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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. PeterW

    PeterW alias Wickie

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    My Motion Simulator:
    6DOF
    Hi Adrian
    Hi Adrian,
    I had a quick look to the Odrive Dokumentation and community comments regarding the Hall Effect sensor. They say that Hall sensors are not suitable for a Position Control. The Counts per Revolution seems to be too low for this job. In my experience you can feel the smallest movements of the Motor at slow Motion. So I would reccomend to order a AMT 102 as a fallback solution
    Wickie
  2. Adrian Culda

    Adrian Culda Member Gold Contributor

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    They have been already ordered :)
    They will serve as rpm sensor for the O-Drive and will be back up in case the AMT unit ever fails. I used to work as aircraft mechanic so all my projects have a fail safe of some sort built in.
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  3. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Since its Friday i figured i would post a quick update...

    Only thing that had arrived was a the bag of knobs for the rotary switches. Other than that I finally tracked down an Arduino UNO and was able to burn a boot loader onto my Ender5 and installed the TH3D firmware and fine tuned it a tad, and now printing a few parts for a button box along with its paddle shifter parts and other accessories to go with it. the big MiGE is now stuck in US / Canadian Customs and i might not see it till Monday at this point. Today i spent the better part of the day playing around with Fusion360 and working towards finishing up the accelerator pedal position sensor housing resolved as by the time the master and slave cylinders arrive i can easily just mount, plumb and plug them in. Here's a quick peek...
    Front bushing.jpg

    As can be observed this bushing will bolt onto the back my wilwood pedal set just like a master cylinder. There's a few more parts that go together to form an assembly but this is a teaser for now.. more to come as im slowly picking away at it along with covers for the OSW Power supply as well a beauty plate to cover up terminal block and act as a housing for the IEC connector. Right now the printer is working on the SimuCUBE motherboard enclosure I had posted earlier.
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  4. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Welp..
    A quick sneak peek at the main body
    APP.jpg
    Changed my mind mid design and decided to avid the headache of clocking the threads between the front cover and main body together and decided to make them as one.
    this way if you want change out the spring its as simple as removing the rear cap.

    The body will be 3D printed with PLA+, same with the piston, and there will be 2 shims also printed from TPU to act as a cushion and reduce "banging" when you go off the gas pedal suddenly and smash it to the floor again. The back cap will have a conical stopper the same way not only to stop the spring from being crushed but also act as a soft landing. When everything is printed and proven/tested, I will have it machined out of T6061 and have it powder coated black to match the Wilwood GS Master cylinders.

    By the way, this is the Linear Potentiometer i decided to use:

    linear pot front.jpg linear pot back.jpg
  5. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Mid week update...
    The flow of packages has slowed down MiGE is stuck in US/Canadian Customs... lack of paperwork apparently. Other than that nothing much to report other than more CAD work.
    From 95948856_1147443408941516_2675752990341595136_n.jpg to RJ45 Breakout Board.jpg
    Now since the PCB has been modeled, I now can start making the enclosure for it.
  6. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well... Week went by, back to work and nothing much to report on other than dialing in my Ender 5 and finally upgraded to Marlin 2.0.x and getting some pretty decent prints now! Seemed like the factory Creality firmware sucked at larger prints and had a large percentage of failed vs successful prints. that all changed once I build a custom version of Marlin for my setup... can be seen in the following pics :p
    97751970_936342193460882_3023039506115723264_n.jpg 96234942_274613320339284_7737975511841767424_n.jpg 96364637_2497483383915242_4037741352455241728_n.jpg 97356654_535113797167226_6328861531605827584_n.jpg 97998248_1415659135302787_1705566766333165568_n.jpg 96413836_594451914541957_5369067908683005952_n.jpg 96800617_232308808031449_8061242380063342592_n.jpg

    Now onto building the "piston" assembly and end cap which will house the spring.

    MiGE has cleared US customs and hoping to see it at my door step tomorrow.

    Will post more pics as the prints roll off the heated bed :thumbs
    But all in all looks like she fits :)
    96026011_177015323558170_2460054411271995392_n.jpg
    Last edited: May 11, 2020
  7. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Welp...

    Tee Fittings came in today at NAPA and put the slave cylinders along with the pressure sensors together today.
    96845212_244942773266647_8205763575692656640_n.jpg 97466057_859637984448847_4019456611524280320_n.jpg 96520194_927012231084284_6647507135275991040_n.jpg

    E-Brake still hasn't showed up but i did order the 1/8NPT to AN3 fitting for the slave cylinder as well as an assortment of die springs and a few different durometer skateboard bushings from soft to hard, which in the we will call the "tuning kit".

    Placed my order with the Metal Supermarket today for some 6" x 18" x 1/2" and 2" x 18" x 1/2" 6061 T6 plate aluminium.

    Just realized my E-brake unit i ordered comes with a master cylinder :D
    s-l1600 (2).jpg
    • Like Like x 2
  8. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Nothing special to really note this week other than the MiGE finally arriving after i do believe them loosing it a few times and then falsely recording an attempted delivery where they said they were at my residence when i was at home for lunch and supposedly rang the door bell several times and left without leaving a tag behind... either way. There's no way I'm ever using TNT or FedEx ever again.
    It has been crazy busy at work and seems like everyone is starting to resume normal life until this ugly thing rears its head again. nothing else really to report on other than more homework and waiting on aluminum plates to get machined at my buddies shop as he took it upon himself to get this done for me.
  9. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Good morning peeps!

    Nothing to report on this end... quite a few packages still inbound and to top it all off work has been crazy busy, therefore I haven't had much time to thinker.
    Today is my regular day off as my shift requires me to work on weekend on and the other I'm off ( 6 on, 1 off and 4 on, 3 off ), just came off my 6 days stretch and hopefully looking at a light week ahead and hoping more packages arrive.
  10. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well..
    I found the perfect match for my SimuCUBE1 !!
    This RIM and DISPLAY MODULE is my choice for GP/ F1 wheel!
    Need to add in the SHIFT and CLUTCH mechanisms to complete the set!
    • Like Like x 1
    Last edited: May 29, 2020
  11. Adrian Culda

    Adrian Culda Member Gold Contributor

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    This week has been uneventful at best.

    The Manufacturer i was getting my quote from has decided to inflate prices of shipping with this pandemic and that increased the price by almost 60% of the original quote. So I had a decision to make :

    A. Keep looking or B. Bite the Bullet
    Decided that it might be a better option to have a look around and see if i can find an "industrial" servo for the DC domain.

    Decided to have a peek at the catalog that MiGE sent me when I got my Big MiGE in. I did not see any DC offerings so i shot a quick message to Lisa over at MiGE early this week. After a few messages were exchanged, I ended up pulling the trigger and ordering 6x MiGE 80ST-M02430 in a Permanent Magnet without Brake configured for 48VDC. Nice part is that they already come with a 2500PPR Incremental encoder which is the better option when pairing with ODrive boards.

    Specs are as follows :
    Size : 80.4 mm x 80.4 mm x 151 mm ( 3.165" x 3.165" x 5.944 " )
    Shaft : 19mm
    Shaft Keyway : 5mm x 25m
    Weight : 2.9 Kg

    Rated Power : 0.75KW
    Rated Voltage : 48VDC
    Rated Speed : 3000 RPM
    Rated Torque : 2.39 NM
    Peak Torque : 7.1 NM
    Encoder Type : Incremental 2500PPR
    Insulation Class: Class F
    Safety Class : IP65
    Termination : Shielded Cables - 3.0M - No Connectors

    Leaving this here as note for future use to make life easy when wiring it up ;)

    Pin Out :
    Motor Winding Plue : U - Red, V - Yellow, W - Blue, PE - Yellow/Green

    Encoder Plug ( 15 pin ) :
    Pin # -> Function
    #1 -> PE
    #2 -> 5V
    #3 ->0V
    #4 -> B
    #5 -> Z-
    #6 -> U
    #7 -> Z
    #8 -> U-
    #9 -> A
    #10 -> V
    #11 -> W
    #12 ->V-
    #13 -> A-
    #14 - > B-
    #15 -> W-
  12. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well.. got an email last night that my ball screws have been shipped Friday and upon inspecting the receipt i realized they have sent me 2005's instead of 1605's, guess chalk this up win of the week :)
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  13. Adrian Culda

    Adrian Culda Member Gold Contributor

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    For those interested... MiGE 80ST-M02430 48VDC.jpg
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  14. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Hey guys... nothing new here.
    Did fail to mention that my servos have a 12 Day lead time to have them built to spec...
    Other that that nothing else showed up in the mail either :(
  15. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Mid Week update :)

    Happy hump day to all lol

    OMP Quick release arrived, 12 position rotary switches arrived along with what I thought was Arduino Nanos ( turns out they are STM32 Dev boards ) as well as the fused IEC Socket.

    DHL got back to me as well and they have finally setup a business account i can ship under and save some money when i need something brought in.

    All in all slow progress, but progress none the less :thumbs

    PS: Kids having all this time off from school managed to hammer my computer fairly steadily to the point where they are both streaming 4K movies off plex and is making this a tad sluggish and forced my hand to have to build another computer as NAS/Dedicated PLEX Server so i can have my local resources back at my disposal once again.


    UGH this year is turning into the year of 101 projects !!
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  16. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Hi everyone...
    Sorry been quiet lately but work has picked up and pretty swamped!
    So there isn't much to report, a few packages arrived, finally setup a DHL Business account and MiGE has my servos ready for collection. My original order of 1605's that was shipped as 2005's were "lost" and marked as delivered and thankfully it was insured, so now I'm waiting on replacement from the same factory and looking at another 14 days before they are ready. I have been doing some homework and spoke to a few decided this time around to go with 2010's in 1100mm length which they have offered to me as an upgrade over the fiasco with the lost shipment. This is what the dimensions are as well as they will be a keyway on the XX side with a plum shaft coupling on each end for high torque motors to match the MiGE 80ST-M02430 in accordance with the MiGE blueprint.
    674403a332e6cbc08b215a83ab76db3f.jpg
    Also was presented with a support bearing upgrade to the FK for a few bucks more so decided to go for it
    07401a1308d5d29f14095ef6a4aa8b28.jpg

    Other than that, I have ordered some more parts and soon will start making a daughter board for the Teensy V4.1 as my controller for the oDrive 3.6's. single point of control via CAN or Serial will be an option. Decided the best way to interconnect them would be a shielded twisted pair and the only option would be something with a standard and readily available, which I opted as the best choice for me would be CAT6 or CAT7 Ethernet patch cables. So ordered a few odd's and ends...
    20200626_201612.jpg
    The panel mount is going on the oDrive side and the male connectors will be cut off and will be directly soldered to the boards adding an easy way to connect each Motor Controller pair to the Main controller.

    Other than that progress has been slow on everything... including the NAS build that new had turned into 2 builds since my daughter decided she wants to build her own gaming PC with a Custom Watercooled loop and lots of EK goodies and a 2920X Threadripper along side a RTX2080Ti... of course dad has to help put it all together and get it up and running.
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  17. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well.. this never happened to me where a package showed up 4 DAYS FASTER than the estimated time !!
    Holy batman DHL !!
    Shipment was picked up at 1507 on Tuesday, June 30 in ZHEJIANG PROVINCE - CHINA MAINLAND and was dropped onto my doorstep today at 1413 !!

    Yes.. it was a tad north of the $450 mark with insurance and customs for 2 boxes weighing in a total of 21.5 Kg ( 48lbs ) but well worth it.

    Here's a few pictures :)
    106128323_602593854019487_9024375999049564208_n.jpg 79092920_703217297138133_8731799335644510100_n.jpg

    And a few extras they have included:
    107035067_1706790149504274_8813977531573694010_n.jpg 106069819_959103551196503_8875841367451723914_n.jpg

    I may change out the encoder plug for a DB15 or DB25 connector... but we shall ponder on that later on.
    first things first though!!

    That panel mount connector will be swapped over to the other end as they are retained by a small clip and will swap the housings so the motor side is male x male and the panel mount is female x female. This will make life easy when designing the Power Packs ( 1x oDrive V3.6 + 1 1000W 48V Power Supply ). This will it easy when setting 3 of these things up :)
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  18. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Well, lets get to work...
    Connectors were fairly simple to work with if you have a bit of mechanical background...
    106368870_407019650199744_2601485031745281283_n.jpg clip the retaining clip and remove, set nut shell aside...
    105482688_740879266685906_7219213376669435978_n.jpg Slide back protective cover and repeat on motor side to "recover" panel mount shell..
    106244173_312483320154032_5289586096490513368_n.jpg try not to disturb the 2 half's as pins are keyed and they only go in 1 way
    push pin into new nut housing, reinstall lock ring and solder back in place, slide protective cover back on. Make sure lock is fully seated before soldering! at the end of it all you should have something like this...
    105684457_294128251944255_5896213959927739755_n.jpg
    Factory on left, right side is my "fix", now can use the panel mount plug at power pack where it belongs.
    All power connectors have been successfully swapped and panel mounts have been set aside for the power packs :)

    Here's a better pic of the label on Servo
    JPEG_20200702_213528.jpg
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  19. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Quick Weekend update :

    Got an email from Tina Tang over at Wuxi HXH Bearing
    Guess my ball screws are shipping out tomorrow morning :)
    Grand total was $231USD ( $38.50 x 6 ) + shipping on my DHL account

    And that's another step closer to making my actuators !!!
    • Like Like x 1
    Last edited: Jul 7, 2020
  20. Adrian Culda

    Adrian Culda Member Gold Contributor

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    Woke up this morning and found this in my inbox :)

    ballscrews.jpg

    She was absolute delight to deal with and will definitely deal with them again, here's her contact info:

    Contact Name: Tina Tang
    Company Name: Wuxi HXW Bearing Co. LTD
    Products : Linear Motion Guide Bearing, Ball Bearing, Roller Bearing, Ball Screws
    https://wxhxh.en.alibaba.com/?spm=a2700.9014153.0.0.68d63e5f7GNNL6