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DIY G-seat Insert using 1 AC Servo - WIP

Discussion in 'DIY Motion Simulator Projects' started by sberns, Dec 6, 2019.

  1. sberns

    sberns Member Gold Contributor

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    My Motion Simulator:
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    Concept: DIY Back-panel only GSeat insert that can be placed/secured on top of any racing seat powered by a single 220V AC Servo Motor and a bowden cable system.

    Background: My current motion rig is an amalgamation of a Stage 2 SimXperience seat mover on top of an SFX100 actuator system, DIY Simwind, Buttkickers x4, @SeatTime's fantastic active harness tensioner, and a DIY GSeat insert. My seatmover + belt tensioner + buttkickers are great for accel/decel cues, and the SFX100 is ideal for pitch/roll/heave. The Gseat fills in the otherwise missing lateral Gs very well. I have tried using the GSeat for other effects but found it was overkill and led to too many motion cues for me -- less is more. Therefore, I am limiting my efforts to recreating lateral G-forces only. This plan could easily be modified to use a second AC Servo motor to recreate other effects.

    Why: All of my previous GSeats have used RC Servos. While they work well, I continue to miss the power and responsiveness that stronger/faster motors can provide.

    Main Parts List:

    3d printed and Custom steel Parts: see pics of (main) pieces (back panel will have a mirror image as well)
    220V AC Servo Motor: https://www.aliexpress.com/item/328...1.0&pvid=b7eaabe9-65ed-40da-8312-4be4407b7219
    200mm Linear Guide Slide Table: https://www.aliexpress.com/item/400...1.0&pvid=b7eaabe9-65ed-40da-8312-4be4407b7219
    300mm Linear Rails x 2: https://www.banggood.com/Machifit-3...-p-1239194.html?rmmds=search&cur_warehouse=CN
    Linear Rail Block x 2: https://www.banggood.com/Machifit-M...-p-1238091.html?rmmds=search&cur_warehouse=CN
    Bowden Cables: (we need 2 rear brake cables) www.amazon.ca/gp/product/B00L8NDVD6/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1
    www.amazon.ca/dp/B001V4WU16/?coliid=I11Z902DZ4D23E&colid=1IDRNLKKUPSPQ&psc=1&ref_=lv_ov_lig_dp_it

    STLs: (so far): (rename .pdf to .stl)


    IMG_6313.jpg IMG_6314.jpg Back Panel.jpg Back Plate.jpg

    Attached Files:

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    Last edited: Dec 14, 2019
  2. Ads Master

    Ads Master

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  3. noorbeast

    noorbeast VR - The Next Generation Staff Member Moderator

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    My Motion Simulator:
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    I am looking forward to seeing this come together, it should be a powerful system.
  4. Sebj

    Sebj Active Member

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    Yikes. Can't wait to see this too. You're building a close to ideal system available today.
    Keep us updated
  5. Sebj

    Sebj Active Member

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    Do you have a pic of your current rig
  6. sberns

    sberns Member Gold Contributor

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    My Motion Simulator:
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    Here are two pics of the current rig including current RC servo GSeat insert:
    IMG_6323.jpg IMG_6324.jpg
    • Like Like x 2
  7. Sebj

    Sebj Active Member

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    Thanks for posting. How are the servos holding up with all the weight?
  8. sberns

    sberns Member Gold Contributor

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    My Motion Simulator:
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    I have 6 rc servos per panel, each can move 22kgcm. They work reasonable well, but leave a lot to be desired. They also need replacing every so many months, which ends up being quite the chore - to figure out which is failing, to sync them all together...and the linkages fail periodically as well, but much less often.
    • Informative Informative x 1
  9. RacingMat

    RacingMat Well-Known Member Gold Contributor

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    your rig is awesome :)

    interesting project! keep going and sharing :popcorn

    yeah, that's a pain needing several motors for 1 actuator... you describe very well the burden
  10. Sebj

    Sebj Active Member

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    Thanks for the info, likely why simx also changed it up for their GS5

    Does your SFX perform 100% with the simx gear on top? Not too heavy? I have an 8020 2dof w TL, I fancy putting up on SFX in the future
  11. sberns

    sberns Member Gold Contributor

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    Definitely not too heavy. Throws it around like it’s a feather! But there is a very small amount of flex in the simX rig design. A friend has an SFX system on a P1X. I find I have to use almost twice the heave setting (15% vs 8%) to get the same road texture feel (only for heave as the bigger motions feel the same). It’s worth it though as Surge feels amazing with the seat mover integration.
    • Informative Informative x 1
  12. sberns

    sberns Member Gold Contributor

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    My Motion Simulator:
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    Most of my steel parts have arrived. Unfortunately I made one mistake with bracket hole placement. That may delay the completion of this project until the beginning of January.

    Some progress: (back plate, will rest on back of seat; sway panels to be mounted to this)
    86D85F1C-9919-469B-98CE-C375E8508B65.jpeg
  13. sberns

    sberns Member Gold Contributor

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    My Motion Simulator:
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    Today’s progress below. Next will be to attach the bowden cables. Need to design and print the cable mounts to the back plate.

    FDB09BCF-8D88-4B8A-AAF9-030A57618180.jpeg FCAEC9A1-76A1-4272-AFEB-C366CF573D62.jpeg 46D273E1-7EAF-49FD-9A31-C3138E48584F.jpeg 6BDDF5FB-D113-4933-9051-7548676C728A.jpeg B79B3F18-A102-4C67-9769-1C95BFA86B28.jpeg 02033BDD-8F5F-4BA1-B579-E879A99C9FE6.jpeg
    • Like Like x 5
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    Last edited: Dec 19, 2019
  14. sberns

    sberns Member Gold Contributor

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    Latest update: I’ve been working on getting the system up and running and have had troubles along the way. Mostly, this all related to my inexperience working with bowden cables and not anticipating exactly how the forces are transmitted. That all resulted in many iterations and redesigns of 3d prints and the use of a bicycle hollow stem screw to achieve reliable function without destroying the 3d prints. After much frustration, I finally have a working Gseat! Still much to optimize, and I may add some compression springs to return the panels to neutral once the force is released. Here are some pics of the current state. Video will be challenging for now as the panels do not return to neutral when in use without a passenger.
    5F067863-24B8-4385-9A9D-C96B7220BD22.jpeg 67715EB4-77CA-4FFB-B9AC-31FE83F357C2.jpeg 67E71C9F-2C3E-409D-8B8B-6023A6CEDCC1.jpeg E7A72A90-B06F-48F7-9664-F5EE609B84DA.jpeg 2EE58F82-1D42-4F6F-B658-77A8BD67788F.jpeg 46A3E484-E933-4FB7-B369-59515756446A.jpeg A805528E-6F42-43C8-A69A-CB51091CCFAB.jpeg 41B4226C-A6BF-4F23-976A-7C3FA72BEA1B.jpeg 1E677CFE-F239-48B3-B3D1-C18CFC968FEB.jpeg
    • Like Like x 5
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  15. sberns

    sberns Member Gold Contributor

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    Well I continue to learn....check out the picture below. Both my bowden cables snapped during testing. I also resorted to steel for the motor side cable bracket and even that still bent during testing, while the other end bracket that is only 3d printed is still holding up without any failures. My conclusions: I need to source thicker bowden cables. :think They were 1/16” and I’ll have to move to at least 3/32” or slightly larger. I also need to construct a motor side bracket that maintains the pull force in only one plane (vs my current setup that exerts force in two planes because the motor bracket is 2cm taller than the slide table). Revisions continue. Any tips or suggestions? @SeatTime or anyone else? Would be much appreciated.
    7A374C70-D26E-4A0B-8BA2-D48912E9E5E3.jpeg
    Last edited: Jan 25, 2020
  16. SeatTime

    SeatTime Well-Known Member

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    Hmm, if there are any side forces on the bowden cable leaving the outer sleave, or if it got bent if it went loose, depending on the materials being used, it may wear the cable and possibly cause failure. Bowden cables can wear over time, but I've never had one fail on me in the time I have been using them.
  17. RacingMat

    RacingMat Well-Known Member Gold Contributor

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    do you have a video? it would be easier to understand your system and give advices :)

    you can use https://streamable.com/ no registering, no account needed
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  18. sberns

    sberns Member Gold Contributor

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    Will try and make one as soon as I get replacement parts. Thanks.
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  19. sberns

    sberns Member Gold Contributor

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    Got the replacement parts! I will link short videos from two perspectives to show how it works. The motor pulls on the bowden cables (one cable per side panel), and the cables then pull and move the panels along the linear rails. My problem has been finding a way to secure the bowden sheaths on either side of the slide table to withstand the force of the motor when the cables are pulled. So far, my 3d prints were always breaking. I finally found a solution for the bowden sheath on the motor side of the slide table - I drilled into the aluminum block that the motor is bolted against and that has been bullet proof :). The other end has still been a problem and I can’t use the same solution because the aluminum plate is too short for where I need the hole drilled. So far, I just keep making the 3d print thicker. I am thinking of finding a steel U-bracket to place over it for added support. Anyone have suggestions?


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    Last edited: Feb 17, 2020 at 21:08
  20. sberns

    sberns Member Gold Contributor

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    Just survived a few Mosport laps with some intentional crashes etc. GSeat was solid! Cautiously optimistic with the current state. If all continues to hold up, will post final parts list and stl files to share.
    • Like Like x 2