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Showroom Compact AC Servo 6DOF Rotary Stewart platform

Discussion in 'DIY Motion Simulator Projects' started by knaufinator, May 26, 2020.

  1. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
    Messages:
    54
    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    A compact 6DOF platform I have been designing/building for the last 2 years, wanted to finally get it properly documented here, as I used this site as a wonderful resource that help guide me to my ultimate design. The design focuses on being compact in size yet still toss a rider around like a ragdoll...

    Rotary Stewart Platform using 6 - 750 W AC servo motors w/50:1 high precision planetary gears.
    Custom PCB that hosts a ESP32 microcontroller for interfacing and controlling of the motors.

    It's also very much so... Bolted to the concrete floor!! It would leap into the air majestically otherwise


    IMG_20200404_094100.jpg

    The project is on Github, PCB, platform code and major parts used, so to help anyone else in their hunt.
    https://github.com/knaufinator/6DOF-Rotary-Stewart-Motion-Simulator

    My Youtube Channel - Subscribe!
    https://www.youtube.com/channel/UCm_IVsEpLjsR-aZIYZF6-_Q

    Overview of platform


    iRacing


    GTAV


    NoLimits 2


    Dirt 2.0
    • Winner Winner x 6
    • Like Like x 4
    • Agree Agree x 1
    Last edited: May 26, 2020
  2. Ads Master

    Ads Master

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  3. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
    Messages:
    54
    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    Build Album
    Chassis was created around the seat itself
    IMG_20180516_181342048.jpg

    Threaded bungs held in place by a jig
    IMG_20180609_190515937_HDR.jpg

    Eye balling orientation
    IMG_20180609_194016097_HDR.jpg

    Welding the Chassis to the bungs
    IMG_20180726_085711154_HDR.jpg

    More,.. Eye balling orientation
    IMG_20180908_174815449_HDR.jpg

    First mating of my gear and motor trial
    IMG_20180924_161034345.jpg

    Imagining more motors and lots of more work to do....
    IMG_20180924_161205890.jpg

    Coped tube ends so they can be welded as cleanly as possible
    IMG_20181006_093055189.jpg

    Seat bracket made, all that eye ballin payed off...
    IMG_20181007_135114564.jpg

    Prevent rust, paint protection.
    IMG_20181008_185946126.jpg

    mocking up pedal box area and slope
    IMG_20181014_134944401.jpg

    Test mounting of pedals for sizing chassis
    IMG_20181016_180039214.jpg

    Pedal Bracket start
    IMG_20181017_134722260.jpg

    Helper
    IMG_20181017_145542108.jpg

    Pedal Bracket END!
    IMG_20181017_153946472.jpg

    Welding up the bottom pedal box brace
    IMG_20181020_182644634.jpg

    Back in place on the jig for more modifications
    IMG_20181021_112722953.jpg

    Welded Pedal bracket onto chassis bottom brace
    IMG_20181021_160737308.jpg

    First arm assembly - with High misalignment heim joints
    IMG_20181104_132824761.jpg

    Welded up the top section of the chassis that will hold the monitor and wheel
    IMG_20181116_201534775.jpg

    Shifter, custom ebrake, and tiny keyboard solidly attached...
    IMG_20190119_121427244.jpg

    Tactile transducer bracket...
    IMG_20190220_154621971.jpg

    Tactile transducer bolted to frame of seat
    IMG_20190220_171501809.jpg

    Newer gear(less backlash)/servo sitting on a 100 pound steel plate
    IMG_20190423_171833913.jpg

    Fabricating Gear bracket 1/4" steel plate
    IMG_20190615_160307768.jpg

    Welded first Gear bracket onto steel plate
    IMG_20190615_162923590.jpg

    2x3 inch steel rectangular tube, to lift the platform off the ground
    IMG_20190629_092400853.jpg

    Mocking up the bottom feet area,.
    IMG_20190629_095454987.jpg

    Gear/motor in place on base for first time -- Giggidy,..
    IMG_20190629_124140649.jpg

    Needed the base to be higher than the rectangle tube would allow, thick steel tubing for an extra few inches
    IMG_20190703_193531918.jpg

    Pre welding mock up
    IMG_20190703_200517926.jpg

    Welded and painted
    IMG_20190703_220717748.jpg

    Gear bracket support added so no flex occurs
    IMG_20190704_113152013.jpg

    More Brackets
    IMG_20190720_120910_244.jpg

    More welding
    IMG_20190721_090537498.jpg

    oh snap,..This is pretty
    IMG_20190721_105307131.jpg

    Rust protection!
    IMG_20190721_112337002.jpg

    First swing arm in place 7 1/4" long
    IMG_20190721_135307547.jpg

    Got a tiny server case to use to mount all of the AC Servo power supplies.. now to figure out how to stuff it all in there...
    IMG_20191005_132216987.jpg

    Running the wires for 220v and distribution blocks
    IMG_20191026_133238568_HDR.jpg

    Filling it UP!
    IMG_20191027_142444455_HDR.jpg

    Swing arm production line...
    IMG_20191109_183140562_HDR.jpg

    AC Servo control box all wired up and TURNED ON!!!!
    IMG_20191117_094336506.jpg

    All motors mounted for first time
    IMG_20191206_154256905.jpg

    Adding threaded bungs to the swing arm for attaching the chassis platform/arms
    IMG_20191208_154218178.jpg

    Lifting the base onto the threaded anchors in the cement floor. using a car jack...
    IMG_20191213_162653789.jpg

    By this time I needed to mod the wheel area for a new Fanatec wheel,... so I hacked of what I did to start over
    IMG_20200207_213756755.jpg

    Welded a extension on to chassis for Fanatec wheel
    IMG_20200207_223445562.jpg

    Blower Fan with 90 degree (car air intake) tube for wind feels
    IMG_20200301_072736.jpg

    Rear surround speakers
    IMG_20200301_072812.jpg

    Oh look,.. its almost done,... Giggidy...
    IMG_20200301_073030.jpg

    Monitor bracket, welded to chassis. (Universal Vesa mount, then I took a angle grinder to it to get the piece i wanted...)
    IMG_20200320_164712.jpg

    Magnetic limit switch installed
    IMG_20200321_113441.jpg

    Beauty shot of the motor base
    IMG_20200325_211417.jpg

    "My muse my flame"
    IMG_20200404_094100.jpg

    Green screen room!!!
    IMG_20200508_114455.jpg

    Needed a room for the rig, May as well make it green!
    IMG_20200508_125314.jpg

    Small monitor attached below the main monitor for SimHub, or video recording display
    IMG_20200516_091733.jpg
    • Like Like x 6
    Last edited: May 27, 2020
  4. Thanos

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

    Joined:
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    928
    Occupation:
    Electronics Engineer
    Location:
    United States
    Balance:
    4,439Coins
    Ratings:
    +791 / 8 / -0
    My Motion Simulator:
    AC motor, Motion platform, 4DOF, 6DOF
    Nice!! Welcome!
    • Like Like x 1
  5. Petertje

    Petertje “Engineering changes the world.” —Isaac Asimov Gold Contributor

    Joined:
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    Occupation:
    Mechanical engineer / battery specialist
    Location:
    The Netherlands
    Balance:
    295Coins
    Ratings:
    +87 / 0 / -0
    My Motion Simulator:
    6DOF
    I'm working on a linear 6dof setup, but this looks good too! Nice video's!
    • Like Like x 1
  6. Thanos

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

    Joined:
    Jul 6, 2017
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    928
    Occupation:
    Electronics Engineer
    Location:
    United States
    Balance:
    4,439Coins
    Ratings:
    +791 / 8 / -0
    My Motion Simulator:
    AC motor, Motion platform, 4DOF, 6DOF
    Be sure to mention that the platform is bolted on the floor... :cheers
    • Agree Agree x 1
  7. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    Lol, post updated!
    • Funny Funny x 1
  8. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    54
    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    I recently added a solid monitor bracket to the motion rig, made a time lapse of the process.


    I have ordered 2 new 50:1 gear boxes to replace the 2 gear boxes I have in the rear. They are older and have more backlash than the rest, 12 arcmin vs 5 arcmin... its enough of a difference ... to get me to spend 500 on replacing them,... in the name of perfection.
    • Like Like x 1
  9. frsim09

    frsim09 New Member

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    Ariège, France
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    My Motion Simulator:
    Arduino
    Congratulations :thumbs, very nice achievement , Thank you for this sharing
    • Like Like x 1
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  10. knaufinator

    knaufinator Member Gold Contributor

    Joined:
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    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    GT Legends tuned up and ready to go.
    • Like Like x 2
  11. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
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    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    I want to build a Cobra kit car,.. so I am getting my practice in
    • Like Like x 1
  12. MarkusB

    MarkusB Active Member Gold Contributor

    Joined:
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    Germany
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    3,461Coins
    Ratings:
    +463 / 1 / -0
    My Motion Simulator:
    2DOF, 3DOF, DC motor, Arduino, Motion platform
    You have really created a fantastic piece of hardware. Congratulations!

    I also love your green screen videos. My favorite is the rollercoaster ride in this post, where I get the impression that your rig does indeed sit on the rails. Amazing!
    • Friendly Friendly x 1
  13. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    Thank you!, compliments never get old!
    • Like Like x 1
  14. thefost

    thefost Member

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    Love the sim! Was wondering how you liked the reclined position for your rig, is it optimal for you or would you prefer a different geometry if you did it all over again? I'm considering doing a similarly reclined rig only with actuators and your rig looks like a good place to start copying =)
  15. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    54
    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    Thanks!, The reclined position was intended to balance the load out as much as possible when a rider is in the seat, to counter balance the mass of the monitor/pedal box area. Once you are in place, the reclined position feels natural, and I would do it the same or similar if I was to do this again.
  16. hooshang

    hooshang Active Member

    Joined:
    Jul 6, 2011
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    258
    Balance:
    219Coins
    Ratings:
    +149 / 3 / -0
    My Motion Simulator:
    2DOF, DC motor, AC motor, Arduino, 6DOF
    good job:cheers
    • Friendly Friendly x 1
  17. hooshang

    hooshang Active Member

    Joined:
    Jul 6, 2011
    Messages:
    258
    Balance:
    219Coins
    Ratings:
    +149 / 3 / -0
    My Motion Simulator:
    2DOF, DC motor, AC motor, Arduino, 6DOF
    IMO your cranks are a little long,dont you have any problem with your motors power for lifting.
    anyhow nice setup mate...
    :thumbs
  18. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    Not at all, the longer the swing arm, the more movement I could get out of it. I first did quite a bit of testing to make sure that a motor/gear could handle the weight... I found that a single motor/gear could lift a rider ~14 inches in less than a second, with a 7.25 inch swing arm. I am a skinny guy @ ~180lbs, but I have had dudes ~250lbs in the rig and it handling just the same.
    • Like Like x 2
  19. hooshang

    hooshang Active Member

    Joined:
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    Balance:
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    Ratings:
    +149 / 3 / -0
    My Motion Simulator:
    2DOF, DC motor, AC motor, Arduino, 6DOF
    good mate.i calculate you have more than 715 N turq at the tip of any actuators,
  20. knaufinator

    knaufinator Member Gold Contributor

    Joined:
    Nov 16, 2017
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    Occupation:
    Computer Engineer - RFID Specialist
    Location:
    akron,ohio
    Balance:
    184Coins
    Ratings:
    +96 / 1 / -0
    My Motion Simulator:
    6DOF
    • Funny Funny x 1
  21. hooshang

    hooshang Active Member

    Joined:
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    Balance:
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    Ratings:
    +149 / 3 / -0
    My Motion Simulator:
    2DOF, DC motor, AC motor, Arduino, 6DOF
    nice green box.i think this is the first time in this community such a video to show clear rig motion with the game:thumbs
    • Friendly Friendly x 1