"Heavy Duty 2DOF Control Box: IBT-2 with Full Relay & Fuse Protection"

Hello everyone,

I’m joining from Turkey and I’m very excited to share my 2DOF motion simulator control unit project with this great community. Since English is not my native language, I apologize in advance for any mistakes.

I am designing a modular and safe control box using Arduino Mega and IBT-2 drivers.

My Setup & Plans:

• Motors: I am using 24V motors, but I plan to power them with two 12V 40A power supplies for now.
• Safety & Reliability: This is my main focus. I designed a custom protection board for each motor. It includes a 40A fuse and a 5-pin automotive relay for emergency cut-off.
• Layout: Everything is housed in a transparent plexiglass box with RGB lighting and dual fans for thermal management.
• Monitoring: I have integrated dual voltmeters/ammeters to track the load on each motor.

Important Note on Wiring:

Please note that the wiring shown in my current 3D concepts might have some minor errors. I am still working on the final cable management and connection points, so they will be corrected during the assembly phase.

I would love to hear your opinions and suggestions on this layout. Do you think 12V will be enough for these motors, or should I consider a 24V upgrade later? Any feedback on the protection circuit would be greatly appreciated!

I would like to add some more details about my engine and power system.

I plan to use 24V wheelchair motors (between 300W and 350W). For the power supply, I am currently considering two 12V 40A units.

I'm curious about your thoughts on this: Do you think a 12V power supply will provide enough torque for these 300-350W motors, or will I see a significant drop in performance? Your experience and feedback on this power configuration is very important to me.

Thank you in advance for your comments!

"Hello everyone, I need technical advice on my power supply."

I have two 24V 40A DC motors. For the power supply, I plan to use two separate 12V 40A transformers, connecting each motor to its own dedicated 12V power supply.

I know I will apply low voltage to the motors. My question is: since these motors will be used in a motion simulator (especially truck simulation where extreme speeds are not required), will 12V be enough to provide sufficient torque and response time?

Also, will running these 24V motors with 12V cause any problems for the motors or the BTS7960 drivers in the long run?

Thank you in advance for your help.

I'm currently using 24VDC wheel chair motors with Arduino and IBT-2's.

I have 500 watt 20 amp adjustable power supplies currently and run them from 17VDC-18VDC.

Turning up to 20VDC brings a noticeable increase in the torque of the motion sim.

Tried them as low as 16VDC and the torque is definitely lower than when set at 17VDC-18VDC.

The motor may not achieve the rated RPM when running at a lower voltage as well. Not a huge deal but the loss of torque is the major concern.

I suggest saving up and just starting with the 24v.. unless you're just using the 24's because you already have them. But a 24V power Supply isnt that expensive and will save you and upgrade later... You will need more than 12 volts...

"Thank you for the feedback. This confirms my concerns about torque loss. Since I am using 24V motors, running them at 12V might indeed be too weak for a motion rig.

Based on your experience, I will consider connecting my two 12V 40A power supplies in series to achieve the full 24V potential, while ensuring they are properly isolated. This should help me maintain the necessary torque for the simulator. Thanks for the insight!"

"Hi Jon, thanks for the straightforward advice. I understand your point about the costs; in the long run, investing in a proper 24V supply might indeed be more economical than dealing with performance issues or upgrades later.

I will look into 24V power supply options to ensure I get the best results from my motors right from the start. I appreciate you pointing out that 12V simply won't be enough for this setup."