DESC:4. DESCRIPTION
Technical Field of the Invention

The technical field of the invention relates to firearm training devices, specifically focusing on the creation of a mock-up battle rifle simulator that replicates the SIG 716 rifle, which is chambered for the 7.62x51mm round and features a detachable magazine. This invention is designed to deliver a realistic training experience by simulating various aspects of the real rifle's operation, while ensuring safety, efficiency, and adaptability in firearm training scenarios without the use of live ammunition.

Background of the Invention

The SIG 716 rifle, an advanced and modern battle rifle developed by Sig Sauer, has become one of the primary assault rifles employed by the Indian Army. It is chambered for 7.62x51mm NATO rounds, offering superior power, range, and lethality compared to the Indian Army’s earlier INSAS rifles. The SIG 716’s popularity stems from its ability to function reliably under harsh conditions, thanks to its gas-operated short-stroke piston system. The rifle’s ambidextrous controls, modular design, and six-position telescoping stock further enhance its operational versatility and adaptability in mountainous and difficult terrains. These features make the SIG 716 an ideal weapon for border and high-altitude operations, which are vital to India's defense strategy along its frontiers.

However, effective and comprehensive training of soldiers for handling the SIG 716 rifle poses significant challenges. While live training with actual rifles in controlled environments is the preferred method, several limitations arise in live training exercises. Conducting large-scale, real-world exercises is logistically difficult and expensive. The cost of ammunition, maintenance of firing ranges, and ensuring the safety of participants during live fire training create financial and operational hurdles. Additionally, repeated exposure to high-power weapons like the SIG 716 can lead to fatigue, hearing damage, and safety risks, especially in environments where live ammunition is used extensively.

Moreover, live fire training is restricted by the availability of resources such as time, space, and supervision. While shooting ranges are essential for live-fire practice, their limited availability, coupled with the need for supervision and safety precautions, reduces training effectiveness. These limitations impact the ability to fully engage in sustained and realistic combat scenarios, which are crucial for preparing soldiers for real-world situations. Therefore, reliance on live training alone is often insufficient to ensure that the crew is fully trained in the intricacies of handling the SIG 716, particularly for critical features like ambidextrous controls, modular adjustments, and safety mechanisms.

To address the limitations of live training, several prior-art weapon simulators have been introduced. Firearm simulators for training purposes are not new, with several iterations developed for various weapons, including both real and virtual environments. Simulators often incorporate laser targeting systems, electronic recoil mechanisms, and computer-based feedback to simulate firing, handling, and aiming. However, these existing simulators have primarily focused on basic weapon operations, such as firing and reloading, without incorporating critical features specific to advanced weapons like the SIG 716.

One of the closest prior arts includes laser-based training systems, which allow trainees to aim and fire at virtual targets using non-firing mock-ups. These systems provide basic feedback on accuracy and target engagement but fail to simulate realistic recoil, weapon handling, or modular components like the Picatinny rail system used for accessory attachments. Such simulators lack the flexibility to replicate various firing modes and are often confined to static environments without the ability to incorporate movement, sensor data, or realistic combat scenarios.

Other available alternatives include recoil simulation systems, which attempt to mimic the feel of a live weapon. However, these systems often rely on mechanical recoil mechanisms that do not adequately replicate the dynamic recoil behavior of real firearms, especially with weapons like the SIG 716, which has significant recoil and power. Moreover, these systems tend to be heavy and cumbersome, making it difficult to use them for extensive, mobile training exercises where soldiers must simulate battlefield conditions.

Another form of prior art is virtual reality (VR)-based simulators. These systems provide a fully immersive experience by placing trainees in a virtual environment where they can interact with avatars and environments. However, VR systems often fail to replicate the physical handling characteristics of real weapons, including the weight, balance, and modular adaptability required for a true-to-life simulation. Furthermore, VR systems are prone to technological limitations like lag, low-resolution feedback, and poor hardware integration, which diminishes the realism required for effective military training.

The primary drawback of existing training solutions is their inability to provide a holistic training environment that captures the real-world functionality of the SIG 716 rifle. Most simulators lack critical features such as realistic recoil simulation, tactile feedback on trigger pulls, ambidextrous controls, and adjustable modular components. Without these, trainees cannot gain a true understanding of how the rifle handles under various conditions, particularly in combat.

Another major drawback is the limited adaptability of current simulators. For instance, the Picatinny and M-LOK rail systems, which are crucial for attaching accessories such as scopes, sights, or grips, are often absent in simulators. Without these features, trainees cannot practice customizing the rifle to their operational needs, which is an essential aspect of real-world combat.

Additionally, existing systems fail to integrate sensor-based feedback mechanisms effectively. Real-time data collection on critical functions like breechblock position, trigger pull pressure, and bolt movement is essential for ensuring that soldiers are trained to handle these aspects under stress. Current simulators do not offer these sensor-based functionalities, limiting their usefulness in preparing trainees for the complex, multi-faceted nature of battlefield operations.

Finally, the lack of reliable power management in existing systems means that extended training sessions are often cut short due to battery life constraints. Without a dependable power source, simulations can be interrupted, leading to incomplete or ineffective training.

Given the significant limitations of live training and the shortcomings of existing simulator technologies, there is an urgent need for a comprehensive, realistic, and adaptable training system for the SIG 716 rifle. This system must replicate the physical handling characteristics, recoil patterns, and operational complexity of the actual weapon to ensure that trainees are adequately prepared for real-world combat situations.

The development of a sensorized simulator system, which integrates recoil simulation, laser targeting, and modular adaptability, addresses the critical gaps in current training methods. By combining air-based recoil mechanisms, advanced PCB controllers, and real-time feedback sensors, this system provides an immersive and realistic training environment. The system’s ambidextrous controls, Picatinny rail system, and adjustable stock further enhance the trainee's ability to experience the full range of the rifle’s capabilities, ensuring that every aspect of the weapon is covered in training.

Brief Summary of the Invention

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

The primary object of the present invention is to provide a simulator system for the SIG 716 battle rifle that replicates the physical and operational characteristics of the real weapon, allowing personnel to train effectively without the need for live ammunition. The invention aims to offer a safe and cost-effective training environment, addressing the limitations of live fire exercises.

Another object of the invention is to integrate sensor-based feedback mechanisms to monitor and simulate critical operational parameters of the rifle, such as breechblock movement, hammer position, magazine insertion, and recoil control. The use of real-time feedback enables the trainees to experience weapon operation and receive immediate data on their performance.

A further object of the invention is to incorporate modular design elements, specifically through the use of Picatinny and M-LOK rail systems, allowing for the attachment of various accessories, such as scopes, grips, and sights. This modularity ensures that the system can be customized for different training scenarios, making the simulation more versatile.

The invention also aims to offer an air-based recoil simulation system that mimics the recoil action of the real rifle. This feature enhances the realism of the training by providing authentic recoil feedback to the user, enabling them to practice handling and controlling the weapon under simulated recoil conditions.

Another object of the invention is to provide ambidextrous controls, including the magazine release, fire selector, and bolt catch, to simulate the user experience of the SIG 716’s real operational features. These controls are essential for training personnel in the proper use and handling of the rifle in dynamic, real-world scenarios.

The invention further seeks to offer a realistic trigger mechanism, including the replication of trigger pull resistance, reset function, and the tactile feedback associated with a real firearm. This ensures that the trainees can develop muscle memory for proper trigger discipline and firing techniques.

A final object of the invention is to provide an optional virtual environment for target practice, which includes laser targeting and projector-based virtual targets. This allows for immersive training experiences in environments that simulate real combat scenarios without the use of live rounds.

The present invention relates to a simulator system designed for training personnel in the handling and operation of the battle rifle. The system replicates both the physical appearance and the operational characteristics of the rifle, providing a realistic and immersive training experience. The mock-up rifle incorporates various features that mimic the real firearm, including a barrel unit, triggering unit, breechblock assembly, and butt assembly. Each of these components is designed to closely match the dimensions, weight, and functionality of the actual rifle.

A key aspect of the present invention is the incorporation of ambidextrous controls such as the magazine release, fire selector, and bolt catch. These controls are integrated into the simulator to provide trainees with a realistic experience of handling the SIG 716’s versatile, ambidextrous design. This is particularly important for soldiers who may need to operate the weapon under various conditions, using both their dominant and non-dominant hands.

The system is characterized by a magazine assembly that simulates the insertion and removal of a magazine with realistic tactile feedback. The magazine unit includes air input and air output valves, along with an air storage chamber that provides simulated firing and recoil operations. Air control valves are employed to regulate airflow between the magazine unit, the bolt assembly, and the breech block assembly, enabling a realistic recoil experience for the user. This air-based recoil simulation is essential for providing an authentic feel of weapon discharge and recoil control.

The invention also features a Picatinny rail and M-LOK rail systems that allow for the attachment of various accessories. This modular aspect of the design enables the system to adapt to different training scenarios, allowing trainees to practice with various configurations of the rifle. The rails support accessories such as scopes, sights, and grips, further enhancing the realism of the training environment.

A central feature of the simulator is the PCB controller, which manages the mock-up rifle’s various functions. The PCB controller includes a mode selector that allows trainees to switch between semi-automatic, burst, and fully automatic firing modes, closely mimicking the capabilities of the rifle. The controller is integrated with hall effect sensors to monitor the positions of the breech block, hammer, and magazine, providing real-time data on the rifle’s status during operation. A solenoid is used to control the recoil effects, ensuring that each simulated shot generates a realistic recoil response.

For targeting and accuracy training, the system includes a laser unit that simulates the bullet trajectory. The laser unit is designed to work in conjunction with a projector and screen setup that can generate virtual targets for dynamic training scenarios. This feature enables the trainees to practice target engagement without the use of live ammunition, making the training process safer and more cost-effective.

The triggering unit is designed to replicate the trigger pull resistance and reset mechanism of a real firearm. The inclusion of realistic trigger feedback is crucial for teaching trainees proper trigger discipline and firing techniques, which are essential skills in real-world combat situations. The trigger guard provides protection for the trigger while maintaining ergonomic support for the user’s hand.

Another important aspect of the invention is the butt assembly, which provides structural support and ergonomic comfort to the trainee. The buttstock is adjustable, with six-position telescoping capabilities, allowing users to customize the length of the stock to their preference. This feature ensures that the simulator can accommodate users of various sizes and stances, further enhancing the realism of the training experience.

The system is powered by a battery that supports all operational features, including recoil simulation, laser targeting, and sensor feedback. The battery is designed to provide extended power for long-duration training sessions, ensuring that the system can be used without frequent recharging or interruptions.

In one aspect of the invention, a method for manufacturing the simulator system is provided. The method includes constructing the mock-up rifle to replicate the real battle rifle’s dimensions, weight, and functional controls. The process involves embedding digital hall effect sensors at critical locations such as the breechblock, hammer, and magazine positions, to detect and monitor movements. The laser and sensing units are incorporated into the ILU assembly to simulate target engagement and provide performance feedback based on hits and misses. Additionally, the system’s magazine unit is designed with air input/output units and an air storage chamber to simulate firing and recoil effects.

The method also involves integrating the PCB controller to manage the system’s mock-up functions, such as mode selection, recoil control, and sensor data analysis. The air control valves are installed to regulate airflow between the magazine unit, bolt assembly, and breech block assembly, enabling realistic recoil simulation during training. A laser unit is embedded within the rifle to simulate bullet trajectory and enhance targeting feedback for virtual or physical targets. The method further includes the construction of the trigger assembly to simulate trigger pull resistance and reset functionality, and the design of the safety mechanism to replicate real firearm safety actions.

The primary advantage of the present invention is its ability to provide a realistic, immersive training environment that closely mimics the operation of the battle rifle. The use of sensor-based feedback, air-based recoil simulation, and modular adaptability ensures that trainees receive comprehensive training in the weapon’s use without the need for live ammunition. This reduces the cost of training while minimizing safety risks associated with live fire exercises.

Another significant advantage is the integration of ambidextrous controls, which allows trainees to practice operating the weapon with either hand. This is particularly useful in real-world combat scenarios where soldiers may need to switch hands due to injuries or environmental constraints.

The invention’s modular design, incorporating Picatinny and M-LOK rail systems, allows for the attachment of various accessories. This adaptability enables the simulator to be customized for different training scenarios, ensuring that trainees are prepared for various mission requirements.

The air-based recoil system provides a highly realistic simulation of weapon discharge, giving trainees the opportunity to practice recoil control and accuracy without the need for live ammunition. The inclusion of laser targeting and virtual environment setups further enhances the system’s versatility, making it suitable for both indoor and outdoor training.

Additionally, the adjustable buttstock ensures that the system can accommodate a wide range of users, making the training experience more inclusive. The battery-powered system allows for extended training sessions, reducing downtime and ensuring continuous use in the field.

The present invention is applicable not only for military training but also for law enforcement agencies, security personnel, and private training facilities. Its safe, cost-effective, and realistic approach to firearm training makes it a valuable tool for preparing personnel for real-world combat and operational scenarios.

Further objects, features, and advantages of the invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

The above and other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:

FIG. 1 illustrates a mock-up battle rifle simulator disclosing various components in accordance with an exemplary embodiment of the present invention.

FIG. 2 illustrates a mock-up sectional battle rifle simulator system in accordance with an exemplary embodiment of the present invention.

FIG. 3 illustrates a block diagram disclosing a PCB controller of disclosed battle rifle simulator in accordance with an exemplary embodiment of the present invention.

It is appreciated that not all aspects and structures of the present invention are visible in a single drawing, and as such multiple views of the invention are presented so as to clearly show the structures of the invention.

Detailed Description of the Invention

It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

The present invention provides an exemplary simulator system designed to replicate the functionalities and handling of the SIG 716 battle rifle for training purposes. Below are the exemplary embodiments of the invention, detailing the structure, functionality, and technical features.

In one embodiment, the simulator system comprises a mock-up battle rifle that closely resembles the SIG 716 rifle in terms of its weight, dimensions, and functional controls. The external structure includes components like the barrel unit, breechblock assembly, triggering unit, and butt assembly, which are manufactured to match the physical characteristics of the real rifle. The simulator also includes ambidextrous controls such as a magazine release, fire selector, and bolt catch.

The mock-up rifle’s barrel unit is designed with a flash suppressor and muzzle, replicating the look and feel of the real rifle’s barrel. The butt assembly features a six-position telescoping stock, allowing for customization and comfort during training sessions. This adjustability ensures that the system can accommodate users of various sizes and preferences, enhancing the realism of the training environment.

The magazine assembly is another critical component in this embodiment. The magazine is designed to simulate realistic magazine insertion and removal. It incorporates air input and air output units, as well as an air storage chamber to generate simulated firing effects. When the user inserts the magazine into the mock-up rifle, the system activates the air-based recoil simulation through the magazine.

Air control valves are placed to regulate the flow of air between the magazine unit, the bolt assembly, and the breech block assembly. This air system enables realistic recoil effects, ensuring that the trainee experiences the same physical feedback as they would with a real firearm. The recoil simulation closely mimics the discharge of live rounds, allowing users to practice recoil control and accuracy without live ammunition.

One of the key innovations of the present invention is the PCB controller, which manages all mock-up operations. The mode selector on the PCB allows trainees to switch between semi-automatic, burst, and fully automatic firing modes, just like on the actual SIG 716 rifle. The ability to change modes is critical for realistic training, as it mimics the various firing options soldiers may encounter in combat.

The PCB controller is equipped with hall effect sensors to monitor the positions of the breechblock, hammer, and magazine. These sensors provide real-time data to the PCB controller, which uses this information to control the firing mechanism, recoil, and feedback. The solenoid within the system is responsible for controlling recoil effects during the firing cycle.

In another embodiment, the simulator includes a laser unit designed for target engagement training. The laser replicates the bullet trajectory of a real round and provides performance feedback to the trainee. The laser can interact with virtual or physical targets, providing immediate feedback on accuracy, hits, and misses.

For an immersive training experience, the system can be used with a projector and screen setup, generating virtual targets in a dynamic training environment. These virtual targets can simulate a range of combat scenarios, allowing trainees to practice firing under various conditions without the need for live ammunition or real targets.

The triggering unit in the mock-up rifle is another embodiment that provides realistic trigger pull resistance and a trigger reset function. The system simulates the same tactile feedback a user would feel when pulling the trigger on the real SIG 716. This is essential for developing muscle memory and ensuring proper trigger discipline during real-world combat situations.

The safety mechanism is also replicated, with audible and tactile feedback that lets the user know when the safety is engaged or disengaged. This replication of the real rifle’s safety features ensures that trainees can practice safely handling the weapon without any risk.

The modular design of the mock-up rifle, through the inclusion of Picatinny and M-LOK rail systems, allows users to attach and remove various accessories. These rails are compatible with a wide range of attachments, such as scopes, sights, grips, and laser pointers, enabling the customization of the rifle for different training scenarios. Trainees can practice handling the rifle with different accessories, preparing them for real-world use where customization is often necessary.

The system is powered by a battery that supports all key functions, including recoil simulation, laser targeting, and sensor feedback. The power management system ensures that the simulator can be used for extended training sessions without frequent interruptions for recharging.

In one embodiment, the battery is designed for long-duration training, allowing trainees to complete multiple sessions without needing to replace or recharge the battery frequently. The power system ensures that all the electronic and pneumatic systems function seamlessly.

Referring to figures, Figure 1 illustrates a mock-up battle rifle simulator system (100) designed for training crew in handling and operating the SIG 716 rifle. The system incorporates an ILU assembly (1), which includes laser and sensing units to simulate target engagement, providing realistic feedback on accuracy. The barrel unit (2), with flash suppressor and muzzle components, replicates the appearance and dimensions of a real firearm's barrel.

The magazine assembly (3) simulates the insertion and removal of a magazine with realistic tactile feedback, mimicking actual magazine handling. Additionally, the butt assembly (4) provides ergonomic handling and structural support, closely mimicking the feel of a real firearm’s buttstock, and is adjustable to suit different users' preferences, contributing to a realistic training experience.

The system features a breechblock assembly (5) designed to replicate the movement and operation of a real firearm’s breech block, connected to the bolt assembly (6), which simulates the bolt action of the SIG 716 rifle. The triggering unit (7), along with the trigger guard (8), is configured to simulate the resistance and pull of a real firearm's trigger mechanism. The holding grip (9) is ergonomically designed to replicate the feel of the real firearm's grip.

For enhanced safety, a safety mechanism (10) is incorporated to accurately replicate the safety engagement and disengagement actions of the SIG 716, providing audible and tactile feedback on the safety status. The system also includes a Picatinny rail (11) for accessory attachment, allowing customization with scopes, sights, and other accessories for various training scenarios.

Figure 2 depicts the magazine unit (3) coupled with the breechblock assembly (5), connected via the bolt assembly (6) to enable recoil simulation. The magazine unit (3) comprises air input (21) and air output (22) units and an air storage chamber (23), designed to simulate the firing and recoil experience. The airflow from the magazine to the breechblock assembly (5) is controlled by two air control valves (24, 25), allowing precise control over recoil simulation. This air-based recoil mechanism replicates the real-life firing experience by simulating the backward motion experienced during firing, without the need for live ammunition.

Figure 3 presents a block diagram (300) of the system's PCB controller (30). This controller is central to the functioning of the simulator, managing the mock-up operations. It includes:

• A mode PCB (31), which allows for selecting various operational modes, such as semi-automatic, burst fire, and fully automatic, mimicking the firing options available on the SIG 716 rifle.
• Digital hall effect sensors (32, 34, 35), which monitor the positions of the breechblock (32), hammer (34), and magazine (35), providing real-time data to the system and allowing the simulated operations to closely follow the real firearm's behavior.
• A solenoid (36), which controls the recoil effects, generating a realistic kickback that simulates the weapon's recoil when fired.
• A laser unit (37) provides targeting capabilities, enabling precision training, while the system is powered by a battery (33).

The system can also be configured with a projector and screen to generate virtual targets, creating a dynamic training environment for soldiers. These virtual targets can simulate combat scenarios, providing a comprehensive and immersive training experience.

In this embodiment, the magazine unit (3), equipped with multiple air input/output units and control valves, plays a critical role in providing a realistic recoil experience. The integration of air storage chambers (23) ensures that the system can maintain consistent performance during extended training sessions, with the ability to simulate various firing conditions.

The air control valves (24, 25) regulate the airflow between the magazine and the breechblock assembly (5), enabling trainees to experience the recoil and cycling of the weapon, including the sensation of firing live rounds. This feature provides valuable feedback for mastering weapon control and accuracy.

The PCB controller (30) arrangement, as depicted in Figure 3, is responsible for managing the system's mock-up operations. It ensures the rifle's various components work together to simulate real-world behavior as closely as possible. The mode PCB (31) offers the ability to switch between different firing modes, while the hall effect sensors monitor the system’s internal operations.

The use of three digital hall effect sensors allows precise tracking of the breechblock, hammer, and magazine positions. This ensures that each part of the firing sequence is accurately replicated, contributing to the system's overall realism. For instance, the breechblock movement is critical for simulating recoil and reloading, and the hammer's position helps replicate the timing and force of a real gunshot.

The solenoid (36) is crucial for generating mechanical recoil effects. When triggered by the system, the solenoid mimics the kickback experienced during firing, ensuring trainees experience the full range of physical feedback associated with firing a high-power weapon.

Additionally, the laser unit (37) enables precision targeting, allowing trainees to practice aiming and firing at virtual targets. This laser unit works in tandem with the system’s projector and screen, which generate dynamic virtual environments, simulating combat scenarios where live ammunition is not practical.

The battery (33) powers the entire system, ensuring that all components, including the recoil mechanism, laser targeting, and feedback sensors, function seamlessly during extended training sessions. This enables uninterrupted training, ensuring trainees can complete their exercises without needing to stop for frequent recharging.

In this embodiment, the magazine unit (3) also plays a significant role in balancing the weapon and ensuring realistic handling during training exercises. Its construction mimics the weight and feel of a real magazine, while the air storage chambers (23) ensure continuous operation, allowing for prolonged training without interruptions. This combination of features provides a comprehensive training tool that accurately replicates the real-world use of the SIG 716 rifle.

The system's air control valves (24, 25) ensure precise control over airflow, generating realistic recoil forces based on the simulated firing mode selected. Whether in semi-automatic or burst mode, the system provides trainees with an accurate representation of how the firearm operates, including the sensation of recoil.

The PCB controller (30) monitors and adjusts these settings in real time, ensuring the system operates seamlessly. It is programmed to provide immediate feedback, which is essential for training in dynamic and fast-paced combat scenarios.

The hall effect sensors (32, 34, 35) continuously track the movement and position of the rifle’s internal components, allowing the system to adjust recoil forces and firing sequences to closely match the real rifle’s operation. This real-time tracking ensures that every action performed by the trainee is mirrored by the system, providing a fully immersive experience.

The solenoid (36) is responsible for simulating the mechanical recoil experienced during firing. It engages rapidly when the system is triggered, providing a realistic backward motion that simulates the kickback of the rifle. This allows trainees to experience how the weapon reacts under various firing conditions, enhancing their ability to manage recoil and maintain accuracy.

Finally, the laser unit (37) enables the system to simulate bullet trajectory, allowing trainees to practice aiming and firing at both physical and virtual targets. The integration of virtual target environments further enhances the training experience by creating dynamic scenarios that replicate real-world combat conditions.
In accordance with the exemplary embodiment of the present invention wherein the sensors and tracking devices provide real-time feedback and analysis of user interactions and movements. The system includes a plurality of software components include a library of customizable training scenarios. The software accurately replicates the ballistic characteristics of a rifle.

In accordance with the exemplary embodiment of the present invention the software records and analyses user performance metrics, including accuracy, reaction time, and shot grouping. Wherein the software includes safety features to prevent accidental discharges during training exercises. This simulator's training environment is designed with safety as a paramount consideration.

The features and functions described above, along with potential alternatives, may be combined into various simulation systems or applications. Numerous unforeseen or unanticipated alternatives, modifications, variations, or improvements may be made by those skilled in the art, each of which is intended to fall within the scope of the disclosed embodiments.

The exemplary embodiments described herein are to be considered as illustrative and not restrictive in any sense. Variations in the arrangement of the structure are possible and fall within the scope of the invention, as indicated by the appended claims. All changes falling within the meaning and range of equivalency of the claims are intended to be encompassed by them.
,CLAIMS:CLAIMS
I/We claim:
1. A simulator system (100) for training crew to use a battle rifle, comprising:
a mock-up battle rifle incorporated with an ILU assembly (1), comprising laser and sensing units for simulating target engagement and providing realistic feedback on target engagement accuracy;
a barrel unit (2) comprising flash suppressor and muzzle components that replicate the appearance and dimensions of a real firearm's barrel components;
a magazine assembly (3) designed to simulate the insertion and removal of a magazine with a realistic feel;
a butt assembly (4) providing structural support and ergonomic handling similar to a real firearm's butt stock;
a breech block assembly (5) simulating the movement and operation of a real firearm's breech block;
a bolt assembly (6) replicating the firearm's bolt operation;
a triggering unit (7) configured to simulate the resistance and trigger pull of a real firearm's trigger mechanism;
a trigger guard (8) providing trigger protection and ergonomic support;
a holding grip (9) replicating the firearm's grip;
a safety mechanism (10) designed to replicate the safety engagement and disengagement actions of a real firearm's safety mechanism;
a Picatinny rail (11) allowing the attachment of accessories for various training scenarios;
a laser unit (37) for targeting capabilities, and a battery (33) powers the system;
Characterized in that,
the magazine unit (3) comprises air input (21), air output (22) units with an air storage chamber (23) for simulated firing operations;
air control valves (24, 25) regulate airflow between the magazine unit (3), bolt assembly (6), and breech block assembly (5) to simulate recoil;
a PCB controller (30) manages the system’s mock-up functions, including mode selection and sensor feedback for detecting breechblock (32), hammer (34), and magazine positions (35), and a solenoid (36) for controlling recoil effects; and
the system simulates ambidextrous controls, including magazine release, fire selector, and bolt catch.

2. The system (100) as claimed in claim 1, wherein the ILU assembly (1) comprises laser and sensing units that replicate the targeting system of a real firearm, providing realistic feedback on target engagement by simulating hits and misses.

3. The system (100) as claimed in claim 1, wherein the barrel unit (2) comprises flash suppressor and muzzle components replicating a real firearm's barrel, including flash and sound suppression characteristics.

4. The system (100) as claimed in claim 1, wherein the magazine assembly (3) simulates magazine insertion and removal with realistic feel, including a magazine release mechanism and capacity simulation.

5. The system (100) as claimed in claim 1, wherein the butt assembly (4) provides structural support and ergonomic handling with adjustable stock length and cheek rest for user customization.

6. The system (100) as claimed in claim 1, wherein the breech block assembly (5) simulates the movement and operation of a real firearm's breech block, including lock and release mechanisms for reloading.

7. The system (100) as claimed in claim 1, wherein the triggering unit (7) simulates the resistance and trigger pull of a real firearm's trigger mechanism, including trigger reset functionality for follow-up shots.

8. The system (100) as claimed in claim 1, wherein the safety mechanism (10) replicates the safety engagement/disengagement actions of a real firearm's safety mechanism with audible and tactile feedback indicating its status.

9. The system (100) as claimed in claim 1, wherein the Picatinny rail (11) allows for the attachment of accessories such as scopes and sights for customizable training scenarios.

10. A method of manufacturing a simulator system (100) as claimed in claim 1, comprising:
manufacturing the mock-up rifle to replicate the dimensions, weight, and functional controls of the real battle rifle, including the barrel, buttstock, and Picatinny rail for accessory attachment;
embedding digital hall effect sensors at critical locations (breechblock, hammer, and magazine positions) to detect and monitor movements, ensuring accurate real-time data feedback during training;
incorporating the laser and sensing units into the ILU assembly (1) to simulate target engagement and provide performance feedback based on hits and misses;
integrating a PCB controller to manage the system’s mock-up functions, such as mode selection (semi-automatic, burst fire, etc.), recoil control, and sensor data analysis;
manufacturing the magazine assembly (3) with air input and output units, along with an air storage chamber;
installing input (24) and output (25) air control valves to regulate airflow between the magazine unit (3), bolt assembly (6), and breech block assembly (5), enabling recoil simulation during training;
embedding a laser unit (37) within the rifle to simulate bullet trajectory and enhance targeting feedback for virtual or physical targets;
configuring an optional projector and screen components to generate artificial targets, allowing for dynamic training environments without live ammunition;
constructing the trigger assembly to simulate the resistance, trigger pull, and reset mechanism of a real firearm’s trigger;
designing the safety engagement and disengagement actions with audible and tactile feedback to match the real firearm’s safety features;
integrating a battery (33) to provide reliable power to the system for extended training sessions;
testing the entire system under controlled conditions to ensure that each component, including the recoil simulation, sensor feedback, and firing dynamics, accurately replicates real-world firearm behaviour;
fine-tuning the weight distribution, recoil force, and trigger feedback to enhance the realistic training experience for users.

6. DATE AND SIGNATURE
Dated this 09th September 2024

Signature

Mr. Srinivas Maddipati
IN/PA 3124- In house Patent Agent
For., Zen Technologies Limited