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My first 2DOF racing sim project

Discussion in 'DIY Motion Simulator Projects' started by 427Cobra, Aug 18, 2019.

  1. 427Cobra

    427Cobra There is no substitute for cubic inches

    Joined:
    Dec 26, 2018
    Messages:
    31
    Location:
    Sweden
    Balance:
    353Coins
    Ratings:
    +16 / 1 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Hello!

    I'm from Sweden and have started a 2DOF racing sim project which will be done in three steps. It's a long term project and the goal is to get it ready before the end of the year.
    The project thread is made in three main posts, one for each step, to keep them close to each other and easy for you to follow, and then I will update each one with new information when there is something to show about the progress.

    My project will be done like this…
    Step1: The construction of the electrical control unit started from a modified Dell server chassis from which I used the PSU's and put the rest of the electrical components inside the cabinet, like the JRK G2’s and other parts. By using the server chassis I’m able to ”plug-and-play” the PSU’s without any soldering if they need to be replaced, but also get a nice looking cabinet.

    Step2: A small test rig using 12V/2W worm gear motors. This rig will help me to play with the settings to learn how to make the basics settings before I start the setup of the full size rig.

    Step3: A full size rig based on a modified fixed FK Automotive sim racing seat plus welded frames and reinforcements. 200W 12VDC 50:1 worm gear two shaft motors and hall potentiometers and JRK’s will control the movement.

    Let’s start the project journey!!!


    Step 1 – Cabinet with all electric and electronic stuff.

    1. Starting point, an old Dell server with two 12VDC, 64Amp, Power Supplies. A perfect chassis to start from.
    [​IMG]

    2. Label on the power supply.
    [​IMG]

    3. The old server chassis was too big and needed to be resized and rebuilt after the old electronics was removed.
    [​IMG]

    4. I reused the front panel from the old server and kept the two slots for the power supplies. The front panel will get the main power switch.
    [​IMG]

    5. Some unused metal for recycling…
    [​IMG]

    6. The power supply contacts will be reused and be put back in the chassis when the circuit board is removed to be able to ”plug-and-play” the power supplies without soldering or mechanical work.
    [​IMG]

    7. The contacts are not soldered and can be removed carfully from the circuit board by a screw driver. Start with a small one to open a gap and then use a bigger one to ease the contact from the circuit board.
    [​IMG]

    [​IMG]

    8. A buddy made brackets in his 3D printer for the Pololu JRK G2 12V27
    Download the STL file from ... https://www.thingiverse.com/thing:3837389
    (too large to be uploaded here)

    [​IMG][​IMG]

    9. The rear side of the cabinet got connections for the USB connection, motor power outlets, potentiometers, switches for PSU fan speed, emergency stop circuit and main power input. And the front panel got a main power switch witch control the mini contactor (in the middle of the chassis).
    [​IMG]

    10. The contacts for the power supply in place and connected.
    [​IMG]

    11. View of the componets. Note that no heat sink is needed on the JRK G2’s.
    [​IMG][​IMG]

    12. View from the back of the cabinet with all components in place and ready for test.
    [​IMG]

    13. Ready! Before and after…
    [​IMG]


    Today status: All components has been tested and works as expected and it’s ready to be used, first for the mini test rig and then the full rig :)


    Main components used…
    2 x Pololu JRK G2 18V27 USB
    1 x USB hub
    1 x Fuse holder + 30Amp fuses
    1 x Main power contactor. Schneider Electric type: LC7K0910M7 (230VAC control voltage)
    2 x Power outlets/plugs for motor control
    2 x Switches for PSU high/automatic fan speed
    2 x Microphone outlets/plugs to connect the hall potentiometers (3-pole)
    1 x USB outlet (USB connections on both sides)
    1 x 230V AC main power input
    1 x Main power switch. Green illuminated 2-pole, 2 way. Schneider Electric type XB4-BK…
    1 x 230V outlet/plug for the external emergency switch. (switch of the main power contactor control circuit)


    Suppliers…
    1. Contacts and Pololu JRK’s
    http://www.tme.eu
    2. Schneider Electric components from a local shop

    Attached Files:

    • Like Like x 2
    Last edited: Aug 30, 2019
  2. Ads Master

    Ads Master

    Balance:
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    Ratings:
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  3. 427Cobra

    427Cobra There is no substitute for cubic inches

    Joined:
    Dec 26, 2018
    Messages:
    31
    Location:
    Sweden
    Balance:
    353Coins
    Ratings:
    +16 / 1 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Step 2 – Mini test rig


    The small test rig use 12V/2W worm gear motors and will help me to test that everything works as expected and to play with the settings to learn the basics before I start the setup of the full size rig.

    So far it has not been tested, focus now is to make the full size rig because I have limited time to spend on the project in the coming months.

    1. The small worm gear motors, flexible couplers for the potentiometers and M6 rod ends arrived.
    [​IMG]

    2. 12VDC, 65rpm, worm gear motor
    [​IMG]

    3. One of the two hall potentiometers.
    [​IMG]

    4. The test rig, and of course an AC Cobra model on top if it :)
    Almost complete except two rod ends and rods.
    [​IMG]

    5. A closer look. The u-joint is from a ½” tool set.
    [​IMG]


    Main components used…
    2 x Worm gear motors 12VDC 65rpm
    4 x M6 Rod ends
    2 x Hall potentiometers
    2 x Flexible couplers (between motor and potentiometer, 6mm inner diameter)

    Suppliers…
    1. Motors
    https://www.aliexpress.com/item/0-6...290.html?spm=a2g0s.9042311.0.0.61084c4dbdVWm5
    2. Hall potentiometers
    https://www.aliexpress.com/item/2PC...059.html?spm=a2g0s.9042311.0.0.a1a04c4d2clzMB

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    • Like Like x 1
    Last edited: Aug 18, 2019
  4. 427Cobra

    427Cobra There is no substitute for cubic inches

    Joined:
    Dec 26, 2018
    Messages:
    31
    Location:
    Sweden
    Balance:
    353Coins
    Ratings:
    +16 / 1 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    Step3: Full size rig

    The full size rig is based on a modified fixed FK Automotive sim racing seat plus welded frames and 200W, 12VDC, 50:1 worm gear motors. The reason why I modify a fixed rig like this one is to save time on the construction and to get a flexible starting point to test wheel and pedal possitions etc. before the welding and final measures are fixed.

    1. The FK Racing seat and fixed rig arrived
    [​IMG]

    2. Unboxing
    [​IMG]

    3. This is how it looked like before the modification started
    [​IMG]

    4. Worm gear motors (200W, 12VDC, 50:1) and couplers arrived from China.
    [​IMG]

    5. Motor specification and dimensions. Motor type KS-80ZYJ08-12V-200W-50K
    [​IMG]

    6. Before modification. The frame is a very good starting point and will save me a lot of work :)
    [​IMG]

    7. The original frame is not stable enough and needed some reinforcements, both for it’s stability and to get mounting points for the rods. An additional frame under the moving part of the rig is made of 25x25x2mm, and the frame in front on the picture is the one to be on the floor, made of 30x30x2mm tubes.
    Reinforcements and fixing points for the rods are also made in 30x30x2mm.
    [​IMG]

    8. The frame for the u-joint is made of 25x25x2 mm but is not welded in the correct place yet because the balance point is not measured (only placed there for the picture). Note the possibility to fine tune balance point and possition of the u-joint if needed after the rig is finalized.
    [​IMG]



    Main components used…
    2 x Worm gear motors KS-80ZYJ08-12V-200W-50K
    4 x M10 Rod ends
    2 x Hall potentiometers (same as used in the test rig)
    2 x Couplers (between motor drive shaft and motor lever)
    1 x Emergency switch in plastic box. Schneider Electric type xxx
    1 x Volvo 240 U-joint

    Suppliers
    1. Motors KS-80ZYJ08-12V-200W-50K. 12V, 200W, 3000rpm (no load speed 3600rpm), 50:1 gear
    https://dakemotor.en.alibaba.com/pr...ml?spm=a2700.icbuShop.41413.48.789b3f0cYfH1qc
    2. Racing seat
    https://www.fk-shop.de/en/Tuning/Sp...me-consoles-imitation-leather-black-blue.html
    3. Rod ends
    https://www.aliexpress.com/item/10m...476.html?spm=a2g0s.9042311.0.0.a1a04c4d7Cc8fT

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    Last edited: Nov 14, 2019
  5. 427Cobra

    427Cobra There is no substitute for cubic inches

    Joined:
    Dec 26, 2018
    Messages:
    31
    Location:
    Sweden
    Balance:
    353Coins
    Ratings:
    +16 / 1 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    My project is slowly moving forward and it’s time to add some updates on what I have done since last time I updated this thread.

    9. The moving part of the rig is ready. Made two front brakets to be able to change the distance between the brakets and balance point.
    [​IMG]

    10. Construction of the lower fixing point for the u-joint on the frame.
    [​IMG]

    11. The u-joint and column in place.
    [​IMG]

    [​IMG]

    12. The upper u-joint fixing point is adjustable to fine tune the balance point if needed.
    [​IMG]

    13. Approx location of the motor with enough space between motor and frame for the movement. The motor mounts will get two possitions to be aligned with the two upper brackets for the push rods.
    [​IMG]


    The construction is still ongoing ... adjustable motor mounts and push rods are next to be done.…more info and pictures to come later…

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    • Like Like x 2
  6. 427Cobra

    427Cobra There is no substitute for cubic inches

    Joined:
    Dec 26, 2018
    Messages:
    31
    Location:
    Sweden
    Balance:
    353Coins
    Ratings:
    +16 / 1 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    It's time to make an update of the progress of my project.

    14. Construction of motor brackets. Used 15x15x3mm and 30x30x3mm to get it stable.

    [​IMG]
    15. A 30x5mm is welded to the motor shaft couple on which the motor lever is bolted for easy exchange to a lever with different CTC distance if needed.
    [​IMG] [​IMG]

    16. The motor has two fixed locations for the bracket on the frame and can be moved to change the pitch movement if needed.
    [​IMG]

    17. Left side is done. Note the two fixing points for the motor bracket and the rod to be able to change the pitch movement. Hope the possibility to change the pitch and CTC on the motor lever will make it flexible enough to fine tune the movement.
    [​IMG]

    18. The mechanical construction is now almost done :)
    Final step is to add fixings for the Hall potentiometers, a stabilization bar between the motors, cable ducts and the box for the electrical connections before disassembly and painting
    [​IMG]

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  7. 427Cobra

    427Cobra There is no substitute for cubic inches

    Joined:
    Dec 26, 2018
    Messages:
    31
    Location:
    Sweden
    Balance:
    353Coins
    Ratings:
    +16 / 1 / -0
    My Motion Simulator:
    2DOF, DC motor, JRK
    My project is moving forward, the rig is now disassembled and painted. Just started the final assembling by adding an electrical connection box to be able to disconnect and remove components easily without soldering of cables.

    19. Painting done.
    [​IMG] [​IMG]

    20. The motors and the new electrical connection box are in place.
    [​IMG] [​IMG]

    [​IMG] [​IMG]

    Next is to mount the moving parts of the rig and the Logitech racing wheel. Then the fun, but probably time consuming, part will start to learn how to set up the software and to get it work :)

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    Last edited by a moderator: Aug 1, 2020