Flight Simulator as a Learning Experience Part 2

I had wanted to build something more than just a viewing piece. I wanted something that the viewer could experience. Coupling the aircraft with a flight simulator seemed to be the natural choice.

In my first article, I described ripping apart a Wingman Extreme joystick and using the 'inards' to convert the display aircraft to a full size simulator. In closing, I had told readers that I would return in a few weeks with an article describing installation of rudder pedals and computer graphics.

Well, a few weeks turned into a few months. I apologize.

In those few months however, much has changed. The stripped down Wingman Extreme joystick I wrote about in my previous article worked fine, but the more I read about Phidgets... the more I wondered if I couldn't do a whole lot more. Suffice it to say, it was back to the drawing board.

I contacted the good folks at Phidgets who, as it turned out, were just down the road a few miles at Calgary, Alberta, Canada (their US distributor I believe is PhidgetsUSA). They supplied me with an 8/8/8 Phidgets Interphase Kit, a 4-motor Phidget Servo, and 4 Phidget slide sensors. Using FSUIPC along with FS2Phidgets I have been able to outfit the display aircraft with full aileron, elevator, rudder, and throttle control; as well as air speed, vertical speed, and turn and bank indicators. Soon I will be obtaining another 4-motor servo controller to add an artificial horizon, engine RPM and a couple of engine instruments.

     

The joystick was the easiest to construct. These pictures show the stick just as it would be constructed. A Phidget slide sensor was mounted on the underside of the control structure to provide elevator control, while another mounted on the floorboard provides aileron control. Both use simple to construct remote control fittings and pushrods. Although the joystick travel is very close to that of the slide, I decided to add a couple of bends to the push rods to allow for some flex. This way, it provides some durability to the Phidgets. Although they seem very durable, some of the kids have been known to throw the controls around pretty good. If a slide should reach the end of its travel, flex in the push rod will prevent damage.

Rudder and ground handling control was done in a similar manner. Being a full size aircraft, it is not only equipped with pedals, but control cables running back to a functioning rudder. Rudder control was accomplished by mounting a 'Phidget slider' parallel to the rudder cable with the same type of 'non-rigid' attachments. I am currently using tensioned 1/4 inch bungee cords but am fabricating a more precise system using the same RC aircraft push rods. The bungee cords work well, but offer a less precise centering position.

Panel

Using the Phidgets 4 motor servo controller I was able to create an airspeed indicator (1 servo), a vertical speed indicator (1 servo), and a turn coordinator (2 servos). Soon another 4 motor servo controller will be added so I can add Engine RPM and an artificial horizon and possibly even some smaller engine monitoring gauges (such as oil pressure, etc.). The green item at the top of the picture is the 4 motor servo control. It actually mounts to the back of the panel. (indicator needles are not shown because I quickly set this up for a photo before mounting it).

To give the gauges full rotation (340 degrees for the airspeed, and 350 degrees for the VS) I simply used gear ratios (larger gear attached to the servo and smaller gear mounted on the shaft that passes through to the front of the gauge.

For the turn and bank, a small mini servo is mounted 'through the board' for the aircraft needle and a larger servo operates the 'ball'. (The picture to the right doesn't show the larger servo as it hadn't been mounted yet.)

I found there is plenty of information on the net with regard to making servo gauges. All you really need to know is that Phidgets is the perfect system for operating them. Please note however that Phidgets is only the hardware associated with the things I've mentioned. FSUIPC and FS2Phidgets are the programs needed to integrate the hardware with your system.

Currently, my Starduster sim is fully operational. Half the aircraft has been covered leaving the other half open for viewing. Pulling the aircraft out of the trailer, the wings and empennage are mounted within 10 minutes, the computer is plugged in via USB, and if power isn't available, the generator in the trailer is powered up to run the thing.

Using a couple of flights I added to FSX 'Kiosk', participants simply sit in the craft, flick the master power on using the toggle button at the top of the electrical panel, push to start (the square red button on the left of the electrical panel configured to imitate 'Ctrl E') and add power using the throttle slide sensor (mounted directly under the electrical panel).

As I said in my previous article... this aircraft would fly if not for suspected wood rot and a bit of glue separation in the wings. To add to the realism, I am mounting a continental C65 dummy engine and prop to the front of it, finishing the cowling, and again using Phidgets; creating a motion platform with 10 degrees bank and pitch.

I'll be displaying the aircraft over the summer... Once I have pictures of the completed project, I'll send a final article. (Shouldn't be long... my significant other desperately wants that engine out of the basement.)

Happy Flights.

Daryl Lowey
Living Sky Aerobatics
dlowey@livingskyaerobatics.com
www.livingskyaerobatics.com