TurbuSafe

What it does

TurbuSafe is a mechanical safety device that automatically locks aircraft service trolleys in place during turbulence, preventing them from lifting or moving and reducing the risk of injury to flight crew and passengers.

Your inspiration

We were inspired by real incidents where flight attendants were injured by in-flight trolleys lifting during turbulence. Despite advances in aviation, trolley safety remains outdated, often relying on manual brakes that don't address sudden vertical motion. Recognising this overlooked risk, we set out to design a passive, mechanical solution that activates automatically during turbulence, requiring no electronics or crew input. Our goal was to enhance cabin safety through simple, effective engineering.

How it works

TurbuSafe is a purely mechanical safety system designed to secure in-flight service trolleys during turbulence. It works by using a spring-loaded magnetic mechanism that activates automatically when the trolley lifts off the cabin floor, an event that typically occurs during sudden vertical turbulence. The system is mounted underneath the trolley and consists of a trigger plate that detects lift, a sliding latch, and a powerful Neodymium magnet. When the trolley is lifted, the trigger releases the latch, allowing the magnet to drop and lock onto a steel plate installed on the cabin floor. This prevents the trolley from lifting or moving further. The system resets manually and includes a safety pin to prevent accidental activation. It requires no electronics, wiring, or power, making it simple, reliable, and ideal for retrofitting into existing trolley fleets.

Design process

We began by identifying the core failure in current trolley systems: the lack of vertical locking during turbulence. Our initial concept involved a spring-activated mechanism that could deploy a magnet upon lift. We developed multiple CAD models, exploring different trigger styles, release methods, and magnet placements. The first prototype used 3D-printed components and a drop-in magnetic module, but it lacked a release control, which led to accidental deployment. In Conceptual Design 2, we introduced a spring-drop mechanism triggered by vertical displacement. However, during testing, the magnet housing failed under stress due to weak materials and insufficient geometry. We iterated the design, reinforcing key components, adding a manual release pin for safe transport, and integrating a roller-based trigger to reduce friction. Our final prototype, built at full scale, was tested through controlled lift and drop experiments. It successfully deployed in lift scenarios but revealed material limitations in drop conditions. These tests helped us validate the mechanism’s logic and refine tolerances, laying the groundwork for future development using stronger materials and spring calibration.

How it is different

Unlike existing trolley safety systems that rely on manual brakes or floor latches, TurbuSafe is a completely passive and mechanical solution that activates automatically during vertical displacement, no crew action or electronics required. Most current systems fail to address lift-off during turbulence, focusing only on wheel locking. TurbuSafe uniquely uses a spring-drop magnetic mechanism that locks the trolley to a steel floor plate the moment it begins to rise. It’s also modular and retrofittable, meaning it can be added to existing trolleys without altering their structure. This combination of automatic activation, vertical locking, and plug-and-play integration makes it unlike any solution currently in use.

Future plans

Our next step is to replace the 3D-printed components with stronger, aerospace-grade materials to improve durability under high-impact conditions. We also plan to fine-tune the spring mechanism for faster deployment. Once optimised, we aim to conduct high-fidelity simulations and seek regulatory guidance for aviation safety compliance. Our goal is to pilot the system with airline partners and move toward certification for widespread adoption in commercial aircraft.

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