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DIY 6 Axis Sim

Discussion in 'DIY Motion Simulator Projects' started by Eugene Pearson, Nov 20, 2018.

  1. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    Hello to all, first time posting here and my first simulator project.

    I've been slowly building a PVC pipe frame 6 axis simulator from second hand parts.
    Its using a G25 steering setup, ive flipped the pedals to mounted them to a steel plate with some carpet tiles.

    The motors run off 2 JRK boards, The boards themselves looked a little cooked so im using some intel cpu coolers as heat sinks with 90mm pvc joiners ontop to make them forced air fans. JRKs sandwhich between an 80mm case fan and the intel coolers have had the copper plug hammered down a few mm to clear the bottom of the PCB. Silicon heat transfer pads are used between the cooler and JRK to avoid shorting.

    I had to rebuild the screw gears, they were missing bearings and the roller bearings were totalled. They run smooth with 0 play now :) Welded up some brackets and uni joints trying to keep things neat and tidy.
    Whilst looking around the junkyard for the intel heatsinks I found enough parts to build an i5 PC better than the one I was using which was a nice bonus.

    I still have to figure out a mounting system for the screen and weld up a seat rail but its coming along nicely.

    I also have to mount some 10k 5 turn pots as the original sensor system was a terrible design.


    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
  2. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    Did some more work on the project over the past few days. Made the mounts for the screen and centre speaker, speaker poles, gear stick, wheel, seat+rails.
    Still waiting on the gear rack to show up so I can finish the last bit of hardware and test everything out. Have to make a box to house the PC and other bits but running out of room fast...
  3. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    [​IMG]

    [​IMG]

    [​IMG]
    • Like Like x 1
  4. Gadget999

    Gadget999 Active Member

    Joined:
    Dec 27, 2015
    Messages:
    564
    Location:
    London
    Balance:
    4,293Coins
    Ratings:
    +104 / 4 / -0
    My Motion Simulator:
    2DOF, Arduino
    what type of actuators are you using ?
  5. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    They are old brick movers, not sure of the brand or model but im assuming china based as the bearings were labelled CHINA (Now the say JAPAN :)
    Not sure if you can see my pictures yet due to the 3 post rule.
  6. Gadget999

    Gadget999 Active Member

    Joined:
    Dec 27, 2015
    Messages:
    564
    Location:
    London
    Balance:
    4,293Coins
    Ratings:
    +104 / 4 / -0
    My Motion Simulator:
    2DOF, Arduino
    What is a brick mover ?
  7. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    Hey Gadget, didnt expect you here :)

    Umm a brick mover moves bricks? IDK its what the linear actuators were being used for before sim life.
    • Like Like x 1
  8. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    Been busy chipping away at the actuator sensor system.
    After much thought I decided to mount the pots off a bracket and have a rack gear connected to the shaft. The bonus here is the bolts act as a guide.
    I polished up and greased the mating surfaces and tightened the pots down, they move freely but have 0 free play or chatter, super chuffed with the end result I hope it actually works though.
    [​IMG]
    [​IMG]
    [​IMG]



    All painted up with the motors fit, man do I hate painting.

    [​IMG]



    Had another idea about mounting the fans to the heatsinks with efficient cooling. Cutting up a 90mm pvc joiner in the right spots meant i didnt need to make spacers and the JRK boards are now force cooled :)

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]



    I also finished building the PC that it will run off, put it in an old XP Dell case.

    [​IMG]


    Just waiting on some silicone pads for the heat sinks and have to cut out a hole for the sub but its very close to completion
    • Like Like x 2
    Last edited: Dec 7, 2018
  9. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    Pretty much just wiring too do now and I can go for a test drive :)

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]



    Sunk the subwoofer into the floor as there was no space anywhere else but I think people will probably stand on it before long.

    [​IMG]


    The bar under the screen is to hold the centre speaker but also apply pressure on the screen when the bolts are tightened. It still had some noise from vibrations so i added single sided tape to dampen it which worked perfectly.
    Rock solid screen mounting has always been a concern of mine during this project. Managed to pull it off with $4 of steel and a welder.
    [​IMG]
    • Like Like x 3
    Last edited: Dec 8, 2018
  10. Haraguchi

    Haraguchi Member

    Joined:
    Dec 13, 2017
    Messages:
    76
    Occupation:
    Gas rig operator
    Location:
    Brasil
    Balance:
    255Coins
    Ratings:
    +64 / 0 / -0
    My Motion Simulator:
    2DOF, Arduino
    Nice job !
    Did you used a PVC tubes !?


    And they can handle it?

    Congrts !
  11. Eugene Pearson

    Eugene Pearson New Member

    Joined:
    Nov 20, 2018
    Messages:
    8
    Balance:
    109Coins
    Ratings:
    +7 / 0 / -0
    My Motion Simulator:
    JRK
    The PVC is 5mm thick and 10mm on the joins, glued and screwed. I can jump on it in the middle and it doesnt flex :)

    Im having major issues with driving the motors though. Keep getting motor driver error, the motors will drop from their position then they cant get back up because the system is too heavy, so they shudder badly then shutdown.

    Im guessing the motors are too big for the boards as these puppies can lift well over 400kg each no worries. What do I do? Board upgrade? Heatsink? Motor swap?
    They are 4500 RPM 200W motors im thinking the RPM is WAY too high?

    The 12v12 are an old model hey?

    Oh and the LCD mounting I think was a really bad idea, Screen goes white when you shake it, was actually kinda funny.
    Last edited: Dec 10, 2018 at 01:13
  12. Haraguchi

    Haraguchi Member

    Joined:
    Dec 13, 2017
    Messages:
    76
    Occupation:
    Gas rig operator
    Location:
    Brasil
    Balance:
    255Coins
    Ratings:
    +64 / 0 / -0
    My Motion Simulator:
    2DOF, Arduino
  13. noorbeast

    noorbeast VR - The Next Generation Staff Member Moderator SimTools 2.0 Beta Tester

    Joined:
    Jul 13, 2014
    Messages:
    11,780
    Occupation:
    Innovative tech specialist for NGOs
    Location:
    St Helens, Tasmania, Australia
    Balance:
    91,521Coins
    Ratings:
    +7,693 / 37 / -2
    My Motion Simulator:
    3DOF, DC motor, JRK
    I don't think the old JRKs to be particularly well suited to very high speed motors (new ones have a bit more headroom), @Avenga76 detailed his journey and struggle with high speed motors and JRKs starting from here: https://www.xsimulator.net/community/threads/my-3-dof-seat-mover-gs-4-simvibe.5596/page-5#post-68100

    Sabertooth would be a better option in my view.