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My 6DOF build with OSW and Overhung Hydraulic Pedal Set

Discussion in 'DIY Motion Simulator Projects' started by Adrian Culda, Apr 6, 2020.

  1. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Hey guys

    I have been poking around here for a bit and been learning and drawing ideas for my own build. With this pandemic i need to keep the kids busy and myself on my days off so I don't start bouncing off the walls as you can only watch so much TV before your bored.

    The 3 members i drew my inspiration from is @pmvcda, @PeterW and @SilentChill whose brain I have been picking a bit over the ODrive which I think its the best option but that is purely my opinion ( Thanks for that Bud !! ) . I have access to a Machine Shop and know how to operate and program the machines so the next part may seem like total overkill for most... but if your questioning it, go and see my introduction LOL

    - Linear Actuator :

    Plan is to somewhat clone @PeterW actuators with a few changes as my ball screws are 800mm long with a 735mm usable travel area and slightly larger motor ODrive Robotics D6374 which in comparison to his KEDA 63-64 which nets me a 56% increase in torque. RPM will be limited so i think bottom end torque will be more crucial than top end. Also I will be using 4" tubing with 4" SCH80 pipe as end collars for the end caps to bolt into. The SCH 80 tubing will be machined to interference fit onto the pipe. The installation of the collars will done by expanding the collar using heat while liquid nitrogen dipping the pipe to shrink. Once I get enough expansion / contraction between the two, the pipe will be pushed into the collar. once this has been performed on both ends, then the shoulders will be machined square and drilled and tapped to accept the end caps. The SCH 80 piping will give me plenty of "Meat" to drill and tap 4mm bolts to hold the end caps. Both end caps are going to be machined fit and will be milled / turned out of a solid 4" billet chunk. The piston assembly will be assembly will be a 2 piece affair with a PTFE or HDPE "piston ring" that will act as the rub strip. The top of the cylinder where the piston shaft will exit the cylinder will be treated the same way, body will clearanced in such a way that any moving parts will be clearance to 0.5 mm to allow the PTFE / HDPE to contact the wall instead of allowing to touch. The piston "ring" will be 101mm OD x 81mm ID x 15mm Height, while the top shaft seal / support will be 63.5mm ID x 75mm OD x 51mm Height.

    - Servo Drivers :

    I will be using the ODrive V3.6 Driver as they seem to be the simplest solution electronically, however i did hear setup is i pain in the ass to set up and program. I will be machining a mounting plate that will allow the mounting of the board inside the lower frame of the sim and facilitate the mounting of a heatsink. think of treating them as a plate amplifier on the back off a home cinema subwoofer.

    - Power Supply :

    Cheapest and best option for a fairly power hungry build is something proven for 24/7, 365 operation and when you get up there in power output they can get very spendy!! So... I will be using a crowd favorite the Cisco Catalyst 6000W monster power supply which should offer plenty of juice and reliability to boot at a fraction of the cost of anything on the market at the level of quality and reliability. There will be an additional DC to DC converter for the 12V for the pedals and a few other accessories and USB hub power for simplicity sake

    - OSW :

    This is quite simple really... Order MiGE 130ST-M15015 SERVO with BISS C Encoder, Granite Devices SimuCUBE and IONI PRO HC with an 750W 48V Meanwel Power Supply.

    Thats until you run into the issue with the input rating on the SimuCUBE. Most pressure sensors are rated for 5VDC operation meanwhile the SimuCUBE only tolerates 3V on its inputs. There are a few options here:
    1.- Optoisolator
    2.- Pull down resistor
    3.- Arduino.

    The Arduino route would be ideal as i want to use haptic feedback on the brake pedal during hard braking to simulate ABS activation. Would most likely use the Uno I have laying around in the garage from a daughters long forgotten project and is 12V tolerant on the power input which would allow me to drop a motor hat onto, and can use its regulated 5V and GND for the pressure sensors and the ouput signal would be sent to one of the unused ADC. Sampled data from the pressure sensors then will be sampled and processed. this data then will be output using the AnalogWrite and limited to 3V and using a 8C8P port will be sent to the SimuCUBE.

    - Steering Wheel :

    This one is up in the air at the moment... LOL
    Probably because it will be the last item on the list, but playing around with the idea of using a cheap clock spring or a wiper system act as a USB connection to the wheel. If it all fails will be looking at a BT alternative and when not in use use a USB cord to charge internal battery.

    - Pedals :

    Pedal assembly will be overhung like in a real car and will be based on measurements from an R8. here as well i will try and keep weight down as much as possible and they will be water jetted from 3mm aluminum plates and will be a 3 piece affair. once i achieved the 3 pieces will then be welded together and a 1" sch80 pipe will be used at the top pivot point which later will be bored out to accept a roller bearing. all 3 pedals will be the same and will be cloned. The only difference will be the pedal faces and the fact that the bottom of the brake pedal will have the Haptic motor mounted behind the pedal.

    - Sim Sled :

    This part will be all 1.5" Square tube Aluminum to reduce sprung weight. I still have quite a few riv-nuts left over from another project and will be using to mount the seat and slide rails. Will be using and NRG FRP-311 seat for the same reason and had the luck testing the seat, as a friend has this exact seat in his track car. They fit me perfectly and it is fairly light. Down the road I can upgrade if it comes to it..

    - Lower Frame :

    This will have to be the heavy and strong so it will not shift or move easily. Been even playing with the idea of adding some plates from a old / retired gym to increase stability. Most likely will be using 2" x 4" heavy wall tube. The corners will be boxed in to allow the mounting of the servos as close as possible to the Drives and keep inductance and capacitance of long wires as low as possible.

    That's all for now... if i think of something else i will add to the thread.
    Thanks for tanking the time and reading all this and hopefully i have time to start putting this all into Fusion360 and start making chips :)
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  2. Ads Master

    Ads Master

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  3. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well...
    the Shopping has Started!!

    1. - 130ST-M15015 Big MIGE SERVO - CHECK
    2. - Granite Devices SimuCUBE Motherboard - CHECK
    3. - Astec Cisco 6000W Power Supply AA23340
    4. - 800W Switching Power Supply for OSW - CHECK
    5. - 320mm Leather Superqua Flat Racing Steering Wheel - CHECK
    6. - Need For Speed arcade shifter mech - CHECK ( See the irony here ?? LOL )
    7. - Wilwood GS Integral Master Cylinder - .750" Bore -> x3 - CHECK
    8. - Wilwood Pull Type 7/8 in Bore Clutch Slave Cylinder Pull Type ->x2 CHECK
    9. - Hydraulic Parking Brake Assembly BLACK - CHECK
    10. - Pressure Transducer w/ 2m Cable 500 PSI ->x3 - CHECK
    11. - OMP Racing 3 Pedal Set Smooth Aluminium
    12. - EC8 8mm Bullet Banana Connector x10 Pairs with bullets - CHECK
    13. - RJ45 8P8C Right Angle Shielded Jack Breakout Board ->x4 - CHECK
    14. - SOC UART Bluetooth low energy BLE 4.2 module ->x4 - CHECK
    15. - Ultra Thin Flat Ethernet Network LAN Cable - 8M - CHECK
    16. - 2PCS 200x100x18mm Large Black Anodized Aluminum Heatsink x2 - CHECK
    17. - 10X10mm CNC Flexible Jaw Spider Plum Coupling -> X6 - CHECK
    18. - Waterproof Momentary ON/OFF Push Button Round SPST Switch M4 12mm -> 7 Colours x 10 - CHECK
    19. - NiceCNC Billet Brake Pedal Lever -> x3 - CHECK

    Will post total up Tomorrow once everything has gone through...
    Adding a 3D printer as the kids been asking one for a while and I think its time to take the dive. Looking at a Ender 5 Pro at the moment but they are hard to find, so i think the Ender 5 will have to do.

    I was going to use an NRG seat, but have since came across a few other manufactures on Alibaba I'm trying to convince to sell me a single one as a sample. Seat1.jpg Seatback.jpg

    Also picked up locally another steering wheel...
    80190864_10212151549344057_656125918833541120_o.jpg
    Was too good of a deal to pass up :p

    Once I have Seat sorted, i will be working on drawing up the skid. So far I worked it out that the frame will be made out of 38mm ( 1.75") 6061T6 Aluminum tubing. features an 1.65mm ( 0.065" ) wall thickness which is plenty strong when reinforced properly while keeping weight low. Pulled a random pic off Google as an example what the idea will roughly look like... SS-Formula.jpg
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  4. JAD

    JAD Active Member

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    Watching with interest.
    Thanks for starting your build log
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  5. Adrian Culda

    Adrian Culda Member Gold Contributor

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    No worries, I will share as much as I can as I progress along...
  6. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Quick Update as of this morning...

    Have been receiving quite a few notifications that items have shipped, but not all have made the "cut"

    1. - 130ST-M15015 Big MIGE SERVO - Shipped
    2. - Astec Cisco 6000W Power Supply AA23340 - Shipped
    3. - 800W Switching Power Supply for OSW - Shipped
    4. - 320mm Leather Superqua Flat Racing Steering Wheel - Shipped
    5. - Need For Speed arcade shifter mech - Shipped
    6. - Hydraulic Parking Brake Assembly BLACK - Shipped
    7. - Pressure Transducer w/ 2m Cable 500 PSI ->x3 - Shipped
    8. - OMP Racing 3 Pedal Set Smooth Aluminium - Shipped
    9. - RJ45 8P8C Right Angle Shielded Jack Breakout Board ->x4 - Shipped
    10. - Waterproof Momentary ON/OFF Push Button Round SPST Switch M4 12mm -> 7 Colours x 10 - Shipped

    Guess some of it is better than nothing during these times... I will spend some time today and follow up with the rest.
    I did end up adding a few other things that weren't mentioned on the list above and figured i would add that on here :

    1. - Emergency Stop & Push Button Switch Box - Added for the 6DOF to allow to add a "Park" and "Pause" modes / functionality ( see notes bellow )
    2. - 1 Pole 12 Position PANEL PCB Wiring ROTARY Switch - More Steering Wheel Switches
    3. - Rotary Switch For Potentiometer Knob Volume Control Rotary Knob - knobbies !!
    4. - 12mm Rotary Encoder Push Button Switch - and a few more...
    5. - Practical For MCU 10K AVR Electronic Block Slide Potentiometer Linear
    6. - Arduino STM32F103C8T6 Button Box / Pedal Box Duty

    I dropped the SimuCube off the list as for some odd reason my credit card company marked that transaction as fraudulent and it never was placed until I got home from work and read the email but then decided to wait it out and get the IONI Pro HC at the same time to save on shipping cost, so instead I ordered a Creality Ender 5 Pro 3D printer.
    But for now I must be off as the lil one is itching to play some Project Cars 2 and its a NO GO with the PS4 controller so im picking him up a Thrustmaster Ferrari 458 spider wheel for the PS4.
    • Like Like x 1
    Last edited: Apr 16, 2020
  7. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Had a closer look at my paypal just now and noticed a bunch of refunds. I'm guessing they aren't willing to ship and canceled the transactions.

    On the Bright side...
    I dodged a bullet as i found these beauties !!!
    s-l500 (1).jpg s-l500 (2).jpg

    Guess why re-invent the wheel :)
    Left Set will be your standard Brake / Clutch meanwhile the single will be the Gas pedal and will probably use the shaft from the pull type slave cylinders as a the actuating rod - reuse / recycle :)
    My Creality Ender 5 is stuck somewhere and still haven't arrived, but will most likely print a dummy master cylinder and out of PLA with a Nylon piston to engage the tab the that linear potetiometer and act as the TPS ( Throttle Position Sensor ). Idea is to be able to bolt it in and plug it in the Arduino and call it a day!
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  8. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well.. the only thing that has shown up so far is my Creality Ender 5 Pro, almost everything has been shipped so far too! Now that everything above is en-route, I'm now watching tracking numbers and the mailbox like a hawk hopefully something shows up and can start thinkering/playing with something as cabin fever is setting in LOL

    Ordered a few more things today as well:
    1. - Granite Devices SimuCUBE - WIKI
    2. - Granite Devices IONI Pro HC Stepper Driver
    3. - Wilwood 340-13834 Swing Mount Clutch / Brake Pedal Assembly - X3 - DATASHEET
    4. - ST-Link V2 Programmer Mini STM8 STM32 Emulator
    5. - 10A 250V 3 Pin IEC320 C14 AC Inlet

    May have found a Seat as well, but waiting to hear back..

    PS:
    Forgot to add in that I have ordered the slave cylinders..
    6. - Pull Type Slave Cylinder x3
    Last edited: Apr 18, 2020
  9. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Hi All :)

    Figured I'd chime in with an Update...
    Power supply has arrived yesterday and is a monster, I mean I'm still looking at the size and the weight of this thing is nothing to joke about and can easily pass for a portable welder LOL

    Now need to sort out the turn on and wiring the output leads which i have been toying with the idea of using XT90 connectors to each O-Drive control board.
    This Morning DHL dropped off the SimuCUBE with the IONi HC PRO R2. Powersupply for OSW is en-route and is in customs in Toronto as well as TNT taking their sweet time with the MiGE, but at least it seems that most of it will be here by Friday ( Fingers Crossed !! ). Shifter is in Canada Post's hands and same for a few other items...

    It's all slowly coming together :D
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  10. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Build Notes:

    Power Supply seems to be broken down into 3 sections: Top Board seems to me logic and low voltage supply ( 3.3V @ 25.0A and 12V @ 12.0A ) mean while the Bottom and Center Boards are the High Voltage ( 42VDC ) supplies running parallel to each other which explains the following snippet from Cisco's Documentation :

    Power supply dissection :
    Back of output board
    ASTEC AA23340 BACK CONNECTOR.jpg
    This is what i was able to track down so far without my multimeter, but also noting a few SMT transistors that may be responsible for the power cap based on chassis as this would make a more logical way of limiting power based on which pin gets pulled low implementing a power cap. Pins 11, 12 and 14 seem to lead to these transistors - possible wake up pins... Plan is to Map out the connector entirely by then end of the day.

    Pigtail from output board to Main Control Board.
    ASTEC AA23340 CONTROL PINOUT.jpg

    There is still lot of home work to be done...

    But did find this and wanted to note this in here as I don't want to go searching for random text later on:
    NOTE: Connector leads to output board, same one posted above these but at the other end.
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  11. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Quick Thursday night update :

    Some more parts started to trickle in...

    94674256_866039697141740_7199477511611219968_n.jpg 94393185_4446303102061805_2496095809725005824_n.jpg

    And spent most of they day on this:
    93840213_2830826760363292_6730103118769422336_n.png

    Once I printed it and verified fitment, I will be posting it up on Thingieverse.
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  12. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Welp...
    Got a few goodies in the mail for my Ender-5 and got ahead of myself :/
    Creality does't install a bootloader and now im stranded as i cant even load the new one to accept the BL Touch. so yay... no printing this weekend :/

    On the other hand found out that there flashing firmware to the SimuCUBE is a PITA. you cant just load the newest firmware and call it a day, but instead have to load an older firmware and then perform a mock setup and then install the latest release ( took me a few tries and a cup or two of cherry whiskey )
    94504937_2899596200131698_1939970653826318336_n.jpg

    On the other hand...
    128 BUTTONS ?!?!?!

    In my boredom, I made a quick and cheap adapter from a logitech pedal set i had kicking around to the OSW setup.
    • Informative Informative x 1
    Last edited: Apr 26, 2020
  13. JAD

    JAD Active Member

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    Im interested in the info on upgrading the voltage.
    Would you post the source link please for those details for adding the resistor.
    Thanks
  14. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Here you go...
    Sorry it took so long but i have been fairly busy and i had to dig it out of my surfing history... was on page 43 LOL
    Link to RCGROUP SERVER POWER SUPPLY CONVERSION Thread - was able to even pin point the post for you
    • Informative Informative x 1
  15. JAD

    JAD Active Member

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    Great! Thanks.
    I looked through the thread and that certainly was the needle in the haystack. Good Find

    I noticed over at Silentchill's build with ODrives that he had some trouble with the PSU.
    He started with the Cisco PSU but changed somewhere along the line to 35 V 15A 540 W PSU.
    Im not sure of the reason but someone said something about the Cisco tripping the Odrive.
    Just something to consider before upgrading the PSU to 48V. Might be worth running it at 42V to start with.
  16. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Yes, currently the O-Drive 56V modules are currently limited to 39.2V due to some ongoing R&D. I have been keeping a close eye but for me building a 6 DOF its the best option as a BLDC driver as is cheap and feature rich at the cost of a steep learning curve. There has been chatter of a python based setup utility that was started but never completed and someone is picking up that slack and will continue on / finishing it. @SilentChill is in the same Discord Group ;)

    Either way, if this supply doesn't pan out ( My loss is only $45 USD ) then I'm jumping to 3x 48V 25A ( 1200W ) supplies, as this way each O-Drive would have its own dedicated supply and would most likely make an enclosure for the drivers to sit as close as possible to the power supply and adding a heat sink to the drivers FET's and using the supply cooling fan to keep temps down as well. Found a hidden gem of a Brushless DC motor manufacturer and picked out a beefy 6384 Frame motor. Supplier is capable of manufacturing them to my spec and capable of producing them from 120KV up to 280KV for just under $60USD each !!
    This would also include sealed Japanese bearings and German made Hall Effect sensors with a 10mm Keyed Shaft.

    Plan all along was to build it within an certain budget as if those constrains wouldn't be there I might as well paid someone to build me one or bought off the shelf equipment.
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  17. cfischer

    cfischer Active Member Gold Contributor

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    Care to share the supplier? Sounds interesting.
  18. Adrian Culda

    Adrian Culda Member Gold Contributor

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  19. PeterW

    PeterW alias Wickie

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    My Motion Simulator:
    6DOF
    Hi Adrian
    I know this morors from my search at Alibaba, but I saw this motor has a 10mm shaft - but the common Odrive encoder AMT 102 has a maximum diameter of 8mm. So how do you intend to fix this (?) encoder?
    Wickie
  20. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Hi @PeterW ,

    After speaking directly with the manufacturer directly, they will manufacture the motor to my specification, in this case front shaft instead of being a D-shaft, they will machine for 3mm keyway as well as extend rear shaft 20mm and machine down from 10 to 8mm instead of shaft being flush with rear hub. These motors are also sensored and have an internal Hall Effect pick ups which would work with the O-Drive however you would not have the accuracy of the AMT Encoder.
    These changes are easily performed by the manufacturer as well as extending the cabling to 50cm.
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  21. Adrian Culda

    Adrian Culda Member Gold Contributor

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    I think I'm due for a quick update on this...

    Parts are arriving more frequently now and soon I will be in full swing and tinkering full time, which is good as being home with this pandemic is slowly hitting the crazy button LOL

    So...
    what has arrives yesterday and today:
    Shifter
    95343597_158930888880531_6743217109918023680_n.jpg 94786537_160655898686549_7283187102815092736_n.jpg
    Service Manual & Parts Sheet

    SimuCUBE Power Supply and E-Stop

    94711094_321575118811353_1827557465470795776_n.jpg

    Pedal Box Sensors ( Pressure Sensor and Linear Pot )
    94878467_1105805113121426_5430542389770977280_n.jpg

    and Last but not least the Willwood Pedals
    95151253_579888605973788_174343550157193216_n.jpg

    Still waiting on Wilwood GS Master Cylinders, Wilwood Slave Cylinders, E Brake assembly as well as a few other knick knacks.

    On a side note... my $25 shifter is missing the torsion spring along with the retaining bolt and spacer. Not a big deal, but can easily machine a spacer and pick up a random spring locally at princess auto.
    • Like Like x 1
    Last edited: Apr 28, 2020