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Showroom Dschadu's 6 DOF build

Discussion in 'DIY Motion Simulator Projects' started by Dschadu, May 23, 2020 at 13:07.

  1. Dschadu

    Dschadu New Member

    Jan 2, 2017
    +33 / 1 / -0
    D-Hi everyone,

    long in the planing, finally making it! I started to research on motion platforms 5 years ago and started to plan my own actuators and electronics.
    But these tasks turned out to be enormous and I ditched the DIY-electronics (which already eaten up about 300h development - with approximately 200 more to go).
    Recently @SilentChill showed his BLDC Actuators - the design is simple, easy to build and powerful!

    So I started to buy stuff...
    3x oDrive 3.6 56V Version without connectors - 183,46€ each
    6 x Turnigy Aerodrive SK3 - 6374-149KV Brushless Outrunner Motor - 89,18€ each
    12x IGUS GSM121425 bearing - 1,20€ each
    6x IGUS GFM252625 bearing - 1,33€ each
    6x Encoder AMT102-V - 20,55€ each
    IMG_0007.JPG IMG_0008.JPG IMG_0010.JPG
    IMG_0011.JPG IMG_0013.JPG IMG_0014.JPG

    The encoders do come with a lot of different mounting hardware. The biggest plus is that they are wear-free as there are no moving or touching parts.
    IMG_0020.JPG IMG_0021.JPG

    To get things right, the I also bought the correct connector:
    6x MOLEX 50-57-9405 - 3,29€ each
    100x MOLEX 16-02-0069 - 7,92€

    And a nice SubD9 connector, too:
    ENCITECH 6355-0009-01 - 1,78€ each

    And the other SubD stuff:
    50m LIYCY 5 x 0.25 - 35,20€
    6x D-Sub Female - 0,30€ each
    6x D-Sub Male - 0,96€ each (I have no idea why the are 3x the price...)

    To keep the odrive cool, I got these 40mm fans:
    12x 12VDC 40x40x10m 15,7dBA; SUNON HA40101V4-1000U-A99 - 2,55€ each
    12x 40 x 40mm fan grill - 0,43€ each
    50x Screw STP5X10 4.2mm - 4,55€

    And some connectors I already had:

    oDrive Case and assembly:
    Its not fully assembled on the last picutre. Still needs the leads for the second motor and the subd9 connector.
    Airflow is designed to go over the cooling fins. They get controlled from a central spot to keep them as quiet as possible. At 7 V they are very silent and they do push a lot of air ofter the odrive board.
    IMG_0031.JPG IMG_0032.JPG IMG_0038.JPG IMG_0039.JPG IMG_0042.JPG

    The encoder cable is fully shielded.
    IMG_0041.JPG IMG_0043.JPG

    As power source I bought a WS-CAC-6000W - 38€. The scrap price would score more... absolutely incredible.
    IMG_0035.JPG IMG_0036.JPG IMG_0037.JPG

    Only downside: The fan is really loud. So I removed it and put a more silent one in, only to discover that the integrated fan controller is not happy with the low RPM and shuts down the output. Solution was a simple NE555 circuit to emulate a faster spinning fan. And it worked :)
    Heat-shrink around it to avoid bad thinks from happening and put it all back together.

    More pictures and infos to come!

    Attached Files:

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  2. Ads Master

    Ads Master

    +0 / 0 / -0
  3. hannibal

    hannibal Active Member

    Sep 29, 2018
    +214 / 2 / -0
    My Motion Simulator:
    3DOF, 6DOF
  4. Dschadu

    Dschadu New Member

    Jan 2, 2017
    +33 / 1 / -0
    A custom connector for the power supply. Its not perfect and also looks not that good, but it should do the job!
    IMG_20200508_171928.jpg IMG_20200508_171950.jpg

    The actuator itself - as mentioned above - is based on SilentChills design. But I had to do some changes to fit the parts I'm able to supply. In particular I had to change the bottom mounting, as I couldn't find the huge U-Bolts that are used in the original design. While I where on it, I removed some material in some place that is not structural critical, mainly to reduce printing time. I also added the possibility to add a 40mm fan below the motor, just in case.
    Some prints turned out great with the first print, some parts needed adjustment, usually because I didn't get the tolerances right.
    After everything arrived, I could start to build the first actuator.

    6x Bearing FK12 - 15,90€ each
    6x Ballscrew 1605 600mm - 36,90€ each
    4x Aluminium pipe 12x1mm, 2000mm, 2,64€ each
    4x Aluminium pipe 25x2mm, 2000mm, 7,04€ each
    Different bolts and nuts in M4 - M6, too much to list here.
    IMG_20200510_121348.jpg IMG_20200510_121404.jpg

    Now with everything in place... time to test the odrive. The documentation is not optimal and the usage is a pain, as there is no UI. But I got the hang of it pretty quickly and it turned out that there are not many commands and settings. I limited the motor to 10 A @ 24 V and 150 rpm for testing and it worked so far. Final version will go with 70 A @ 42 V (at least that's the plan).

    Then the outer pipes arrived:
    6x Aluminium pipe 90x3mm, 800m, 18,40€ each

    The first actuator is nearly completed:
    IMG_20200515_154145.jpg IMG_20200516_164916.jpg

    And a short video on how it is assembled:

    Now my 3d printer needs to print all the other parts (~160h), but this will take some time as I don't let it run unattended. So only a few parts on weekends.
    In the meantime I can prepare the pipes and start building the frame.
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