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Aluminum 80/20 Profile Rig with 2DOF Seat Mover for PS4 / PC (w/ Projector Screen)

Discussion in 'DIY Motion Simulator Projects' started by Redblues59, Jan 27, 2019.

  1. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Starting building my sim racing rig with aluminum 80/20 profile parts, a projector screen, and a DIY 2DOF seat mover (shoulder type). I will keep updating the thread with my progress.

    Main parts:
    Rig with 45mm profile parts
    Rig dimensions:
    Approx. length: 175 cm (exact length depends on pedal position)
    Width without screen: 85 cm
    Approx. screen width: 110 cm

    Overview:
    simrig1.jpeg simrig2.jpeg
    simrig3.jpeg simrig4.jpeg

    *Seat fixed for now (u-joint will not be working until I fix the motors / shoulder links in place)

    MayCad file:
    I couldn't find a way to upload this file yet - I will check again.
    (Please send a direct message to me if you need it for now.)

    2x 25:1 12 Volt Gear Motors
    2x JRK 12v12 USB Motor Controller
    2x HP DL380 G4 DPS-600 PB Power Supply
    1x Universal Joint from Ebay

    ujoint.jpg

    1x Sparco Evo II Racing Seat
    1x Optoma GT760 Short Throw Projector

    1x DIY Projector Screen
    • Like Like x 3
  2. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Some pictures from recent work.

    Floor structure:

    IMG_2063.jpg

    Pedal base:

    IMG_2064.jpg IMG_2068.jpg
    IMG_2070.jpg IMG_2071.jpg IMG_2073.jpg

    U-Joint & Seat Structure:

    IMG_2102.jpg IMG_2104.jpg IMG_2105.jpg
    IMG_2106.jpg IMG_2107.jpg IMG_2109.jpg
    IMG_2110.jpg IMG_2111.jpg

    Attached Files:

  3. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Cardboard Template for Projector screen:
    IMG_2429.jpg

    3mm mdf board cut according to the template:
    IMG_2430.jpg

    80/20 backbone:
    IMG_2432.jpg IMG_2435.jpg

    Matte gray projector screen stapled on to the mdf board:
    IMG_2447.jpg IMG_2448.jpg IMG_2449.jpg

    19mm felt tape for the borders:
    IMG_2450.jpg

    Joined on to the backbone using 2 sided acrylic adhesive tape (quite strong):
    IMG_2451.jpg
    • Like Like x 1
  4. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Couple of pictures with the screen installed:

    IMG_2470.jpg

    IMG_2471.jpg

    IMG_2461.jpg
  5. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Working on rod, lever length, motor locations etc.

    Does the following look ok to start with? (for 25:1; 40Nm / 160 rpm motors)
    I'd appreciate any comments.

    simcalc.JPG
  6. noorbeast

    noorbeast VR - The Next Generation Staff Member Moderator

    Joined:
    Jul 13, 2014
    Messages:
    12,744
    Occupation:
    Innovative tech specialist for NGOs
    Location:
    St Helens, Tasmania, Australia
    Balance:
    97,375Coins
    Ratings:
    +8,170 / 40 / -2
    My Motion Simulator:
    3DOF, DC motor, JRK
    • Like Like x 1
  7. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Thanks @noorbeast . I have now given it a bit more leverage.

    Not sure how to approach the tradeoff between roll/pitch angle ranges and torques - I think I will go with adjustable parts/placement as much as possible and will do some further trials on the physical setup.

    simcalc2 (1).JPG
  8. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Working on brackets, rods, levers etc. Inspired by some designs from the site & web.
    I will post the cad files & technical drawings later on.

    Asm1.jpeg ASM3.jpeg ASM4.jpeg ASM5.jpeg
    • Like Like x 1
  9. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Here are the cad files and technical drawings for the parts - attached.
    I am getting the parts produced in a local workshop - cost around 120USD.

    Attached Files:

    • Useful Useful x 1
  10. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Parts have arrived.

    IMG_2608.JPG IMG_2609.JPG
    • Like Like x 2
  11. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Changing the shaft direction:

    IMG_2610.jpg
  12. Redblues59

    Redblues59 New Member

    Joined:
    Feb 18, 2018
    Messages:
    12
    Location:
    Türkiye
    Balance:
    95Coins
    Ratings:
    +8 / 0 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Well, my intention was to join the solid shaft, lever and motor's hollow shaft with a snug fit 4mm pin as you can see in the previous posts. The result is not as elagant as I want it to be. Here are my lessons learned:

    1) First of all, although I had measured it, I ignored the fact that one of the motors had a slightly smaller inner shaft diameter (around 80 microns). I didn't take this into account in my drawings. Consequently I had to hammer the solid shaft into the hollow shaft heavily and couldn't make pin holes align perfectly. I had to put two pins into the hole from opposite sides.

    2) Although, it was easier to push the solid shaft into the the second motor, still I couldn't align the holes 100%. And the pin couldn't make it through to the other side. I had to use a second pin, again.

    Then, I cut the parts of the pins remaining outside. Still, it looks ok, and functions without additional backlash. However, I won't be able take the lever apart without cutting it through.

    The best approach would be trying out the parts & assembly during the manufacturing process, so that final mods can be done live.

    IMG_2655.jpg IMG_2662.jpg IMG_2663.jpg