RLS and AFormX bring the flying experience closer

Just as musicians learn to play their instruments without consciously thinking about the movements required or looking at their instruments, pilots in a VR flight simulator use kinesthetic memory learning to acquire new cognitive skills and develop or refine technical skills. One of the many advantages of flight training in a VR flight simulator is the flexibility in selecting a virtual scenario that can be easily customized to the trainee’s learning needs. The highly realistic virtual environment has the greatest impact on improving the pilot’s performance.

AFormX is a Slovenian company that manufactures and develops advanced aircraft as well as VR flight simulators. It consists of engineers and designers who gained experience and knowledge working on challenging aviation and VR projects requiring creativity and extensive industry knowledge. Their work has been publicly recognized and awarded. In 2017 they received a Golden National Innovation Award and in 2018–2019 they were winners of the Royal Aeronautical Society General Aviation Design Challenge.

AFormX's two best-selling simulators are X-ALPHA 200 and FlyZmaj for simulating hang gliding. The X-ALPHA 200 simulates the Pipistrel Alpha Trainer and Virus aircraft. It is used in many educational and training facilities around the world.

"The idea of combining a simulator with an aircraft and building a truly crazy simulator for the 21st century came from our deep understanding of the principles of VR." - Sa?o Knez , owner and CEO of AFormX

The challenge

AFormX has built flight simulators before, but putting one inside a real aerobatic aircraft has proven to be something completely different. Modifications to the aircraft structure are prohibited and may not become heavier. AFormX joined forces with the aerobatic pilot and flight instructor Jago Stemberger to disassemble the Ultimate 20-300S aerobatic aircraft and install a VR simulator.

The Ultimate 20-300S aerobatic biplane of Canadian origin was designed in the eighties by Gordon Price.

“We teamed up with AFormX, who manufacture simulators for Pipistrel, and RLS to develop a hybrid simulator. We wanted to offer users a unique experience of sitting in a real aerobatic plane, training in a simulator, and using the cockpit controls.” - Jago Stemberger, aerobatic pilot and flight instructor

The solution

The key factor in a simulator is a highly realistic virtual environment, providing the pilot with an immersive training experience. “The simulator must provide a top user experience. The VR headset must display the landscape in high resolution for a realistic flight experience,” said the R&D engineer Ines Repnik to underline her passion for developing the best VR experience.

It also has to be possible for the pilot to react in real-time in the virtual environment. The motion of the sticks and pedals must be accurate enough to enable good control.

“The experience of flying in a simulator must convince the pilot that they are really aviating. The motion of the aeroplane in the simulator must follow the sticks and pedals accurately,” explains Ines Repnik.

RLS rotary and linear motion sensors are used in the simulator for position feedback. They are used to determine the movement of the sticks with the best accuracy and repeatability. AFormX had to find suitable sensors for the Ultimate 20-300S aeroplane and RLS helped to find a proper solution.

Nino Razpotnik , the development engineer at AFormX, is responsible for the electronics: “The sensors measure the mechanical deflections of sticks and pedals. The signals are then fed via a controller to the computer as feedback for aeroplane control.” AFormX previously used potentiometers for position feedback, but they had a big disadvantage – short life. The potentiometers simply were not up to the task or failed too often. After thorough research, the AFormX team decided to install the RE22 rotary magnetic encoders in their simulator.

The RE22 is a compact, high-speed encoder designed for harsh environments. The encoder is very easy to install as it already has a magnet attached to the shaft in the encoder housing at a perfect distance from the sensor part, i.e. the encoder IC. The encoder chip processes the received signals to enable resolutions of up to 13 bits at high operating speeds. The encoder has a diameter of only 22 mm and is dirt-resistant (IP68). Thanks to the non-contact design, the encoder is wear-free and extremely reliable.

The results

With support from RLS, AFormX has managed to expand its offer of simulators and make an even more innovative version, i.e. a hybrid simulator installed in an aerobatic plane.

The Ultimate 20-300S biplane simulator lets the pilot use the same sticks and pedals to control the aeroplane in the simulator and in the real world.

“AFormX and RLS will remain partners, as we continue to source RLS sensors for our simulators. This is crucial, because we ship our simulators worldwide and need the reliability that only RLS sensors can provide.” - Sa?o Knez , owner and CEO of AFormX

More on RLS website: https://www.rls.si