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Showroom 3DOF with heave and 220v AC Motors

Discussion in 'DIY Motion Simulator Projects' started by T R Para, Jan 15, 2019.

  1. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    I am starting on a 3dof heave rig. I guess I need an anti yaw device in the middle.
    I do not have cnc.
    More like a drill press and an old piece of sandpaper for tools.
    Has anyone run across a simpler ideal than Tim's awesome work of art??
    I was thinking about a telescoping seat mount for a small fishing boat and cutting a slot in it for anti rotation. They say it will telescope from 12"to 18".
    post_.jpg
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  2. sam poole

    sam poole Active Member Gold Contributor

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    My Motion Simulator:
    3DOF, DC motor, Arduino, Motion platform, 4DOF
    If you can find one in a scrap yard or something a telescopic drive shaft or prop shaft is pre splined
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  3. noorbeast

    noorbeast VR - The Next Generation Staff Member Moderator SimTools 2.0 Beta Tester

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    My Motion Simulator:
    3DOF, DC motor, JRK
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  4. Tim McGuire

    Tim McGuire "Forever a work in progress"

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    My Motion Simulator:
    3DOF, DC motor
    I recommend going with a solution like @noorbeast 's rig. Mine is ridiculously overbuilt, and was only designed that way because I knew I'd have access to a CnC beforehand. For a telescoping mechanism to to work properly the fit needs to be absolutely perfect or the mechanism will bind when it's travelling up and down.
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  5. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    Ok thanks for all the tips. So far I am still collecting motors (one to go) and cutting the levers out of aluminum bar.. I really did not even understand I needed a center post type device for 3 dof. I saw the dual output shaft motor with the "inverted Y" yoke type levers and I guess that solves their yaw problems.
    I do have one of those seat mounts like @noorbeast used.
    How much travel do you get with that ??
    As far as binding goes. I would of thought the motors did all the heavy work and the centerpost just would stop yaw rotation. I did not think binding would be much of a issue but then my mechanical aptitude is pretty low.
    I hope to start posting pictures soon.
    This project is going to be a bit more intense than my first 2dof .
    I am going to need your guys help for sure.. lol
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  6. Tim McGuire

    Tim McGuire "Forever a work in progress"

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    My Motion Simulator:
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    Feel free to shoot me a PM or @ me in your thread anytime :)
  7. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    I got my seat post today (ordered last week) and I think it has possibilities.
    It is of course 2 steel tubes that telescope.
    The construction looks pretty strong.
    The outer tube is swaged to form a close tolerance fit at the top to the inner tube.
    The Inside tube looks to be 1/8" diameter smaller than the outer.
    I am thinking of trying some delrin as a sliding bearing surface to keep the tubes aligned.
    I have seen small delrin buttons used for this purpose.
    So far under $15 invested lol
    • Like Like x 1
  8. sulfail

    sulfail Member Gold Contributor

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    My Motion Simulator:
    2DOF, Arduino
    I recommend silentblocks of 250 kilos, they are silent and 2 rods do not turn, my cokpit is very silent thanks to the silentblcoks and they are economical. 20181211_215452.jpg
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  9. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
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    @sulfail Ok I do not think that will work with my setup.

    I did make a delrin sleeve out of 1mm sheet for my seat post.
    It runs the full length of the tube and I think it will do the job.
    I am going to run a regular automotive U-Joint for the top swivel.
    Motor mount plates arrived today and I ordered a dozen 14mm end rod balls.
    Any opinions on how much heave motion I need for a flight sim or roller coaster?
    • Like Like x 1
  10. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    I have completed the output levers.
    They are made from 200mm long x 65mm wide x 25mm thick aluminum bar.
    The 6mm keyway was cut with a broach.
    The shape was cut with a bandsaw.
    20mm 13mm and 12mm holes made with a drill press.
    There are 6 levers because I hope this will eventually be a 6 dof build.
    The motors cost about $600 each shipped from China.
    So far I have 2 and hope #3 in February.
    The rig is based on @Grigory 's rig and awesome software.
    It will start out as a 3dof and hopefully progress to 6dof by summer.

    Attached Files:

    • Like Like x 2
  11. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    Things have progressed well. I have the rig configured for 2dof and it it is working well.
    All the hardware associated with the levers has arrived. The bolts shown are lug bolts from an automobile. They are 14mm x 52mm x 1.75 thread. The rod ends are from China and I saw these on so many other builds they must be magical !!! (so I had to have them).

    Attached Files:

    • Like Like x 3
  12. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    Here are a few pictures of the rig so far. The Chassis is from an old 1993 treadmill.
    The motors are the 1kw 220vac servo motors with 20:1 planetary gear reduction.
    I like the treadmill frame. It is very sturdy and has an interesting spring suspension in the back.
    The front wheels can raise up several inches and can really boost the pitch up. (not yet implemented)...

    Attached Files:

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  13. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    The cockpit floor is set to allow either racing pedals or rudder pedals. They are a friction fit but can only slide so far forward.
    The racing wheel is held in with 3 bolts and the whole assembly rises up to allow easy access.
    The distance from the wheel is adjustable by several inches..
    The racing wheel can be swapped out with my DIY FFB yoke pretty easily.

    Motor #3 which will allow me to upgrade to 3dof is on its way from China :cheers

    Attached Files:

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    Last edited: Feb 14, 2019
  14. sam poole

    sam poole Active Member Gold Contributor

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    My Motion Simulator:
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    I used this inner cv joint on my first rig it had about 6.5cm of usable travel but had an annoying knock so I'd suggest something with zero free play

    Attached Files:

    Last edited: Feb 17, 2019 at 00:58
  15. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    I looked around after your post for some type of splined joint.
    I found several things like the cv joints but no one specifies the dimensions since they are built for a specific vehicle..
    Ok on the clacking. I would of never thought of that problem.
    I will try my telescoping seat post if nothing else comes my way..
    • Like Like x 1
  16. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino

    Attached Files:

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    Last edited: Feb 18, 2019 at 18:33
  17. misoswan

    misoswan Active Member

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    hi
    how much maximum movement spring? 30mm or 100mm? thanks
  18. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    I got the splined shaft assembly today and it is really nice. Virtually zero slop.
    I think it is going to work just fine.
    The splined shaft is 300mm long x 35mm wide.
    The hubs are 121mm x 57mm at the wide base.
    Now to figure out the best way to mount things..

    Attached Files:

    • Like Like x 1
  19. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    I mounted the new spline shaft using the supplied hubs. It is nested in the original telescoping seat post. It appears to have good action. Very smooth and very tight tolerances.
    Motor #3 arrived today. I am looking forward to completing the 3dof stage of the build very soon.

    Attached Files:

    • Like Like x 2
  20. T R Para

    T R Para i make stuff up Gold Contributor

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    My Motion Simulator:
    2DOF, AC motor, Arduino
    Here are some pictures of the motor drives.
    These are 220vac stepper motors with a 20:1 2 stage planetary speed reducer.
    The speed reducers are rated at 10 arcmin of backlash.
    The stepper motor torque is rated as 4nm nominal and 12nm peak. I am not sure what peak really means.. :think
    However the speed reducer should boost the torque to 80 nm and 240 nm peak.
    80 nm equates to 708 inch pounds or 815 kg/cm
    My levers are 150mm and I am using the output hole at 120mm so I guess that gives me 65kg or 143 lbs of force.

    According to Grigory's calculations the speed is almost 1400mm/s when used with 120mm CTC levers (no load).
    It does not take a rocket scientist to figure out these motors are pretty nice. (BTW Grigory is a rocket scientist)...

    I am using metal brackets to mount the motors to a flat board. I have also made up some 13mm thick aluminum motor mounts which I will use for the 6dof rebuild later this year.

    The power system is very easy to hook up.
    You have 2 main cables that run to each motor.
    The controller runs off 220v and contains the motors power supply.
    Its closed loop , fast and powerful .
    A bargain at $600USD each shipped :grin (not funny)..

    Attached Files:

    • Like Like x 3