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Showroom 6DOF 48V Brushless DC Project

Discussion in 'DIY Motion Simulator Projects' started by robjos1, Apr 3, 2020.

  1. robjos1

    robjos1 Member

    Joined:
    Jun 17, 2018
    Messages:
    40
    Occupation:
    Flying about
    Location:
    United Kingdom
    Balance:
    285Coins
    Ratings:
    +23 / 0 / -0
    My Motion Simulator:
    6DOF
    So after much research here is my 6DOF Simulator.

    A massive thank you to pmvcda (FlyPT) for his amazing work on which this project is largely based. Also thanks to SilentChill for much inspiration and Hoddem, SeatTime, wannabeaflyer2 for actuator design ideas. Gabor Pittner for an improved control board design. Finally to My.stAr for great 6DOF explanations and noorbeast & the Xsimulator staff for this amazing platform.

    The primary aims for this simulator:
    - 6DOF with decent angles and rapid motion >300mm/sec
    - Compact as possible whilst retaining the recessed hexapod low centre of gravity design and a 1.5m dia floor working area
    - Quiet smooth motion
    - Lightweight (Aluminium + Composite seat) and easy to move/disassemble
    - Relatively low budget <£2000 inc seat but + accessories

    Sim.jpg

    I assessed 4 Motor options and 2 actuator designs
    - Ampflow e30-150 24V DC Brushed + Sabertooth 2X60 with pot feedback
    - 57BLF03 24V BLDC Motor + 8015A Controller using FlyPTs Hall feedback
    - 86BLF03 48V BLDC Motor + 8015A Controller using FlyPTs Hall feedback
    - 6374 Outrunner BLDC Motor + Odrive and AMT encoder feedback

    Through testing the Ampflow has excellent RPM (5000rpm) and good noise levels (67db on bench - max rpm - no load) but the potentiometer feedback required more complexity and Sabertooth were controllers more expensive. The outrunner BLDC motor was noisy (86db) when tested with available controller (Vesc) and Odrives + encoders are an expensive option. Power levels were good and many winding/rpm options are availible.

    The Final two motors 57BLF03 and 86BLF03 are in convenient NEMA sizes and though not as powerful as the BLDC option or (in the case of 57BLF03) as much torque as the Ampflow they are cheap, easily available and really quiet (51 and 58db respectively). 86BLF03 was selected in the end as it provided more torque (larger diameter) and at 48V reduced the current. Both motors run 3500rpm no load on the bench despite 3000rpm ratings.

    I have opted for a belt drive (inverted motor) as the actuator is more compact and gearing can be changed. SFU1610 (10mm pitch) ballscrews provide faster motion at lower rpm reducing noise at the expense of more load on the motor.

    Initially had intended on an open frame actuator design with some 3d printed parts but despite ease of manufacture this proved quite noisy - partly due to resonance from the extruded box section at its base. However provided useful information for the final enclosed actuator design.


    More to follow...

    Attached Files:

    • Like Like x 3
    Last edited: Apr 3, 2020
  2. Ads Master

    Ads Master

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  3. robjos1

    robjos1 Member

    Joined:
    Jun 17, 2018
    Messages:
    40
    Occupation:
    Flying about
    Location:
    United Kingdom
    Balance:
    285Coins
    Ratings:
    +23 / 0 / -0
    My Motion Simulator:
    6DOF
    Reserved....
  4. robjos1

    robjos1 Member

    Joined:
    Jun 17, 2018
    Messages:
    40
    Occupation:
    Flying about
    Location:
    United Kingdom
    Balance:
    285Coins
    Ratings:
    +23 / 0 / -0
    My Motion Simulator:
    6DOF
    Reserved...
  5. Will974

    Will974 Member

    Joined:
    Jan 11, 2020
    Messages:
    52
    Occupation:
    Industrial Ingeenering Teacher
    Location:
    Reunion Island
    Balance:
    441Coins
    Ratings:
    +41 / 0 / -0
    My Motion Simulator:
    6DOF
    Interesting.....SFU1610 ballscrew ........I follow your thread to see the result... I like the design of your linear actuator...Can you give more details about your actuator ? (Drawing)
  6. Builder

    Builder New Member

    Joined:
    Nov 20, 2017
    Messages:
    5
    Location:
    Netherlands
    Balance:
    219Coins
    Ratings:
    +0 / 0 / -0
    My Motion Simulator:
    DC motor, 6DOF
    I am very interested in your project. Do you already have more information about the actuators? And do you already have your build working?

    Regards,
    Ronald.