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My 6DOF project

Discussion in 'DIY Motion Simulator Projects' started by Damien602, Jun 4, 2020.

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  1. Damien602

    Damien602 New Member

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    Adelaide, Australia
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    My Motion Simulator:
    6DOF
    After reading awesome write ups from pmvcda (Flypt) and peacemaker I have decided to take the plunge and start building a 6dof sim.
    Knowing very little at the moment I am sure there is a huge learning curve ahead.
    The project plan is as follows:
    Build one actuator and test with electronics and software to ensure that i get an understanding of whether this will all work. Then I will build the platform while waiting on the parts for the next 5 actuators. Last, build 5 more actuators, assemble it all, then get to setup and test.

    Sounds simple when i write it like that - how hard can it be....

    So far have ordered
    • 550mm 1605 ballscrew.
    • Bearings to suit.
    • Motor and driver (BLDC-8015A+57BLF03)
    • Couplers
    • Arduino and electronics
    I will get aluminium tube for shaft and actuator structural elements in next week or so, once I can take day off to go out and pick it up from wholesaler. I am also looking for suitable power supply. I also need to print some 3d parts and once I have measured things accurately can design and print those.

    Meanwhile I will continue to research on this great forum.

    With luck I will remember to take pics and post build notes as I go.
    • Like Like x 3
  2. Ads Master

    Ads Master

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  3. Damien602

    Damien602 New Member

    Joined:
    May 29, 2020
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    21
    Location:
    Adelaide, Australia
    Balance:
    156Coins
    Ratings:
    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    Motor+driver and ball screw have arrived. Motor arrived from China in only about a week. Awesome considering most stuff seems to take more than 6 weeks at present.
    But without bearings and couplers I can't design the 3d printed parts.
    And even if I could design them, I cant print them - a replacement cooling fan I need for my 3d printer is on one of those slow boats :(
    Also bought PVC pipe today for the housing. Think it will be 65 mm pipe rather than 80 at moment.
    Still searching for power supplies. Will try a 1500W 24V PSU. Hopefully I can power 3 actuators and only need 2 power supplies. If not then may need to go with 3 supplies.
    A very slow start, but a start nonetheless.

    The next dilemma - whether to keep a log of the parts and prices...
    • Optimistic Optimistic x 1
  4. Damien602

    Damien602 New Member

    Joined:
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    Location:
    Adelaide, Australia
    Balance:
    156Coins
    Ratings:
    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    Today i did something dumb!!!
    I started tracking costs...
    My aim initially is to build one actuator and test. If all good then I can build more, or else change design, motors, etc.

    Here is where its at so far. Prices are totals, not per each, and are in Australian dollars.
    upload_2020-6-16_15-50-0.png
    • Informative Informative x 1
  5. Damien602

    Damien602 New Member

    Joined:
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    Location:
    Adelaide, Australia
    Balance:
    156Coins
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    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    My first project setback today.
    Went to buy aluminium tube for actuator. They were out of stock. New stock was coming but has been delayed.
    Ahh Covid you are thinking....

    Nope!! The last few days we have had some showers. They dont have a tarp to cover the material while it is on the truck and they don't want the aluminium to get wet.
    Maybe next week I can get some and start designing the printed parts.
  6. Damien602

    Damien602 New Member

    Joined:
    May 29, 2020
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    Adelaide, Australia
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    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    I created my design for the adaptor to fix the aluminium tube to the ball screw.
    This is first design and I have no idea yet if it will work, is right size, will be strong enough, etc etc...
    I am thinking it needs more thickness but will print one first to check dimensions.

    ballscrew adaptor2.JPG ballscrew adaptor1.JPG
  7. Damien602

    Damien602 New Member

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    My Motion Simulator:
    6DOF
    Just realised this design is missing the tabs to stop the whole assembly from spinning. :oops:
    Back to drawing board for me. :(
    The tabs will also be needed to trigger the upper and lower limit switches inside the actuator.
  8. Dirty

    Dirty Well-Known Member Gold Contributor

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    Hey :)

    You can get away without the tabs, if the rod and all of its upper connections can hold the torque of the motors. The ballnut itself then functions as an axial bearing. The error introduced this way is negligible.

    Post some more pictures of the design :)
    • Informative Informative x 1
  9. Damien602

    Damien602 New Member

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    My Motion Simulator:
    6DOF
    thanks. I may consider that.
    The design will have internal rails to hold the actuator together so using them to stop twisting isn't a big deal. And unfortunately I still need some sort of stops to work upper and lower limit switches so a redesign is needed regardless.

    As far as more plans...
    They are all in my head at the moment so nothing on paper yet. This probably isn't the best way to work but its working for now. I will post more bits as I design them though. Unfortunately I need components so i can get exact dimensions for the next parts to build - top and bottom bearing holders.
  10. Damien602

    Damien602 New Member

    Joined:
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    Location:
    Adelaide, Australia
    Balance:
    156Coins
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    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    Back to drawing board...
    Was attempting to design a motor mount and bearing holder last night and discovered that the FF12 bearings have a similar hole mounting pattern to the NEMA 23 motor. Unfortunately the bolts would interfere with each other such that I would need to make 2 pieces and then bolt them together to make it work. I am worried that with the mounting holes, the centre hole and then the holes to bolt two different brackets together that the assembly will not be strong enough.

    Solution - new bearings.
    Have just ordered kfl001 bearing and will try them out instead. The new housing and motor mount design is certainly going to be easier.
  11. Damien602

    Damien602 New Member

    Joined:
    May 29, 2020
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    21
    Location:
    Adelaide, Australia
    Balance:
    156Coins
    Ratings:
    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    Heading back in right direction... New motor mount and bottom bearing has been designed. These now bolt together with the 4 motor mount bolts.
    I may try and print them in one piece but not sue if that will improve strength or just add more complications with fill.
    Either way, until some the needed parts arrive I cant get or confirm exact measurements and cant print and test parts for size and fit.

    upload_2020-6-26_11-0-25.jpeg upload_2020-6-26_11-0-16.jpeg
    • Like Like x 3
  12. Damien602

    Damien602 New Member

    Joined:
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    Location:
    Adelaide, Australia
    Balance:
    156Coins
    Ratings:
    +9 / 1 / -0
    My Motion Simulator:
    6DOF
    Another week patiently waiting for parts to arrive before i can actually start building stuff properly.
    A couple of lesson learned so far. I ordered bearings via Ebay from England but seller only had 3. I chased around locally and found a supplier. They could supply 10 for the price of 3 that I bought from Ebay.
    Lessons - shop locally first and do plenty of research into what is available locally!!
    I now have 13 bearings on the way.
    The price is also steadily increasing. So far $845 for parts. For smaller parts I now have enough parts for 6 actuators - assuming the first one works as intended. Nuts and bolts are also looking like they could get expensive!
    Lesson - dont overlook the small stuff if you are budgeting.
    • Like Like x 1