PCB Stator Haptic Control for Cogging-Free Fly-By-Wire Feedback

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Solution Overview

Problem

Fly-by-wire systems lack high haptic resolution due to limitations in traditional motors, such as cogging torque, which degrades the quality of haptic feedback and makes them inferior to mechanical counterparts.

Innovation Solution

Implementing input and output subsystems with PCB stator motors that transmit electrical signals to mimic mechanical coupling, using input motor controllers and encoders to detect and generate haptic feedback based on output motor position and user input.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional motors with permanent magnets are used in fly-by-wire systems, then the system can transmit electrical signals to replace mechanical connections, but cogging torque degrades haptic feedback quality and reduces positional resolution

Engineering Contradiction:

Improvehaptic resolutionVSAvoidcogging torque

Core Design Contradiction:

Measurement precisionVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes the permanent magnets from the motor design, transitioning from a traditional permanent magnet motor to a PCB stator motor. This extraction eliminates the source of cogging torque while maintaining the motor's core functionality of converting electrical signals to mechanical motion, thereby resolving the haptic feedback quality issue.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the traditional mechanical motor structure with a PCB-based stator system. This substitution eliminates the physical interactions between permanent magnets and stator slots that cause cogging torque, providing smooth haptic feedback without the mechanical limitations of traditional motor designs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If mechanical connections are used to transmit energy from input to output, then haptic feedback quality is maintained, but the system complexity increases and reliability decreases due to additional parts that can fail

Engineering Contradiction:

Improvesystem reliabilityVSAvoidmechanical connection complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical connections with an electrical signal transmission system using PCB stator motors. This substitution eliminates physical linkages, shafts, chains, and belts that require maintenance and can fail, while maintaining system functionality through electronic control and haptic feedback mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The PCB stator motor serves multiple functions simultaneously: it acts as the actuator for mechanical motion, the sensor for detecting user input torque, and the haptic feedback generator. This multi-functionality eliminates the need for separate mechanical components, reducing system complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If fly-by-wire systems eliminate mechanical connections, then system reliability improves, but haptic feedback quality deteriorates due to lack of mechanical feel

Engineering Contradiction:

Improvesystem reliabilityVSAvoidhaptic feedback quality

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent implements a feedback mechanism where the PCB stator motor detects user input torque and generates corresponding haptic feedback. The system continuously monitors the input torque applied to the motor and provides real-time haptic resistance, creating the sensation of mechanical connection without physical linkages, thereby maintaining ease of operation while improving reliability.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent substitutes mechanical haptic feedback with electronically generated haptic feedback through the PCB stator motor. This substitution provides the sensation of mechanical resistance and feedback through controlled electromagnetic forces, eliminating the need for physical mechanical connections while preserving the tactile experience for the operator.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Achieves high haptic resolution and fidelity by minimizing cogging torque, providing a seamless and believable haptic experience without mechanical connections, suitable for applications in aviation, automotive, and other contexts.

Implementation Method 1

PCB stator motors that transmit electrical signals to mimic mechanical coupling

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250385632A1Control systems and methods with haptic feedback

Publication Date: 2025.12.18 NODAL FILM SYST LLC

AI summary

Systems and methods of the inventive subject matter are directed to haptic feedback systems that use PCB stator motors in at least the input subsystems. Systems thus include one or more input subsystems that are configured to operate with an output subsystem (either real or virtual). Input subsystems implement PCB stator motors to eliminate cogging and to create high-fidelity, ultra-realistic haptic feedback that a user would be unable to distinguish from direct operation of a similar mechanical system. In some embodiments, multiple input subsystems are configured to operate with a single output subsystem.