Electric actuators replace hydraulics in flight simulators

Every aircraft flies with its own special feel stemming from its flying and handling parameters. Pilots develop a special sense tuned to the feel of the plane that lets them react appropriately in different situations. Proper pilot reactions are the difference between just flying and flying safely.

The flight-simulation industry is there to let pilots learn the “feel” aspects of flying without the hazards and cost of flying an actual aircraft. According to Aviation Safety magazine, “the high-quality simulator training airline flightcrew members receive from the very first days of their employment” is “the most significant factor” in helping pilots fly safely. Yet, one of the greatest motion-control challenges anywhere lies in simulating realistic flight conditions.

Motion-control systems for full-flight simulators must replicate the conditions and forces that pilots routinely encounter — and new pilots must master — before earning a flight license or rating. Simply put, these motion-control systems contain sophisticated hardware and software intelligence to move a flight simulator and pilot through a virtual sky. Specifically, the motion-control system must seamlessly integrate the operation of a six-degree-of-freedom (6DOF) motion base with control loading hardware that recreates the action and response of primary and secondary control systems, total cockpit instrumentation, and sophisticated visual displays in the cabin.

Hydraulic motion-control systems ruled the flight simulation world for more than 40 years. While there were attempts to create all-electric systems, the results typically fell short in performance or the higher investment needed to own the system deterred customers. So economical allelectric motion-control systems for flight simulation are an engineering breakthrough of sorts.