurization, due to their reliance on heavy and costly hydraulic or electrical solutions, which are not environmentally friendly and require specialized maintenance, and do not replicate the real-world experience effectively.
Innovation Solution
A hydraulic-free device combining mechanical and electrical components, including a mechanical braking module with springs and an electromagnetic friction module, along with simulation software, to provide variable force feedback that mimics the pressurization of the hydraulic braking circuit, ensuring realistic pedal travel and effort feedback without the bulk and maintenance issues of traditional systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic components or electrical solutions are used to simulate braking, then braking simulation fidelity is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts and eliminates the hydraulic system from the braking simulation device, replacing it with a mechanical spring-based system. This removes the complex hydraulic components (pumps, valves, fluid circuits) while retaining the essential braking simulation function through spring pressure and mechanical force transmission.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with a purely mechanical spring-based system. The spring mechanism mechanically replicates the hydraulic pressure effects through elastic deformation and force transmission, eliminating the need for hydraulic fluid and associated components.
2Reliability
If brushless motors with variable speed drives are used, then braking behavior simulation is improved, but implementation bulk and cost increase
Solution Approach 1:
The patent extracts and removes the heavy brushless motor and variable speed drive components from the system. Instead, it uses a compact mechanical spring mechanism that provides the necessary braking force simulation without the bulky electromagnetic components.
Solution Approach 2:
The patent substitutes the electromagnetic motor-driven system with a mechanical spring-based system. The spring mechanism provides the required force simulation through elastic storage and release, eliminating the need for motors, drives, and associated electromagnetic components.
3Force
If hydraulic systems are used, then braking force simulation is improved, but energy consumption and maintenance complexity increase
Solution Approach 1:
The spring-based mechanical system is self-contained and self-regulating. The spring automatically stores and releases energy through its elastic properties, providing braking force simulation without requiring external power sources, hydraulic pumps, or active control systems.
Solution Approach 2:
The patent replaces the energy-intensive hydraulic system with a passive mechanical spring system. The spring mechanism uses elastic potential energy storage and release to generate braking forces, eliminating the need for hydraulic power transmission and associated energy consumption.
4Reliability
If hydraulic components are used, then braking dynamics simulation is improved, but ease of maintenance deteriorates
Solution Approach 1:
The patent removes hydraulic components (fluid circuits, seals, pumps, valves) that require specialized maintenance knowledge. The resulting mechanical spring system consists of simple, robust components that can be easily inspected, adjusted, and replaced by general maintenance personnel.
5Measurement precision
If traditional hydraulic solutions are used, then braking simulation accuracy is improved, but installation space requirements increase
Solution Approach 1:
The patent extracts and eliminates the space-consuming hydraulic reservoirs, fluid lines, and associated components. The mechanical spring system occupies minimal space while maintaining braking simulation accuracy through direct mechanical force transmission to the pedals.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact, low-maintenance, cost-effective, and highly realistic simulation of foot-braking systems, capable of replicating the dynamic effort changes during flight and taxiing operations, meeting stringent certification standards while being energy-efficient and easy to install and maintain.
Implementation Method 1
a mechanical braking module configured for supplying a linear effort value in response to a press on a brake pedal
Implementation Method 2
an electromagnetic friction module configured for supplying a friction force value in response to said press on the brake pedal
Data Source
AI summary
A foot-braking simulation device for a simulator includes a mechanical braking module configured for supplying a linear effort value in response to a press on a brake pedal; an electromagnetic friction module configured for supplying a friction force value in response to the press on brake pedal; and a software calculation module configured for combining the values obtained from the mechanical braking and electromagnetic friction modules to calculate a control value, and generate variable force feedback on the brake pedal as a function of the control value.