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[in progress] 6DOF compact and small footprint

Discussion in 'DIY Motion Simulator Projects' started by Rens, Sep 5, 2020.

  1. Rens

    Rens Member

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    My Motion Simulator:
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    Just in: 360° hall sensors, they fit my couplers perfectly, which will be mounted directly on the backside of the customized shaft. :) I have no levers for the shaft yet, but have a friend that can probably design and cnc this at his company. But that's for a later time.

    IMG_20200921_160155.jpg

    I also made some progress on cabling yesterday. I must say I underestimated the work/time this takes. But it's coming along nicely.

    IMG_20200921_160839.jpg IMG_20200921_160931.jpg IMG_20200921_160952.jpg IMG_20200921_161120.jpg
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    Last edited: Sep 21, 2020
  2. Rens

    Rens Member

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    So I tested the PSU, all seems to be working fine, however the fan is quite loud and I think it's spinning at 100% duty cycle all time. I made a video about the noise compared to a mouse button click. But I am not going to upload it. It's very loud just trust me :) I do not have decibel meter (unfortunately). With headset on and some race sound it won't be an issue I suppose but still I think it's way to loud and should not have to be this loud. So that's not so nice in my opinion about this PSU. I opened the back of the PSU and
    there is the factory default fan named NMB - 3110KL-04W-B79 (3 pin connection) and specs say it's 40.0dB max. Will have to replace it with a quieter one.
    Last edited: Oct 2, 2020
  3. Mike Melga

    Mike Melga Member

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    @Rens Just make sure it has the same (or higher) air flow.
  4. Rens

    Rens Member

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    You think it's going to be issue otherwise?
  5. Mike Melga

    Mike Melga Member

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    Hmmmm....I searched the specs for both and the airflow is almost identical so... you should be ok.
  6. Rens

    Rens Member

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    I looked at the specs myself I found this:
    Old one: 45.9 CFM (1.29m³/min) 77.40m³/h
    New one: 26.3 CFM (0.74m³/min) 44.45 m³/h

    Where did you get specs from?
    Personally I am not to concerned about it since the thing runs at 100% and there will be plenty of airflow in my opinion. But perhaps I can find another fan that does not go above 20dB. I havem't ordered the fan anyways, was planning to do after dinner today. :p
  7. Mike Melga

    Mike Melga Member

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  8. Rens

    Rens Member

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    I decided to order a couple of fans from different bramds (see below). They all come with different specs so will see which one is most quiet compared to good airflow. :)

    Screenshot_20200928_205427.jpg
  9. Rens

    Rens Member

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  10. Rifly

    Rifly Member

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    My Motion Simulator:
    2DOF, DC motor, Arduino
    Your timing for small dc rig is just perfect. I had to abondon plans of servo drive 6dof, and get back to 6 wheelchair motors, wich are around 200-240w so thats really close to your power specs, I thank you for your detailed shopping list since I couldn't find hall pots for decent price it helped me a lot. Before making mine I will start my thread on it since Im not sure how to calculate dimensions to give motors easiest work load and still have to do some research in that regard
  11. Rens

    Rens Member

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    Hi, perhaps I am indeed (I don't know). Regarding the dimensions I am guessing you are referring to the levers for on the motors? I guess you will have to try this out. I probably start with a 50mm lever or something like that and see how that goes. I can't give you any advice since I am a noob at all of this myself. This is my very first rig. Will see how it goes, I still haven't received the motors yet, I hope I will soon :)
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  12. Rens

    Rens Member

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    Still haven't received motors... (after 2 months of ordering). I had contact with Sunrise motors. And they asked me to pay another 90 dollar for shipping due to covid or something. They said that the motors are now finished and ready for shipment. I have paid the extra 90 dollars. But honestly I am not happy with the way they do business since their terms stated that the motors would be shipped within 25 days after first deposit.

    Anyway, I figured I should just get started with the top frame already, and not wait for the motors, because who knows how long I have to wait.

    A week ago I received my racing seat, the simucube 2 sport, Heusinkveld Ultimate pedals, and shifter and handbrake. So I was able to create a new design from scratch with exact measurements. I then ordered all the steel with the correct measurements cutted in the correct length. I have been welding, cutting and drilling holes for a couple of days. The result being that I have completed the top part of the rig. My initial measurements where not completely satisfying when seated. The steering wheel was too close and to hight. So had to alter it a little bit. But now it's pretty much perfect :) I already have done some races (way to much fun honestly).

    Yesterday I connected the VR headset (HTC Vive around 4 years old by now). When I bought it 4 years ago I only used it a couple of times to play "Onward" (FPS game, also a blast). But other than that never really used it ever since. Now it comes to good use again! I installed KartKraft yesterday and man, what a ton of fun that was. Very realistic. Because since 4 years the technology for VR has improved a lot, I might consider upgrading to a better headset, but for the time being the HTC Vive still does a great job! :p

    Below some pictures of the progress of the build itself, and the result so far :)

    1.jpg 2.jpg 3.jpg 4.jpg 5.jpg 6.jpg 7.jpg 8.jpg 9.jpg 91.jpg 92.jpg 93.jpg 94.jpg 95.jpg 96.jpg 97.jpg 98.jpg 99.jpg 991.jpg 992.jpg 993.jpg 994.jpg 995.jpg 996.jpeg 997.jpeg 998.jpg
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  13. Mike Melga

    Mike Melga Member

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    @Rens
    Sorry to hear that you had problems with the motors.

    Your build is starting to look great. :)
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  14. Rens

    Rens Member

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    I received motors today, that's really fast shipping. So I am happy about that :). I am trying to find a good way to attach hall sensors right now. Some pictures for now, as you can see the shaft was customized to fit the coupler/hall sensor nicely :)

    IMG_20201110_170318.jpg IMG_20201110_170325.jpg IMG_20201110_170337.jpg IMG_20201110_170350.jpg
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    Last edited: Nov 10, 2020
  15. Mike Melga

    Mike Melga Member

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    Great to hear that.

    I cutted a round steel plate with 4 holes that go to the side of the motor to fix the sensor.
  16. Rens

    Rens Member

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    Could you share some pictures with me, for better understanding?
  17. Mike Melga

    Mike Melga Member

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    Something like this

    Attached Files:

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  18. Rens

    Rens Member

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    Oh that simple he, that's probably the easiest and best way to go about it. Very solid, thanks for the tip/share :thumbs
  19. Rens

    Rens Member

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    So I have been making good progress. Worked f9r 2 days on the code to improve it. It all seems to be working quite good/smooth (without any load that is). Regarding pot attachments, I used "beer" coasters. Theybseem to be doing a perfect job. They were round at first but had to cut them of, otherwise the plates that connect/hold the motors together wouldn't fit. But otherbthan that I didn't camr accross any unseen/unplanned issues.

    I have tried to put pressurebon the motor with my feet/leg amd the amp measured was max 1.5 if I remember correctly. The motor driver was warm after some time under load but you coukd easily touch witj your finger.

    I am still planning on adding gas springs to help with load. And maybe add some heatsinks to the drivers and maybe a fan. But will have to see how the test goes with the rig without a person in it before I add more weight. I probably have to adjust PID a little bit too based on the total load.

    Here are some pictures and some videos:

    IMG_20201113_165433.jpg
    IMG_20201113_165510.jpg IMG_20201113_165445.jpg
    IMG_20201113_170302_1.jpg
    IMG_20201113_170250.jpg
    IMG_20201110_170350.jpg IMG_20201110_170337.jpg IMG_20201110_170325.jpg IMG_20201110_170318.jpg
    IMG_20201114_152259.jpg
    IMG_20201114_141126.jpg
    IMG_20201114_150754.jpg IMG_20201114_150820.jpg IMG_20201114_150850.jpg
    IMG_20201114_150940.jpg
    IMG_20201114_203749.jpg
    IMG_20201115_105500.jpg
    IMG_20201114_220212.jpg
    IMG_20201114_220221.jpg
    IMG_20201115_105453.jpg
    IMG_20201115_220941.jpg
    IMG_20201117_235352.jpg IMG_20201117_235331.jpg IMG_20201117_235323.jpg





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    Last edited: Nov 20, 2020
  20. Mike Melga

    Mike Melga Member

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