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6DOF project, 750W AC-motors -> 1000W servo motors

Discussion in 'DIY Motion Simulator Projects' started by kaitila, Apr 2, 2020.

  1. kaitila

    kaitila New Member Gold Contributor

    Joined:
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    Finland
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    120Coins
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    My Motion Simulator:
    AC motor, Arduino, 6DOF
    Hi,

    I have been watching this forum for years, and waiting to find suitable cheap motor and frequency converters for my sim.

    First design was greatly influenced by this thread:
    https://motionsim.freeforums.net/thread/176/dof-step-diy-project-blueprints

    This was supposed to be really low budget project. It started at late 2017 when I found used AC motors and 750W frequency converters for really low price. I also ordered AMC1280USB from Thanos kickstarter campaign.

    Soon I realized my cheap motors had wrong gear ratio. So I had to make design with new type motors.

    Here’s my design and some pictures from first version.
    Ver1-01.jpg
    [​IMG]

    Lower frame
    IMG_20180120_140010.jpg
    [​IMG]

    Frame parts
    IMG_20180129_114957.jpg
    [​IMG]

    Upper frame
    IMG_20180227_092051.jpg
    [​IMG]

    3x frequency converter.
    IMG_20180627_222737.jpg

    So all the parts were finished and ready for assembly, just waiting me to order new worm gear motors…

    At this time I was very busy and still tried to find new used AC motors.

    I stopped my project after I started studying more about servo motors, I became more unsure about AC motors ability to provide enough speed for my sim.

    Everything changed for good when I found @Grigory build that he documented on https://www.xsimulator.net/communit...ct-and-no-linear-actuators-220v-servos.11839/

    So I had to redesign my sim totally.

    Here’s my design for second version.
    Ver2-01.jpg
    [​IMG]

    Attached Files:

  2. Ads Master

    Ads Master

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  3. kaitila

    kaitila New Member Gold Contributor

    Joined:
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    Location:
    Finland
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    120Coins
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    +4 / 0 / -0
    My Motion Simulator:
    AC motor, Arduino, 6DOF
    New frame. Idea was to make footprint as compact as possible.
    IMG_20190705_200231.jpg

    IMG_20191012_192455.jpg

    Testing servos.


    3d printed 1:10 scale frame model
    IMG_20191123_082742__01.jpg

    IMG_20190716_193642.jpg

    IMG_20190718_231850.jpg

    IMG_20190824_141120.jpg

    Asymmetric cockpit makes it easyer to go in and out.

    IMG_20191208_145946.jpg

    IMG_20200329_230759.jpg

    IMG_20200305_114616.jpg

    3d printed supports for safety switches.
    IMG_20200305_114644.jpg

    IMG_20200330_215322.jpg

    Monitors are temporary, plan is to get VR.

    First test run.


    Still lot to do. Now struggling with emc problem. I guess arduino is located too close to drivers. Next planning to make metal shield for arduino.

    Attached Files:

    • Winner Winner x 2
    • Informative Informative x 1
  4. Alexis

    Alexis SUAVE Gold Contributor

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    My Motion Simulator:
    3DOF, DC motor, Arduino
    Hi Kaitila, your project looks very solid, I'm glad for your progress
    • Like Like x 1
  5. Thanos

    Thanos Building the Future one AC Servo at a time... or 6

    Joined:
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    Occupation:
    Electronics Engineer
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    My Motion Simulator:
    AC motor, Motion platform, 4DOF, 6DOF
  6. kaitila

    kaitila New Member Gold Contributor

    Joined:
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    My Motion Simulator:
    AC motor, Arduino, 6DOF
    Thank you very much for the information. I think I will try that.
    Is it also possible to use AMC1280USB with reversed 1 and 2 motor levers?
  7. Thanos

    Thanos Building the Future one AC Servo at a time... or 6

    Joined:
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    Occupation:
    Electronics Engineer
    Location:
    United States
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    4,374Coins
    Ratings:
    +698 / 6 / -0
    My Motion Simulator:
    AC motor, Motion platform, 4DOF, 6DOF
    Yes, there is option for rotary actuators where you can define arm angle range, direction and offset from calibration position (homing switch or hard stop torque sensing). Its available since firmware version v2.08:

    Code:
    ======= enc_6dof_AMC_AASD15A_v2_08 =======
    release date: 01/22/2020:
    -Added option for KLM input (e-stop) to either HOLD powered position or Kill power to the Motors
    -Added option for FSW input (Force offline) to either Always Park or let user use park/standby button.
    -Added Actuator type selection for Linear or Rotary type (gearbox reduction). The menus are showing new
        options fit for describing the gearbox like reduction Ratio, Steps of the motor and output Angle range
        as well the CW or CCW direction of the motor.
    
    example calculation for gearbox:
     (500pulses / 360 ) * 180degrees = 250 Pulses
      250Pulses * (50:1 Reduction) = 12500 Pulses
    *keep in mind that the max pulses buffer that AMC-AASD15A can use is 65535!
    

    I'll post soon Gerber files for an easy to use pcb for the DB25 connectors (like the AMC-AASD15A has, to hook up on the AMC1280USB, that has pads on it for the resistors and capacitors as in the diagram...
    • Like Like x 1
    Last edited: Apr 3, 2020
  8. duckdown

    duckdown New Member

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    Kaitila, fantastic build. I am also building a version of Grigory's base platform. I like your solution to the the feet supporting your base. Would you be willing to share the schematics for your base? Thanks.
  9. Thanos

    Thanos Building the Future one AC Servo at a time... or 6

    Joined:
    Jul 6, 2017
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    813
    Occupation:
    Electronics Engineer
    Location:
    United States
    Balance:
    4,374Coins
    Ratings:
    +698 / 6 / -0
    My Motion Simulator:
    AC motor, Motion platform, 4DOF, 6DOF
    Here are some gerber files for PCB's to easy assemble the female DB25 connectors with smt resistors and use on the AMC1280USB:

    https://github.com/tronicgr/AMC-AASD15A-Firmware/tree/master/Upgrade-AMC1280USB

    It will lessen the wiring complexity since it includes the resistors and capacitors on the pcb.

    Thanks
    Thanos
    • Informative Informative x 1
  10. kaitila

    kaitila New Member Gold Contributor

    Joined:
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    Finland
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    My Motion Simulator:
    AC motor, Arduino, 6DOF
    Thanks!
    I have changed my job, and now I don't have any design program available.
    That's why I have very limited amount of drawings.
    Here's files that I found. Apparently couple holes for fixing feets are missing at plate01.
    I can try to find updated drawing.

    Attached Files:

    • Like Like x 1