New eMotion 6DOF 14 tonne full-flight simulator platform off to a flying start

Bosch Rexroth, the leading company in drive and control solutions, has introduced its first 14,000 kg electro-mechanical motion platform certified for commercial aircraft simulators. A modern, high quality design enables the eMotion-14000 to push the envelope in performance, efficiency and safety. Competitively priced, it also significantly lowers total cost of ownership due to greatly reduced energy usage, low vibration and long lifetime.

Outside and in, the design of the new eMotion-14000 full-flight simulator (FFS) platform has a lot to offer. Following the same lines as the proven eMotion 1500 and 2700 models, its sleek exterior is visually attractive and reflects the high build quality. A complete hardware and software solution, all components are built by Rexroth ensuring the best quality at a competitive price point. The system is level D qualified, so it can be used for pilot training simulators. Knuckles make it easy to link to the customer’s equipment. Also, adapters make it simple to upgrade other systems with the eMotion solution without needing to change the existing design.

The eMotion-14000 is highly energy efficient with actuators that have integrated static load compensation to support up to 80% of the payload. This eliminates the need for extra pneumatic cylinders or separate pressurizer, and reduces energy consumption. Also, with less force on the spindles, there is less wear and tear. Furthermore, gravitational energy of descending loads is stored in capacitors with smart energy exchange allowing other cylinders to use it.

An inline motor construction directly couples the motors to the actuators, minimizing noise and vibration. Self-lubricating spindles and bearings are ‘lubricated for life‘, ensuring the smoothest movement, without re-greasing, during the platform’s entire lifetime of up to 30 years. 

The Hypcos control software is rather special too, incorporating several advances in motion cueing together with testing and troubleshooting tools, and special effects. Alternatively, the customer can elect to use their own control software.

Translating instructions from the customer’s host computer, the control software provides optimized motion cueing. This can be tuned to meet the desired pilot or system parameters. However, objective motion cueing – designed in cooperation with legislation institutes – can also be implemented for a more uniform response. This allows limits to be set on the tuneable parameters to ensure standardized simulator operation. So every pilot gets a very similar experience. Care has been taken to make movement smooth and realistic, and the software reduces the effects of reversal bumps and friction.

Built-in safety measures for the eMotion-14000 are the most extensive in the market. Drives are equipped with Bosch Rexroth ‘Safety on Board‘ technology which meets the standards for industrial robotics. Both mechanical and software motion limiting features are utilized and actuators have generous safety zones to absorb energy in case of failure.

“Part of a completely redesigned product family, the eMotion-14000 motion platform delivers high performance across the board, improving specs by some 10% over competitor systems,“ said Hans ten Hagen, Manager Motion Simulation Technology at Bosch Rexroth. “It is the perfect way for us to enter the FFS market, a market that is seeing steady growth now and in the future.“

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