Redesign of an optical force sensor for hand-grip interface in helicopter flight simulators

Abstract

The iterative redesign of a product is essential for advancing its Technology Readiness Level, enabling the transition from conceptual prototypes to reliable, real-world applications. In this study, a tactile force sensor named OPT-IN (OPTical-INceptor) based on the optical phenomena of Frustrated total internal reflection (FTIR) is redesigned as a product to be utilized on helicopter flight simulators as a collective controller. The sensor design includes light detectors, an LED light source, hemispherical silicone probes and a waveguide for transmitting light. The redesigned tactile sensor focuses on minimizing optical losses and measurement bias by reducing light leakage to the light sensing elements through properly shielding the waveguide and optimizing the LEDs placement for efficient signal transmission. Mechanical stability was improved through secure positioning of the photodetectors and probes, along with an ergonomic probe holder designed to improve user interaction. Additionally, cable management and structural integration were refined to enhance signal stability and overall system reliability. Finally, experimental tests involving two manoeuvres: a vertical repositioning and an Acceleration-Deceleration are conducted on an research flight simulator to evaluate the sensor’s performance in field applications.

Keywords: Tactile Force Sensor, Human Machine Interaction (HMI), Contact Area, Hertz Theory, Hand-Grip Sensor

DOI: 10.54941/ahfe1008215