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Showroom Assisted heave 150kg+ rig. Small Wiper motor lever + spring

Discussion in 'DIY Motion Simulator Projects' started by Trigen, May 8, 2020.

  1. Trigen

    Trigen Active Member

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    After seeing some other threads quoted by Noorbeast his own Seat mover i was inspired to start my own heave project for my P1x rig and Gseat. Basically it weighs 150kg+ with me in it. So if you want an ultra low cost setup for your rig this is the way to go! The feeling even with the 1 dof is amazing!

    Note that this is just a test version and it has a lot of flex but it works fantastic. I did a one lap Nordschleife and the motor was 35-45C. This happens to be the smallest wiper motor i could find. It should be noted uses 10-18A so bigger motor is an advantage but seeing as the temps are so low its more than fine for a test version.

    Since it is a lever it will pull and push a tiny bit but my rig is already on wheels and its so minor that its not an issue. I wish to make a 2 dof system but use links that lift from above so you can use one on each side and the rig wont move. It would also mean you could have it on the sides of the rig so you dont use up so much room. I dont actually have the space for it myself though!

    • Creative Creative x 2
    Last edited: May 8, 2020
  2. Ads Master

    Ads Master

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  3. Trigen

    Trigen Active Member

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    Last edited: May 8, 2020
  4. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    I use 60:1 gearboxes on my rig, as they are better suited to a compact design, they hardly get warm with my assisted heave, even with hours of use.
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  5. Trigen

    Trigen Active Member

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    Made a vid for a better overview. No more motor issues. Looks like the previous burned out as it was stalled for to long due to a shift in the test mounting

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    Last edited: May 9, 2020
  6. Trigen

    Trigen Active Member

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    Ive gotten 2x 24V Wheelchair motors 32:1 and 116 rpm on a tip. Hopefully they will work well for this. I got a 175 amp monster server PSU already modded to 24v with fans that sounds like a shuttle launch for RC charging but i hope the VR will drown it out!

    s-l64.jpg s-l500.jpg s-l1600.jpg
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    Last edited: May 10, 2020
  7. Trigen

    Trigen Active Member

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    Ill be raising the rig to get level and have a single pivot in front but another thing im considering but ill have to experiment with it is to set it up more like a seat mover. Perhaps not in perfect balance. Ill have to check how the heave feels but i think since its the whole rig moving it should be fine keeping it balanced. There's still a lot of inertia here but maybe i can lower the lever force needed ever so slightly.
    Seat mover or heave.png
  8. Trigen

    Trigen Active Member

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    So ive been experimenting a lot with motor, lever pivot point and so on and im at a point where i think i have about 2g force. Know that feeling you get when you hit a small bump hard in your car, that nice knock in the body? Well i got that in the simrig now and it rocks! Its honestly amazing what you can get out of a little wiper motor and a spring when it's all set up right.

    Another thing is that to get a good feel of the car you have to include pitch speed. With a combination of pitch pos (which does very little really) pitch speed (which is you main thing.) and vertical acceleration i now feel truly at one with the car. There's a few exceptions related to hitting curbs on the side that i will solve with roll speed later when i have two. Ill release all the drawn up plans when the project is finished. Im also experimenting with a pulley setup to save as much space as possible.

    The spring im using is about 10kg initial 30kg halfway. Not tested to full. The motor is holding 35-40C a it stands right now.

    lever new.jpg
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  9. Trigen

    Trigen Active Member

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    Ive had some 10 hour days messing around and i currently have a double setup and a pretty good feeling of roll. There's some lateral movement though but i think i can solve it by adding some linkages that limits it. Its less when i sit in the pit. Ive also added pivot on mid front to ease the roll. So far its a lot of fun and i suppose being manic does help get things done even though sleeping 3 hours a night aint that great lol... Given how good this feels having actuators must be epic.

  10. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    You are right, the lateral movement is undesirable and needs to be eliminated.
  11. Trigen

    Trigen Active Member

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    The main issue seemed to be the arc of the lever vs the arc (and lateral pull from roll but hard to fix since its a lot more angle) of the rig and that being amplified by both levers. Adding a wheel making it linear works very well as the pressure on the wheel also stops the lateral motion. I'll add a 2 degree angle or so to make it the same as the rig. This means I can increase the range without worrying to much about the arc as a bonus. Wont be 100% linear but close enough. Once the experimentation is done ill have to add bracing under the rig that connects both and change to thicker wood as there is to much flex.

    I can also just about lift it with me in it with 2x and without the springs but it's a bit slow so adding more powerful motor and adjusting spring position will do wonders. OR just making it more compact but it dont matter that much when its on the sides here.

    20200518_111521.jpg
    Last edited: May 18, 2020
  12. Trigen

    Trigen Active Member

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    So many axis going everywhere and I was really wondering how and what I had so I can convert to linear but what do I have for pistons? Then suddenly I recall I got an old scooter I was going to scrap but damn, it has dampers that should be perfect! Gonna do my best and try to convert from rotation to linear using these. I got a rough idea and since they could be slightly weak i may need to add some kind of extra help spring system on the whole thing and i only have tension and not compression springs so all inputs are very welcome!


    They have a 60mm stroke and i had around 30-40mm on the other setup so that should do nicely.

    20200518_190321.jpg
    Last edited: May 18, 2020
  13. Trigen

    Trigen Active Member

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    Here's the basic idea. I'll add springs to the motor lever to offset the weight.

    20200518_210020.jpg
  14. Trigen

    Trigen Active Member

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    Well i got the new wheelchair motors and they turned out to be a bit of a monster. Have to admit figuring out a way to actually mount them was a challenge and the hub is 12mm but not a standard pitch. I had no choice but to force it on halfway and drill out a nut that i also needed to grind down for a shim. Nothing is ever easy. It will probably be better to get a clamp or weld something else on.

    The other issue is of course they add about 30kg or so to the rig so i may need to do sort of a bottom up approach.

    And i loved up on my PSU! Thought it was 24 but it was 12 so ill see if i cant do the other 2 identical 12v in parallell. Well if i dare. Gotta read up. They will run at 12v 60 rpm ish (about the same as my wipers) with lower power though so ill see how it is in the meantime. They are freaking huge after all

    20200520_152839.jpg
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  15. MarkusB

    MarkusB Active Member Gold Contributor

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    Yes, these motors are heavy monsters compared to wiper motors.
    I have six of them in the base of my rig, which is still work in progress.
    IMG_7503.png

    About the voltage: I have two 12V 1300W server PSU connected in series, which gives me the required 24V. On one of the PSUs I have disconnected the ground from the housing in order to avoid a short circuit.
    PSUs.png

    However, you will probably also find 24V power supplies.

    Hope you find a good solution for the non-standard pitch on the gear box axis.
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  16. Trigen

    Trigen Active Member

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    The mount should be good for testing with some and the nut halfway for now. I'll look into just doing the psu I got in series. I'm kind of at the limit for what I want to put into it in terms of cost now. I gotta save for a proper actuator setup too. Appreciate the pics!

    I've done another iteration that I kind of knew wouldn't work as the levers will just be to far away but i wanted to test it and perhaps move the lever point to a connection point other than the base of the damper.

    So my options are to mount them directly on top which looks like it should work or save a lot of weight and mount the motors on the floor and do a push configuration and let gravity do its thing.

    Excuse the cable mess!
    20200520_215107.jpg
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    Last edited: May 20, 2020
  17. Trigen

    Trigen Active Member

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    @MarkusB

    I have a hard time visualizing things and need a few days for it to sink in so to say. Would you mind explaining a little more in depth about how you isolated one or perhaps have a link to a tutorial? Do you use any kind of diode for protection?
  18. Trigen

    Trigen Active Member

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    Alrighty then. To say im impressed is an understatement. Even at 12v these things are immense. They can throw my rig up into the air if i let them. This is still i a test version but i wanted to drive. I really wont be in a hurry to get any proper actuators cause i can feel the minute shake as i hit the limiter on the gears even on a direct input and max 45 degree lever. Once i get some proper pots/gearing on there it will be even better.

    On the psu: The server one is so loud i can hear it trough the headphones with the volume up quite loud so i wont be doing any series on the other two. I'll just get a dedicated one, this setup is more than worth it for years to come.

    I really need a direct rod to the end of the damper so moving the motors to the top will be my next thing. It works great now but there's a bit of flexing going on and a bit of a rattle. Ill just pre tension it with a rubber mat until i get it done.

    Here's a video and its a shit lap and the forces are slightly higher than i would like them to be and even the motor speed it turned down to 180 pid from the 60rpm at 255.


    I see its spiking around 20-25 amps per motor on 12v. Any ideas on a suitable PSU for two of these? 12v is fine if its proven safe for series.


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  19. Trigen

    Trigen Active Member

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    Ive been experimenting a bit with the CG. What i was missing was that thump from the front. You really do feel the forces in the front first so it would be preferable to have a double front single back setup. I will consider moving them forward but i'd have to redesign them a bit. For now its alright here. You loose a bit of that heave feel but you gain a lot. I'd need one more for proper heave really.

    If i want to go any further back i need to bolt things to the floor

    20200523_183254.jpg


    I had to secure it like this cause of the twisting motion of the shaft. I cant just attach it directly.

    20200523_183201.jpg
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  20. prodigy

    prodigy Burning revs

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    That's some real DIY stuff here :thumbs
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  21. Gadget999

    Gadget999 Active Member

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    good job !

    loving the evolution of your sim

    4 more motors and you will have a 6dof !

    what wheel do you use ?