6DOF Cessna 172 VR Hardware Cockpit

Hello,

I introduced in the Newbee corner.
The Idea is to build a 3DOF Platform with Cessna 172 Hardware Cockpit for MSFS 2020.

First I downloaded the Instrument Panel

Then I draw the dimensions

Then I was beginning looking for Actuator. But all the recommended motors with wormgear or planetary gear is too expensive and I have a bad feeling for this, so I start to think of taking

HPV6 Linear Module SFU1204 Ball Screw Linear Actuator with HGR15 Linear Guides with NEMA23 2.8A 56mm 57 Stepper Motor - 200mm

idea is to place on bottom.

I am not realy happy with that , next I will try to add a lever to get max. out of the linear actuators. Advancage of this is the normal G Forces go into the linear guidance, NOT in the spindle (mostly)

Let´s see,,,

I am still finding out what I need to connect everything to work. All I read is "Audorino" and "Sim Tool". I have no Idea if I can use AC Servomotors with integrated board and if yes, what should the motor give for outputs to something I do not know to connect.

On the mechanical side I am ok, and am away from the first idea.

I will use ONLY a ball screw 1605 with a servomotor directly attached with Kardan on both sides (one side the nut, other the motor or fix bearing block). for the 16mm spindle no linear guidance needed.
The ball nut will be mounted via Kardan direktly to the upper platform.
The motor on the other side will go directly on the ground plate via Kardan.

All how to documentation here is from 2013 or 2014. I can imagine something changed from there to easyer fit into Win 10 or concerning motor parts or drivers. I will continue reading the whole google... takes time

let´s see...

Things are getting shape.

Cheap looks different, but it should work and last long.

Now it´s time to detail my CAD Model of all getting together.

Did I forget any important component in my scheme?

You got the basics covered

You also need to add db25 straight male-male cables for interfacing the AMC-AASD15A with AASD-15A servos. And perhaps get some RFI line filters for the power entry of the servos to filter noise back to the mains line. And if the power cable of the servos is not shielded, you could replace it with shielded cable to avoid EMI noise to your rest of the system. There are videos documenting all these, if you have trouble locating them on my YouTube channel, let me know to help.

Good luck! Cockpit looks good!

Thanks
Thanos

@ Thanos
Many thanks, about cables and stuff I did not think about. I am more a mechanical man.

I did in time my first mechanical calculation concerning the forces. The waves is a result of still free rotating Motors, I have to fix them later on.
First calculated Z travel 100mm in 1 second.

From step to step I approach the typical design with single levers attached to a gear :/
In the picture I made a design with 90° levers actuated by linear stages under connected with rods to the levers (not shown)

But The price is the same when I take worm gears or planetary gears.
So perhaps I do it like all other and make a Platform with Levers.

Beware the worm gearboxes have naturally more backlash than planetary gearboxes...

My newest calculation show the moment of levers over 0,5s from Pitch/Roll +20°...-20°
The motors should have 3Nm at 2000 rpm minimum (using 50:1 planet gear). Ui....
I think I can begin order the Motors which most of you simmers use (AC 750W Servomotors)

If I take:
80ST-M02430 220V 750W AC Servo motor 2,39 N.M. 3000RPM 0,75 KW servomotor Single-Phase

There is an Option with "Modbus" do I need that?
What I have to check that it is compatible with Thanos AMC-AASD15A?

I will not waste 1000 Euro to buy the wrong stuff.

There is no need to get the modbus version... all control is done via the DB25 connector. Make sure the drive is AASD-15A and the motors have shielded power cables (to avoid EMI woes).

Thanks
Thanos

-750W AC Servo Motor Drive Kits NEMA32 80mm, AASD-15A: https://www.aliexpress.com/item/32973113245.html

-Matching 50:1 planetary gearbox: https://www.aliexpress.com/item/32835293950.html

-Or 100:1 matching planetary gearbox for more power for larger 6DOF: https://www.aliexpress.com/item/32962968884.html

Work in Progress

Ok, time runs. But now I have my first Motor with Driver on the table.
Now it´s time to start designing the upper plattform. For this I calculated the forces of the joints Motion-rod to Plattform. All with double worst case scenario. 0,5s for the whole +-20° Roll-Pitch travel.


Aditional thinking what type of bended Rod is better, rectangulat Tube welded or round rod bended...


The goal is still to stay with 20° Pitch, Roll, Yaw and ultra compact in hight. see..

In Progress with detail of Platform.
Idea is to use Bosch profile to be maximum flexible when I change to Car or other Simulations.

In last time I build my Forc Feedback Yoke from Jay.
And did some Button and Slider work.
Next days I will order a 6DOF controller Box from motion4sim.

Work in progress. Framework

Pre assembly.
The support feet still missing. And the arms are hanging down. Default is 20° up.
The main idea of my design is to have a compact design. More simpler designs are easyer to build, but are too hight for my little space.

I ordered RAL 1303 red.

Good work and thanks for sharing your build!

IMO,
- levers are too thin. While static, it could look strong but under acceleration, the stress will be great.
- the bent lever will be prone to buckling...

Hi, time is running. I started to make it moving. Now comes the buttons and switches. Pedals and throttle quadrant I made myself.
But! A total Cessna 172 is canceled. I make an universal thing with attachable G1000, Knobs and Switches attachable with dual lock valcro.Comming soon
Achso, Butt Kicker will have too. theese cheep ones...
The hole in the Yoke box is an accident... this will be replaced, or a sticker attached...

@ Racing Mat: Its 20x4 Steel tubes, bended with hydraulic tube bender.

Anyone an idea how to make speed dependent wind with a venting thing? i use FlyPT

An other update on my Cockpit. I wanted to use valcro but ended with Lego
G1000, G430 and AP is following.
What Aircraft I use, I can change position of devices.
With SPAD Next all buttons working.
Selfbuild Buttkicker.
Wind simulator comming next.