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Hoddem's Aluminum Rig V2 (3-DOF, SFX, VR)

Discussion in 'DIY Motion Simulator Projects' started by Hoddem, Feb 17, 2020.

  1. Hoddem

    Hoddem Well-Known Member

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    I needed to cut the 4x3x1/4" aluminum angle and while I know that my chop saw could do it as is, I felt that this was as good of opportunity as ever to buy a blade designed for cutting aluminum.

    On the left is the blade that came with my saw, I use it for just about everything except finish work. It has probably cut several hundred cuts in aluminum extrusion. The new blade is on the right, it set me back a fair amount.

    upload_2020-11-15_12-36-51.jpeg

    all I can say is WOW! I wish I had invested in this blade years ago, it cuts through aluminum plate like butter and it is so much quieter too. my only real complaint is that it turns the chips into dust so cleanup is a bit more of a concern.

    upload_2020-11-15_12-38-15.jpeg


    I cut my angle to length and nicked the corners off. I also cut up some 1/4" plate to act as feet.

    upload_2020-11-15_12-40-31.jpeg

    Next I laid out all the hole locations and then drilled a lot of holes, exactly 99 of them.
    I had to rig up a special jig to hold the angle in a way that I could drill from the flat side.

    upload_2020-11-15_12-42-34.jpeg

    I did a quick sanity check before finishing the remaining parts.

    upload_2020-11-15_12-43-27.jpeg

    After drilling everything, I spent another hour or so cleaning everything up with a sander.

    upload_2020-11-15_12-44-0.jpeg

    Back to the bathtub for a wash.

    upload_2020-11-15_12-44-20.jpeg

    Finished parts all clean and ready for assembly.

    upload_2020-11-15_12-44-52.jpeg

    upload_2020-11-15_12-44-58.jpeg
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  2. Hoddem

    Hoddem Well-Known Member

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    I started assembly by first disassembling my simulator. I had to disconnect all of the electronics and then pull the actuators back off. I was joking to my buddy that it looks like my ride got jacked with it up on blocks.

    upload_2020-11-15_12-46-49.jpeg

    I started to assemble the first actuator and quickly realized that I wasn't happy with how it was going.

    upload_2020-11-15_12-47-36.jpeg

    I am trying to be extra careful here to align everything because I know that any skew will result in amplified problems later. The actuator needs to be as vertical as possible or else as it goes up and down the distance between actuators will change this will be in addition to the already discussed change in distance relative to the platform. Ultimately I was not happy with how the first one went together and I came up with a setup fixture.

    upload_2020-11-15_12-51-22.jpeg

    still not completely satisfied I added a square reference.

    upload_2020-11-15_12-51-53.jpeg


    upload_2020-11-15_12-52-2.jpeg

    I was satisfied with the new assembly method and I was finally able to mount the first actuator to the control box.

    upload_2020-11-15_12-52-52.jpeg

    upload_2020-11-15_12-52-57.jpeg

    upload_2020-11-15_12-53-3.jpeg


    rinse and repeat for the remaining two actuators.

    upload_2020-11-15_12-53-25.jpeg

    With the help of my wife I was able to get the base set in its semi final resting place. I will be moving up against the wall, but will leave it here until all of the wiring is completed. by design It just barely fits on my 4x6 mat.

    upload_2020-11-15_12-55-1.jpeg

    Now I had to switch gears and focus on the rig. I needed to add the extrusion that the actuators will push on.
    I am a little short on pictures for this part.

    I had to remove the front and rear cross members from the frame, not to big of a deal, but not exactly easy either.
    upload_2020-11-15_12-56-23.jpeg

    They needed to be drilled for the hidden fasteners that will hold the new extrusion assemblies.

    upload_2020-11-15_12-57-0.jpeg

    Assembly of the front, again all hidden fasteners.

    upload_2020-11-15_12-57-9.jpeg

    rear assembly is identical except the top member extends 9" on either side.

    upload_2020-11-15_12-58-32.jpeg

    upload_2020-11-15_12-58-40.jpeg

    upload_2020-11-15_12-58-48.jpeg

    It looks pretty funky on the ground, I was able to convince a neighbor to help me throw it up on the box. It is pretty heavy, but manageable for 2 guys.

    upload_2020-11-15_12-59-49.jpeg

    upload_2020-11-15_12-59-53.jpeg

    upload_2020-11-15_12-59-58.jpeg

    The rig is just sitting on the actuators right now, I have some cups printing now that I will throw on to keep it from accidentally sliding off. Overall I am pretty happy with the results. I may need to add some reinforcing plates/brackets depending on how much flex I get.
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    Last edited: Nov 15, 2020
  3. Hoddem

    Hoddem Well-Known Member

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    I need to fit all of this into my new enclosure.

    upload_2020-11-15_13-3-41.jpeg

    I decided to ditch the computer case and go open air with my simulator PC. I picked up a frame kit off amazon and after a month of transit time it showed up at just the right time.

    It doesn't look like much, but it is actually pretty well thought out.

    upload_2020-11-15_13-5-32.jpeg

    Here is the old case stuffed with all sorts of out dated tech. FYI I am planning on upgrading to essentially a new computer once the AMD, INTEL and NVIDIA new release craziness is over. also I will be getting a reverb G2 or index at the same time, depending on how the reviews turn out for sim racing specifically.

    upload_2020-11-15_13-7-1.jpeg



    After gutting the old pc

    upload_2020-11-15_13-8-59.jpeg

    ready for the scrap yard

    upload_2020-11-15_13-9-41.jpeg

    Here is the final configuration for my new open air PC, I removed all but the essentials. I still need to make some 3d printed parts to stack the two hard drives, but all in all it ended up pretty good.

    upload_2020-11-15_13-11-47.jpeg


    upload_2020-11-15_13-12-0.jpeg

    upload_2020-11-15_13-12-12.jpeg


    My next big task is to move all of my electronics into the new box and begin wiring everything again. That will include a new relay bank and new control panel with switches to turn everything on as well as the red/yellow/green buttons for the motor controller.
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  4. noorbeast

    noorbeast VR Tassie Devil Staff Member Moderator Race Director

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    My Motion Simulator:
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    Incredibly detailed work @Hoddem, I am looking forward to the next update an live testing :thumbs
  5. cfischer

    cfischer Active Member Gold Contributor

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    A pleasure seeing all the attention to detail and craftsmanship. Looking forward to reports back on the actuator setup as this is something I want to do with my rig too.
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  6. Hoddem

    Hoddem Well-Known Member

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    @cfischer, @noorbeast

    Thanks Guys, I honestly do enjoy the building process as much or more then the actual racing. This has been a pretty time consuming phase of the project though and I am very much looking forward to being able to do some racing.
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  7. RacingMat

    RacingMat Well-Known Member Gold Contributor

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    My Motion Simulator:
    2DOF, DC motor, Arduino
    :o: my favorite part: ignition ramp!

    upload_2020-11-19_14-19-27.png

    your place is so clean and tidy! respect!
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  8. Hoddem

    Hoddem Well-Known Member

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    Thanks, the idea was that you could get in the simulator and start everything right from the seat. Plus the cool factor when you are booting everything up is level 10.

    Also I do my best with the garage, the biggest challenge is keeping stuff from accumulating.
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  9. Hoddem

    Hoddem Well-Known Member

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    Holy crap time flies, almost a year later and no progress at all on this. Ive had this 90% complete system just sitting under a cover for way to long. I Have a few bigger projects I want to do over the winter and I am committed to getting this thing done so I can free up space in the garage.

    Here is where I am at.

    After I finished building the electronics enclosure/base I ended up making some 3D Printed cups with TPU inserts to allow for some movement due to the geometry changes when the actuators are moving.

    IMG_2607.JPEG

    IMG_2608.JPEG



    IMG_2611.JPEG

    So far in my limited testing they work well, I went through several design iterations on the TPU part and found this last design to be the best. Also I no longer have to worry about the upper frame sliding off of the lower frame. I will also add some limiter straps at some point so that the upper frame is mechanically connected to the lower frame.

    IMG_2613.JPEG

    Really the only thing I have to work on at this point is electronics, I finally took some time to disassembly my old control box. It was a bit of a shame to cannibalize all of that work, but it wouldn't fit in the simulator as is.

    Here it was in all of its glory.


    upload_2021-8-6_10-43-3.jpeg

    And now

    IMG_3381.JPEG

    A whole pile of parts leftover.

    IMG_3382.JPEG

    So what I am working on now is mounting everything inside the control box and finalizing wiring. A big part of that is the switch panel that sits on top of the simulator. Here Is the design so far.

    2021-08-06 10_48_26-Greenshot.png

    I have my 3d printer printing non stop and I am working on final electrical schematics now, I hope to have things up and running soon.

    Also, I am still working on the 3d model as I move along, have some updates that need to get done to that too.

    2021-08-06 11_39_12-Greenshot.png
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  10. Hoddem

    Hoddem Well-Known Member

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    Further progress on my switch box, I started to print parts out and then realized that I had a made an assumption on how the new mounting system would work. After already printing out the side sections I found this little error.
    2021-08-26 12_30_03-Greenshot.png

    I made a correction to the design and I was able to make it work without scrapping all of my existing printed parts.

    2021-08-26 12_31_14-Greenshot.png
    I started by disassembling the old control box and salvaging all the electronics.

    IMG_3411.JPEG

    I then cut the existing aluminum extrusions to fit the new design.

    IMG_3428.JPEG

    Assembly part 1 with the help of some extra brackets for alignment.

    IMG_3429.JPEG

    assembly part 2, Monitor installed and brackets removed. all connections are internal hidden fasteners.

    IMG_3431.JPEG

    I got the electrical box assembled onto the frame, the new design makes assembly much more complicated.

    IMG_3438.JPEG

    IMG_3437.JPEG
    Here is the completed wiring of the switches.

    IMG_3463.JPEG
    And the completed panel.

    IMG_3483.JPEG

    Now I plan on revisiting the actual switch plates, I'm not happy with how the end result turned out. I have been experimenting with sanding and clear coating them but I need some more experimentation to find the right combination.

    IMG_3462.JPEG
    I also started to mock up the inside of the electronics enclosure.

    IMG_3482.JPEG
    That's all for now, but I expect to start wiring soon.

    One last bit, I updated the cad model to be mostly parallel with the status of the actual rig.

    2021-08-26 12_55_14-Greenshot.png
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  11. Zed

    Zed VR Simming w/Reverb Gold Contributor

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    My Motion Simulator:
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    Beautiful work, Hoddem! I really like putting the actuators on the base for less “unsprung” weight, too. Apologies for not reading through until now but might have a solution to the flex mount issue - kinematic mounts. We used to use these on cameras and other parts that needed freedom to move/tilt but precisely constrained in location.

    A ball and cone locate one point in x, y, and z. A groove and ball just constrains in 2D, and the plane constrains in just one. The ball rotates in the cone, rolls in the groove, and rolls on the plane. But that arrangement lets the groove and plane take up contact point dimension changes as the platform moves.

    08128BA5-8526-4AE8-A180-E6B5F278C785.gif

    Amazing work, though!
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  12. Hoddem

    Hoddem Well-Known Member

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    Hey Zed,
    That sounds exactly like what I was thinking about doing before I came up with the TPU inserts. Ultimately I didn't feel comfortable with floating connections at this point. Well see how the TPU inserts workout and if needed I can explore other options later.

    Thanks for the idea and the help with the Reverb G2.
  13. Hoddem

    Hoddem Well-Known Member

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    Not a lot of detail here but some more pictures, I am slowly chipping away at the wiring.
    couple of things I did.

    On the left side of my rig, which will be the entry/exit side I have some AC Infinity fans and smart controller. I didn't want to spring for another set of those so I just picked up their plate and mounted my own 12v fans for the right side.

    IMG_3480.JPEG

    IMG_3500.JPEG

    I made some 3d printed mounting brackets for my open frame pc and screwed that down.

    IMG_3534.JPEG

    I added a power input port to the front of the base. I will just grab an extension cord and plug it in when I want to use the rig vs having a permanent cord to manage when not in use.

    IMG_3498.JPEG
    IMG_3499.JPEG

    I needed a place to mount all my relays, voltage level converter, power distribution etc so I used the top of my transducer amplifier.

    IMG_3533.JPEG

    I also spent a little time cleaning up the wiring on my argon servo drive for my OSW. all connections between the servo drive and the discover board are now internal.

    IMG_3425.JPEG

    IMG_3426.JPEG
    IMG_3427.JPEG

    And here it is about 25 percent wired, I actually have it about half done, but I forgot to snap a picture.

    IMG_3535.JPEG

    One last picture, I like to keep my garage organized and I finally went though all my extra sim gear from various project over the last several years. I ended up with quite the pile of stuff that unfortunately ended up going to the bin. It was bitter sweet, but it also felt pretty good to know that I'm not hoarding anything unnecessary. Side note, if anybody is looking for sabertooth 2x60 motor drivers with dc motors and encoders, I have some for real cheap.

    65196032817__55A82235-DD77-46E7-A0B1-B4BAAD07C1F4.JPEG

    More to come soon, I have been making a big push to get this thing running.
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