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Human Factors in Simulated Avionics: Why Knob Feel, Detents, Throw, and Tactile Realism Matter—And How Simtek Leads the Field

  • ccowley
  • Nov 12
  • 3 min read

Updated: Nov 13


Human Factors in Simulated Avionics — Simtek, Inc.

In a real cockpit, pilots don’t “look” their way through tasks—they feel them. The subtle click of a rotary selector, the travel of a guarded switch, and the friction profile of a potentiometer anchor muscle memory and reduce head‑down time. If a simulator flattens or fakes those cues, it trains hesitation—not confidence. At Simtek, we treat human factors as a primary system requirement, and we engineer tactile realism you can measure, repeat, and trust.


Tactile realism—four pillars that matter


Knob feel (friction, inertia, surface geometry)

A knob’s feel comes from the interplay of materials, bearings, and geometry. Too loose and pilots overshoot; too stiff and they under‑correct. We tune static/dynamic friction, rotational inertia, and knurling so gloved hands achieve precise, eyes‑free control. Simtek advantage: target torque curves validated on test benches ensure unit‑to‑unit consistency.


Detents (the “language” of the knob)

Detents are data. Their spacing, height, and acoustic signature confirm discrete changes: a mode, a channel, a waypoint. Simtek approach: custom detent cams and spring‑loaded followers match OEM patterns (including unequal spacing or dual‑stage actions) while housing geometry tunes the audible “click” to be perceptible, not fatiguing.


Throw (travel, stops, and rate of change)

Linear and rotary throw determine speed, resolution, and predictability. Simtek practice: precise end‑stops with proper cushion, mapped response curves (linear/log/S‑curve) aligned to device behavior, and firmware sampling/debounce that preserves the mechanical feel across the software boundary.


Holistic tactile realism (beyond single parts)

True realism emerges when torque, detents, throw, guards, and backlighting agree. We validate full assemblies at cockpit geometry—seated height, reach, and clearances.


Why this matters for training outcomes

  • Muscle memory you can grade: Repeatable torque and detents build consistent scan patterns.

  • Head‑up time under load: Hands read the panel so eyes stay on PFD/outside references.

  • Fewer negative transfers: Avoid teaching corrections that won’t exist in the aircraft.

  • Confidence in emergencies: Tactile anchors trigger automatic, correct actions.


How Simtek engineers tactile realism


Requirements you can measure

No hand‑wavy “feels right.” We capture torque (N·cm), detent force (N), throw (°/mm), backlash (°). These are living specs tied to QA and traceability.


Mechanisms chosen for simulator duty cycles

Training devices see extreme cycles. We use hardened cams/followers, appropriate bushings/bearings, and replaceable wear components to keep feel stable over millions of actuations.


Electronics that respect the feel

High‑rate sampling and tuned debounce prevent phantom counts without smearing crisp mechanical transitions. No over‑filtering that masks the pilot’s intent.


Test, measure, repeat

Every lot undergoes torque/force verification, and detent uniformity checks.


Real‑world use cases

  • Rotary mode selectors: Unequal detents with a firmer transition into critical modes to prevent bump‑past.

  • COM/NAV frequency knobs: Dual‑concentric encoders with distinct inner/outer torque so fine tuning never drags coarse digits.

  • Range/Brightness controls: Linear throw with a center cue correlated to a calibrated 50% output, NVIS‑aware.

  • Engine/condition levers: Positive end‑stops with cushioned return to train precise muscle memory.


Common pitfalls we solve

1. One‑size‑fits‑all encoders → inconsistent training.

2. Mushy detents from stack‑ups → we control GD&T.

3.  Over‑filtered inputs → we tune debounce, not smother it.

4.  Ignored acoustics → we damp or amplify to target a repeatable “click.”


Why Simtek is the right partner

  • Singular focus on simulated avionics—Flight simulated control panels, displays, instruments.

  • Human‑factors first—tactile specs validated from pilots/SMEs and held through production.

  • Lifecycle‑ready—service kits and stable feel across years and lots.

  • Program‑proven—from rotorcraft trainers to fast‑jet cockpits.


How to engage with us

  1. Bring your feel: We document target tactile specs from aircraft/TRDs.

  2. Prototype fast: Evaluate tactile prototypes with instrumentation data before lock.

  3. Scale reliably: Serialization and QC keep every panel aligned to the signed‑off feel.


FAQ

Can you match legacy/out‑of‑production panels?

Yes—reverse‑engineered tactile profiles with modern internals.



Ready to train by feel, not guesswork? 

Let’s spec your tactile profile and put a prototype in your hands.


Contact us:

Simtek: 817‑283‑1801

 
 
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