AAM/eVTOL Aircraft Flight Simulator Controls

Next-gen 3-axis active control stick for eVTOL/AAM aircraft flight simulators. Innovative custom solutions from a world-class specialist 

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Flight Controls for AAM/eVTOL Development

State-of-the-art active flight controls from Stirling Dynamics are playing a crucial role in the development of Advanced Air Mobility (AAM) and Electric Vertical Take-off and Landing (eVTOL) aircraft.

Our next-generation flight simulator controls are helping development teams to complete design and pre-certification phases faster as they determine the aircraft’s true flight-control laws, handling qualities, control sensitivities and force characteristics.

These active simulator controls can be easily reconfigured as the aircraft’s aerodynamics, propulsion system blending, flight-mode transitions, stability augmentation, envelope-protection logics and haptic feedback philosophy evolve through engineering prototypes, software updates and test-pilot evaluations.

Active control technology allows the engineering team to modify force gradients, damping characteristics, breakout forces, stick travel ratios, control-feel schedules and trim offsets almost instantly through software.

Flight-test insights prompt rapid iteration of the aircraft’s control laws in the simulator. The result is a safe, repeatable, high-fidelity environment in which to explore alternative flight-control philosophies, test extreme conditions and validate workload, pilot harmony and control authority under scenarios that would be impossible or unsafe to attempt in an early prototype.

Once the flight control settings are fully locked in, we can then design, manufacture and supply airworthy passive controls that are much lighter than their active counterparts. They reduce overall aircraft mass, lower power consumption, simplify maintenance and increase reliability.

These passive controls simplify systems, yielding a more robust, lighter and more energy-efficient cockpit – essential for electric aircraft where weight and power budgets are tightly constrained.  

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Next Step in Flight Control Evolution

Designing flight simulator controls for Advanced Air Mobility (AAM) and Electric Vertical Take-off and Landing (eVTOL) aircraft brings a completely new set of challenges. These designs do not fit neatly into the established categories of fixed- or rotary-wing types. They blend aspects of both, putting them at the cutting edge of certified aviation with electric propulsion and multi-axis control architectures.

AAM and eVTOL aircraft designed for urban, short-range and highly automated flight operations use multiple distributed electric rotors or tilt mechanisms to provide both lift and thrust – controlled through a fly-by-wire (FBW) flight control system rather than direct mechanical linkages.

Multiple control effectors such as rotors, fans or control surfaces are combined and coordinated to produce the aircraft’s desired motion – pitch, roll, yaw and thrust – from a single, intuitive pilot input.

This is a fundamental concept in AAM/eVTOL aviation and therefore crucial to replicate correctly in active flight controls. The latest technology from Stirling Dynamics is doing precisely that with a three-axis control stick that delivers a true and configurable solution.

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Why AAM/eVTOL Flight Controls Must Be Different

Designing flight controls for highly innovative aircraft with evolving requirements necessitates versatile and reconfigurable solutions. It requires the expertise of a specialist manufacturer with decades of experience. These are the obstacles that must be overcome:

Lack of Established Flight Data

Traditional aircraft simulators replicate existing aircraft controls based on years of data with defined force-displacement laws, trim behaviour and vibration profiles. But many eVTOL aircraft are often still in prototype or certification phases so engineers require a flexible approach.

The ability to develop and progress control in a simulator environment is a huge benefit in terms of time and cost as flight controls from Stirling Dynamics products are highly reconfigurable.

Novel Control Architectures

Many eVTOLs use conventional side-stick controllers, centre sticks or throttle-like power levers but their functions are non-traditional.

Stirling Dynamics has developed a unique 3-Axis control stick that enables multi-axis control blending. In hover, control stick inputs may be used to govern thrust across multiple power units to vector the aircraft. In forward flight, the same inputs map to aerodynamic control surfaces or differential thrust.

Transition Flight Dynamics

The most complex challenge for eVTOLs is transition – when lift shifts from vertical to forward flight. Having an accurate control system that provides suitable forces and feel is critical. Stirling Dynamics’ active controls allow for various force curves to be developed to meet this vital requirement and ensure the simulator accurately replicates the aircraft.

Human Factors and Certification Uncertainty

Human-machine interface (HMI) design is still under regulatory review for eVTOLs (EASA SC-VTOL, FAA MOSAIC). Simulator controls must therefore support rapid reconfiguration (adjustable travel ranges, stiffness, damping and force curves) as the aircraft’s HMI evolves. Flight controls from Stirling Dynamics can be rapidly reconfigured as required. Grips are fully bespoke and can be changed. The buttons, switches, ramps and detents are configurable.

Space and Ergonomics

AAM cockpits tend to be compact and simplified for short-range operations. Simulator control systems must be lightweight, quiet and compact, often integrated directly into cockpit mock-ups or motion platforms with strict spatial constraints. Our 3-Axis Control Stick is designed for precisely these requirements.

Engineering Characteristics Required for AAM/eVTOL Flight Simulator Controls

Specifying active sticks is the smartest and safest way to develop lightweight passive airworthy controls that meet the unique engineering requirements of AAM/eVTOL aircraft:

Programmable force laws – because the design of the real controls is still under development.
Multi-axis coupling – controls such as pitch and thrust vector may interact dynamically.
Haptic feedback capability – needed for mode or alert indication as required. This may be configured as part of the simulator development process.
Ultra-low latency – prevents cue lag during critical phases of flight such as rapid thrust vectoring or transition.
Full backdriveability to synchronise with dual controls if required and support simulator training.
Compact flightworthy control stick because cockpit space is limited.

 

3-Axis Control Stick for AAM/eVTOL Flight Simulators

Stirling Dynamics’ 3-Axis stick is a natural evolution of our successful Version 4 Control Stick. It is a fully active control that exploits a third axis for applications where weight and space are limiting factors.

With versatility in mind, all our active controls are commanded by a dedicated electronics Inceptor Control Module (ICM), which provides an ethernet interface allowing minimal integration effort.

 

Stirling Dynamics’ active controls interface to your simulator software through a UDP over a LAN connection. Multiple systems can be connected via the LAN if they have their own IP address.

We can provide a separate Graphical User Interface (GUI) that can seed the devices with specific settings, or you can send message sequences to configure your devices in real time. We also provide you with all the integration documentation and support you need to successfully set up your new control product.

3-Axis Control Stick: Key Information

  • Maximum Peak Force Pitch and Roll 70lbf, Yaw 10ft-lb
  • Maximum Continuous Force Pitch and Roll 52lbf, Yaw 4ft-lb
  • Active Travel Pitch and Roll ±25°, Yaw ±45°
  • Maximum Velocity 120°/s (all axes)

 

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Why Stirling Dynamics

Stirling Dynamics (an Expleo company) is a world-class innovator that pioneered active pilot controls in the early 1990s. Our new Version 4 solutions and decades of experience make us a trusted leader in the AAM/eVTOL segment of the simulator/airworthy flight controls market.

We design and manufacture all our AAM/eVTOL controls at our premises in Bristol, UK. Our full bespoke service gives the customer complete choice in control specifications. Grips can be specific to aircraft types: we offer a range of grips to suit different applications.

Expleo is a €1.4 billion group comprising 18,000 innovation-driven experts in 29 countries. It is trusted around the world by brands including Airbus, Dassault Aviation and Spirit Aerosystems.

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