Final Design Report: https://drive.google.com/file/d/17WmMZOjEjBpPgjpJMegJKQqnOUEk_STz/view?usp=sharing

Background

As part of a senior design capstone initiative, our multidisciplinary team of five set out to build Aerodrive, a dual-mode simulator combining flight and racing simulation into a single modular system. The project was supported by the Jacobs Institute for Design Innovation and the ASME student chapter, both of which recognized the project’s potential and awarded a combined $2,500 in grants. The capstone showcase culminated in our team winning the “Best Electro-Mechanical Design” Award.

The initiative was driven by a growing interest in immersive simulation systems for both entertainment and training purposes. Our goal was to deliver an intuitive, high-fidelity experience that seamlessly transitions between flight and racing modes through an innovative modular hardware design.

Problem

The central challenge was to engineer a single simulator capable of delivering an authentic and responsive experience for two distinct applications: automotive racing and aviation flight. This required solving multiple interdisciplinary problems:

Designing a steering interface that could accommodate diverse control demands between flight and racing.
Ensuring modularity and rapid transition between configurations without compromising functionality or durability.
Delivering realistic haptic feedback to enhance user immersion.
Integrating mechanical, electrical, and firmware components into a cohesive and robust system.

Solution

My contributions centered around the end-to-end development of the steering wheel module, which consisted of:

Dual Steering Wheels: Two interchangeable wheels, each equipped with eight programmable buttons and two thumb joysticks to suit different simulation needs.
Haptic Feedback System: Two high-torque motors controlled via a custom PID (Proportional-Integral-Derivative) control algorithm provided dynamic force feedback simulating road texture, resistance, and environmental forces.
Quick Release Mechanism: Designed for seamless transitions between the flight and racing configurations. The mechanism prioritized mechanical robustness, user-friendliness, and electrical continuity using an aux cable.
Mechanical Design and Prototyping: I used CAD modeling, 3D printing, and CNC machining to iterate quickly and achieve ergonomic and structural goals.
Electrical Integration: Developed custom circuitry to support power distribution, sensor integration, and communication protocols with the simulator’s central processor.
Firmware Development: Wrote embedded firmware to interpret sensor data, control motor output through PID, debounce button inputs, and ensure real-time responsiveness.
Testing and Debugging: Conducted rigorous testing, including stress testing the quick-release under dynamic load and tuning the PID parameters for optimal haptic realism.

Design Impacts and Decisions

Several key decisions enhanced both the user experience and technical performance:

Human-Centric Ergonomics: Through user feedback loops and prototype testing, we optimized button layout and wheel diameter for both comfort and accessibility during extended sessions.
Modularity: The quick release system was developed with standardized electrical contacts and a tool-less locking mechanism, reducing reconfiguration time to under 10 seconds.
Feedback Precision: The PID algorithm was refined iteratively using system identification and empirical tuning, achieving smooth and responsive force feedback that accurately mirrored vehicle dynamics.
Fail-Safe Protocols: Safety cutoffs and redundant sensors were included to mitigate potential hardware faults during high-load operations.

Conclusion:

Our team presented the project at the university’s capstone showcase, where it received the “Best Electro-Mechanical Design” Award, recognizing our innovative fusion of hardware, software, and user experience. In addition, we were awarded $2,500 in development grants to complete the project.

Mechatronics Engineering - "Aerodrive"