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Aluminum 80/20 Profile Rig with 2DOF Seat Mover for PS4 / PC (w/ Projector Screen)

Discussion in 'DIY Motion Simulator Projects' started by Redblues59, Jan 27, 2019.

  1. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Starting building my sim racing rig with aluminum 80/20 profile parts, a projector screen, and a DIY 2DOF seat mover (shoulder type). I will keep updating the thread with my progress.

    Main parts:
    Rig with 45mm profile parts
    Rig dimensions:
    Approx. length: 175 cm (exact length depends on pedal position)
    Width without screen: 85 cm
    Approx. screen width: 110 cm

    Overview:
    simrig1.jpeg simrig2.jpeg
    simrig3.jpeg simrig4.jpeg

    *Seat fixed for now (u-joint will not be working until I fix the motors / shoulder links in place)

    MayCad file:
    I couldn't find a way to upload this file yet - I will check again.
    (Please send a direct message to me if you need it for now.)

    2x 25:1 12 Volt Gear Motors
    2x JRK 12v12 USB Motor Controller
    2x HP DL380 G4 DPS-600 PB Power Supply
    1x Universal Joint from Ebay

    ujoint.jpg

    1x Sparco Evo II Racing Seat
    1x Optoma GT760 Short Throw Projector

    1x DIY Projector Screen
    • Like Like x 3
  2. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Some pictures from recent work.

    Floor structure:

    IMG_2063.jpg

    Pedal base:

    IMG_2064.jpg IMG_2068.jpg
    IMG_2070.jpg IMG_2071.jpg IMG_2073.jpg

    U-Joint & Seat Structure:

    IMG_2102.jpg IMG_2104.jpg IMG_2105.jpg
    IMG_2106.jpg IMG_2107.jpg IMG_2109.jpg
    IMG_2110.jpg IMG_2111.jpg

    Attached Files:

  3. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Cardboard Template for Projector screen:
    IMG_2429.jpg

    3mm mdf board cut according to the template:
    IMG_2430.jpg

    80/20 backbone:
    IMG_2432.jpg IMG_2435.jpg

    Matte gray projector screen stapled on to the mdf board:
    IMG_2447.jpg IMG_2448.jpg IMG_2449.jpg

    19mm felt tape for the borders:
    IMG_2450.jpg

    Joined on to the backbone using 2 sided acrylic adhesive tape (quite strong):
    IMG_2451.jpg
    • Like Like x 1
  4. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Couple of pictures with the screen installed:

    IMG_2470.jpg

    IMG_2471.jpg

    IMG_2461.jpg
  5. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Working on rod, lever length, motor locations etc.

    Does the following look ok to start with? (for 25:1; 40Nm / 160 rpm motors)
    I'd appreciate any comments.

    simcalc.JPG
  6. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

    Joined:
    Jul 13, 2014
    Messages:
    20,463
    Occupation:
    Innovative tech specialist for NGOs
    Location:
    St Helens, Tasmania, Australia
    Balance:
    144,614Coins
    Ratings:
    +10,741 / 52 / -2
    My Motion Simulator:
    3DOF, DC motor, JRK
    • Like Like x 1
  7. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Thanks @noorbeast . I have now given it a bit more leverage.

    Not sure how to approach the tradeoff between roll/pitch angle ranges and torques - I think I will go with adjustable parts/placement as much as possible and will do some further trials on the physical setup.

    simcalc2 (1).JPG
  8. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Working on brackets, rods, levers etc. Inspired by some designs from the site & web.
    I will post the cad files & technical drawings later on.

    Asm1.jpeg ASM3.jpeg ASM4.jpeg ASM5.jpeg
    • Like Like x 1
  9. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Here are the cad files and technical drawings for the parts - attached.
    I am getting the parts produced in a local workshop - cost around 120USD.

    Attached Files:

    • Useful Useful x 1
  10. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Parts have arrived.

    IMG_2608.JPG IMG_2609.JPG
    • Like Like x 2
  11. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Changing the shaft direction:

    IMG_2610.jpg
  12. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Well, my intention was to join the solid shaft, lever and motor's hollow shaft with a snug fit 4mm pin as you can see in the previous posts. The result is not as elagant as I want it to be. Here are my lessons learned:

    1) First of all, although I had measured it, I ignored the fact that one of the motors had a slightly smaller inner shaft diameter (around 80 microns). I didn't take this into account in my drawings. Consequently I had to hammer the solid shaft into the hollow shaft heavily and couldn't make pin holes align perfectly. I had to put two pins into the hole from opposite sides.

    2) Although, it was easier to push the solid shaft into the the second motor, still I couldn't align the holes 100%. And the pin couldn't make it through to the other side. I had to use a second pin, again.

    Then, I cut the parts of the pins remaining outside. Still, it looks ok, and functions without additional backlash. However, I won't be able take the lever apart without cutting it through.

    The best approach would be trying out the parts & assembly during the manufacturing process, so that final mods can be done live.

    IMG_2655.jpg IMG_2662.jpg IMG_2663.jpg
  13. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    14
    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Hi again... After a long break I am now working on the electric circuit.
    I would like to insert an emergency break (I have checked the FAQ section) and use the emergency break to short circuit the DC motor ends, and brake the motor as quickly as possible.
    I prepared the attached diagram to show what I am planning to do.
    However, I wonder if the JRK has a short circuit protection as joining the motor ends would also mean joining JRK's motor outputs.
    Could anyone please help with this - would this setup work or should I do something else?

    Attached Files:

  14. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

    Joined:
    Jul 13, 2014
    Messages:
    20,463
    Occupation:
    Innovative tech specialist for NGOs
    Location:
    St Helens, Tasmania, Australia
    Balance:
    144,614Coins
    Ratings:
    +10,741 / 52 / -2
    My Motion Simulator:
    3DOF, DC motor, JRK
    I would think you want the motor connected to the relay, not the board, and it would make sense to have the fan connected to the power to the board side of the toggle switch circuit, as that way the fan would only run when power is activated to the JRK.
  15. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
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    Location:
    Türkiye
    Balance:
    164Coins
    Ratings:
    +9 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Finally had some time to complete most of the electronics.
    Decided to use a circuit very similar to this: https://www.xsimulator.net/community/threads/emergency-stop-switch-wiring.5132/#post-50954

    Not neat in terms of cable order / length but working! :)

    Lessons learned: Always use flex silicon cables. And dont't use heavier gauge than required. Some parts are 8AWG - overkill most probably. Seems like 10 AWG would be more than enough on the motor line.
    Motor's cables themselves are 12 AWG (I think) anyway.

    Attached Files:

    • Like Like x 1