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Design and fabrication advice taken for a ride

A leading maker of aircraft flight simulators has diversified into manufacture of machines designed to simulate car racing and high-speed flying for the leisure market, and has been in touch with TWI over a design task with a difference.

Leisure simulators are bigger than standard flight simulators, having a seating capacity of up to 45. The extra size and weight contribute significant increases in static and inertial loads on the structure. Furthermore, they are often operated virtually non-stop for 12 hours or more per day. This led the simulator manufacturer into a full reappraisal of its design and fabrication procedures, helped by TWI.

The leisure simulators consist of two primary fabrications: a floor structure and a superstructure. The floor structure is a welded space frame in steel tube, sections and castings. The superstructure consists of welded aluminium alloy plate and sections. In a programme running over two years, TWI was able to advise on design, selection of materials, welding (process, procedures and consumables) quality control, inspection and non-destructive testing. The total package was summarised in two detailed documents, one covering design and the other fabrication. As a result, improvements in both quality and efficiency of production were achieved.

For information about TWI’s capabilities please email contactus@twi.co.uk

Leisure simulator in action
Leisure simulator in action
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