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DIY SIM from wheelchair parts

Discussion in 'DIY Motion Simulator Projects' started by Design89, Nov 25, 2022.

  1. Design89

    Design89 Member

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    Hey all! Inspirited by @Halloween2go I'm going to build my own compact model motion sim with old wheelchair motors. I got all the materials and equipment to start and I will also try to create my model in 3D.
    IMG_20221118_183736.jpg Frame 3D.JPG
    Racing chair which I did use in a stationary setup. Steering wheel and paddles from Logitech combined with a Xbox One will be my starting point. Later on I will probably use a computer.
    IMG_20221118_183659.jpg IMG_20221118_183751.jpg
    I've got a small welding machine with a very small co2 bottle, but I want to try to use flux core wire. I'm going to use mainly 40x40x2 mm steel tubes.

    Probably will start with some welding and adjust it later in the 3D model. Some things are easier to make a mockup than designing everything in advance. I've got several parts from the wheelchairs laying around, so I'm still figuring out or I will use it or not. Like this tilt mechanism and the motor mounts.
    IMG_20221123_185023.jpg
    My now idea is to have a multifunctional motion sim, so I can tilt the chair back for a more F1 position. Still have to find a way what to do with the paddles then. And I need to try it on the frame because it's extra weight to move. My motors have a 1:25 ratio and I will use 25amp power supplies.
    First I will create the basic frame before using the extra tilt function of course.

    Extra input and idea's are welcome!
    • Like Like x 1
  2. fabrizio1203

    fabrizio1203 Member

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    Hi @Design89,
    I'm collecting the parts to start building my 2DOF flight simulator.
    I've ordered two 250W 75rpm wheelchair motors and I believe that they are pretty standard for that purpose due to the fact that while searching I've found many similar products with the same characteristics.
    Are your motors 250W 75rpm?
    Last edited by a moderator: Nov 28, 2022
  3. Design89

    Design89 Member

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    I've 2 different types of motors, 2 of each type. One says 0.235kW 96rpm 12.5A and the other type 0.33kW 216rpm 17.5A.
    I was thinking to use the 17.5A ones for 2DOF and the 12.5A for traction loss.
  4. Design89

    Design89 Member

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    My Motion Simulator:
    3DOF, DC motor, Arduino, Motion platform
    Last weekend I did take the wheelchairs apart to see what's useful to use. Motor mounts look really nice to use. IMG_20221126_103904.jpg
    And there is a pivot point which I might be able to use as a pivot between the lower and middle frame. It's just a copper ring without a bearing or something.
    IMG_20221126_112123.jpg IMG_20221126_112130.jpg

    My first test to get some movement with the Arduino en IBT_2's. Just used 2 motors for now.
    IMG_20221127_144912.jpg
    And I'm not sorry for my test setup, this is what I had laying around here.

    I will start working on the frame soon. I will keep you posted.
  5. Design89

    Design89 Member

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    My Motion Simulator:
    3DOF, DC motor, Arduino, Motion platform
    Time for some frame work!
    IMG_20221204_094012.jpg IMG_20221204_115959.jpg
    First I made the base frame, based on some dimensions from @Halloween2go
    With those dimensions I had a good start to create my own frame based on myself.
    IMG_20221204_141418.jpg IMG_20221209_134927.jpg
    Only thing I was nog sure about was the height for the top frame, as I want to use this rig also as a flight sim.
    IMG_20221210_142251.jpg
    I'm trying to figure out the maximum angle the U joint can do.
    IMG_20221217_143629.jpg IMG_20221211_135848.jpg IMG_20221217_183111.jpg
    After I decided to make it like this and I did some test fittings. I came to the conclusion that the U joint should be at least a lot higher, or even directly under the top frame.
    As it is now, the center of gravity moves too far outwards, allowing it to topple over.

    So don't make the same mistake as me!
    Have a look here also: https://www.xsimulator.net/community/faq/universal-joint-placement.108/

    IMG_20221218_111154.jpg IMG_20221218_173137.jpg
    For now I will have a look with everything in place and see or the motors can handle this. Otherwise I will chop it down.
    IMG_20221218_203911.jpg IMG_20221218_203933.jpg IMG_20221218_204038.jpg
    I made some levers from some scrap I had, but this cannot move the upper frame in it's maximum position.
    IMG_20221219_203523.jpg IMG_20221219_202617.jpg IMG_20221219_202303.jpg
    So I took some other scrap and screwed them on the original wheel spacers from the wheelchair. If this works I will need a real good seatbelt to keep me in the chair...
    • Like Like x 1
    Last edited: Jan 3, 2023
  6. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    My Motion Simulator:
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    • Like Like x 2
  7. Design89

    Design89 Member

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    Last edited: Jan 6, 2023
  8. Design89

    Design89 Member

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    My Motion Simulator:
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    Got all the wires hooked up, what a job to do.... @noorbeast I fully agree on your signature line!
    I did use a proto shield on my Arduino, so it would be easier to hookup all the ground and + wires. And also the green wires can be soldered together. Seems pretty easy to use if it works...
    IMG_20221228_183315.jpg IMG_20221228_183301.jpg
    • Like Like x 1
    Last edited: Jan 6, 2023
  9. Design89

    Design89 Member

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    My Motion Simulator:
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    Here are some pictures of my setup so far.

    IMG_20230107_090638.jpg
    I made some mounts for the hall effect potential meters 180 degrees.

    On the 220V side I did use a basic electric box with clamps for multi core and one core wires, easy to hookup.
    IMG_20230107_090419.jpg
    The 220v power plug is going with 3x 2.5mm2 multi core to the electric box. From the box to the power supplies I did use 3x 2.5mm2 single core wires (as used in houses to the wall sockets, ect.) Because the box and the power supplies are mounted on the ground frame, so this will be stationary.
    IMG_20230107_090438.jpg
    From the power supplies to the IBT_2's (mounted on the mid frame) I did use multicore wires again, because the mid frame is moving. Single core could brake over time.
    And for the motors I could use the original sockets from the wheelchair. Only the middle one is adjusted because this was the socket for the batteries and the cable needed to be a bit longer. This is for my traction loss motor.
    IMG_20230107_090152.jpg
    I did use a proto shield, looks easy to use and soldering the wires like the green ones.
    The only thing is that it does not work at the moment, after a lot of testing, trying and reading here on the forums, I came to the conclusion that my IBT_2 are not working right.

    At the moment even my Arduino doesn't work anymore.. I will order new IBT's and an Arduino, start from scratch and try with 1 motor at the time with a small breadboard.
  10. Design89

    Design89 Member

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    Yes I've got some movement. Unfortunately one IBT is already broken, turns in only 1 direction..
    Could be some power delivered back from the motor? Or the IBT has both bridges open at the same time?

    Also when I pull the line in SMC3 down, the motor will make a strange noise. Is this normal or could it be a bad motor?


    For safety I did only test with a 12V battery instead off the 24V power supply.
    I want to put some capacitors in parallel with the motor to protect the IBT when I'm using the power supply again.
  11. Design89

    Design89 Member

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    One motor at the time in SMC3 at the moment. I did replace the motors and those don't make strange noises... Still wondering what that could be though.


    It's way to high like this. Don't think the motors can handle the weight when fully equipped. Still testing with one 12V battery.
  12. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    My Motion Simulator:
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    Nice work.

    The motors may be capable of driving the rig though I suspect not with levers that long.
    Last edited: Jan 15, 2023
  13. Design89

    Design89 Member

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    Last edited by a moderator: Jan 15, 2023
  14. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    • Agree Agree x 1
  15. Design89

    Design89 Member

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    Thanks. Only problem is that I have one 12V battery and my power supply's are 24V.
    Running the motors on only the 12V battery works for testing, but it will not be enough to run my rig.
  16. Design89

    Design89 Member

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    My Motion Simulator:
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    Did some work yesterday on the height of my rig. Uni joint is now almost directly under the top frame. IMG_20230115_194941.jpg
    Yes, that pole on the left is what I did cut out. Could still give it more height if needed with some square tubing.

    IMG_20230115_194953.jpg
    Also I did angled out the motors and I want to try something else with the pivotal point.
    Welding with no gas wire, needs a lot of cleanup with it welds pretty easy.
    • Like Like x 1
  17. Design89

    Design89 Member

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    My Motion Simulator:
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    Works perfect. It's just a copper ring, it was used on the back of a wheelchair as pivot point for the suspension.
    IMG_20221126_112123.jpg IMG_20230117_195805.jpg
  18. Attyla.pl

    Attyla.pl Member

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    Hi were you able to solve the problem of IBT2 breaking down when powered by 24V? I'm building a motion sim with 24V 75RPM motors and I hit the same problem I already broke 2 IBT2 units.
  19. 90kgOver300m

    90kgOver300m Member

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    In response to the IBT2 issues, it may sound obvious but I haven't seen it mentioned in the post anywhere, but are you aware that the motors may have electronic brakes on them? I have some near identical motors, 24v 75rpm and some of them turn through the brake when powered but some don't. The brakes do hold them in position when powered off which is great as they are also a similar ratio and therefore not self locking. Just a consideration to ensure the controllers aren't being overworked.
  20. Liban Sheikh

    Liban Sheikh New Member

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    any updates on this?