Aircraft Simulator Mirror Cell Extension for 180-Degree Field of View
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Solution Overview
Problem
The existing 150 degree mirror cells in flight simulators need to be upgraded to 180 degrees to meet new certification standards, but this requires expensive replacement, and existing technology causes distortion and damage to the Mylar™ material during the process.
Innovation Solution
A unique technique and tooling system is used to extend the 150 degree mirror cells to 180 degrees by attaching extension wing structures with structural reinforcing members, minimizing distortion and allowing the reflective film to be reskinned without damage, while maintaining geometric accuracy and preventing undue stress on the Mylar™ material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If existing 150 degree mirror cells are replaced with new 180 degree mirror cells, then the field of view is expanded to meet certification standards, but the cost increases significantly and existing mirror cells are wasted
Solution Approach 1:
The patent modifies the existing mirror cell by changing its physical parameters - specifically extending the mirror cell structure from 150 degrees to 180 degrees using extension wings, and adjusting the spherical radius to maintain optical accuracy. This allows the existing mirror cell to be upgraded rather than replaced, eliminating waste while achieving the required field of view expansion.
Solution Approach 2:
Instead of discarding the existing 150 degree mirror cells, the patent recovers and reuses them by adding extension structures. The extension wings are attached to the existing mirror cell, extending its angular coverage to 180 degrees while maintaining the original mirror cell as the core component.
2Area of moving object
If traditional mirror installation techniques are used, then the mirror cell can be extended, but distortion and damage occur to the Mylar material
Solution Approach 1:
The patent maintains the spherical geometry of the mirror cell throughout the extension process. Extension wings are designed with matching spherical curvature, and the Mylar material is stretched and sealed to conform to this spherical shape. This curvature consistency prevents distortion and maintains geometric accuracy while expanding the field of view.
Solution Approach 2:
The patent applies preliminary actions to prevent damage - the Mylar material is carefully stretched and positioned before vacuum sealing, and the extension wings are pre-formed with the correct spherical curvature. This preliminary preparation ensures the material is properly conditioned before final attachment, preventing distortion and damage.
3Area of moving object
If the mirror cell is extended without proper support structures, then the field of view increases, but stress and distortion occur to the reflective film
Solution Approach 1:
The patent divides the mirror cell structure into segments - the original 150 degree mirror cell and additional extension wings that provide the remaining 30 degrees. This segmentation allows the extension to be added in controlled portions with appropriate support structures, distributing stress rather than concentrating it on the Mylar material.
Solution Approach 2:
The extension wings act as intermediary structures between the original mirror cell and the external environment. These wings provide structural support and stress distribution, mediating the forces applied to the Mylar material during extension and operation, thereby preventing excessive stress and distortion.
Data Source
AI summary
A method and apparatus for extending the effective circumferential extent of an original an aircraft simulator mirror cell having a base support structure mounted to a movable platform, the base support structure being in generally the shape of a portion of a sphere of a predetermined radius and having a predetermined circumferential extent defined by original edges of the support structure configured to support a vacuum-shaped reflective film. The improvement includes a pair of extension wing structures having substantially the same spherical radius as the base support structure and a substantial circumferential extent, each of the pair of wing structures being attached to one of the original edges of the base support structure and substantially sealed thereto, the extension wing structures, when attached, extending the effective circumferential extent of the base support structure by a substantial amount, each of the pair of extension wing structures having outer edges for supporting a vacuum-shaped reflective film.