Showroom Compact AC Servo 6DOF Rotary Stewart platform

A compact 6DOF platform I have been designing/building for the last 2 years, wanted to finally get it properly documented here, as I used this site as a wonderful resource that help guide me to my ultimate design. The design focuses on being compact in size yet still toss a rider around like a ragdoll...

Rotary Stewart Platform using 6 - 750 W AC servo motors w/50:1 high precision planetary gears.
Custom PCB that hosts a ESP32 microcontroller for interfacing and controlling of the motors.

It's also very much so... Bolted to the concrete floor!! It would leap into the air majestically otherwise




The project is on Github, PCB, platform code and major parts used, so to help anyone else in their hunt.
https://github.com/knaufinator/6DOF-Rotary-Stewart-Motion-Simulator

My Youtube Channel - Subscribe!
https://www.youtube.com/channel/UCm_IVsEpLjsR-aZIYZF6-_Q

Overview of platform


iRacing


GTAV


NoLimits 2


Dirt 2.0

Build Album​

Chassis was created around the seat itself


Threaded bungs held in place by a jig


Eye balling orientation


Welding the Chassis to the bungs


More,.. Eye balling orientation


First mating of my gear and motor trial


Imagining more motors and lots of more work to do....


Coped tube ends so they can be welded as cleanly as possible


Seat bracket made, all that eye ballin payed off...


Prevent rust, paint protection.


mocking up pedal box area and slope


Test mounting of pedals for sizing chassis


Pedal Bracket start


Helper


Pedal Bracket END!


Welding up the bottom pedal box brace


Back in place on the jig for more modifications


Welded Pedal bracket onto chassis bottom brace


First arm assembly - with High misalignment heim joints


Welded up the top section of the chassis that will hold the monitor and wheel


Shifter, custom ebrake, and tiny keyboard solidly attached...


Tactile transducer bracket...


Tactile transducer bolted to frame of seat


Newer gear(less backlash)/servo sitting on a 100 pound steel plate


Fabricating Gear bracket 1/4" steel plate


Welded first Gear bracket onto steel plate


2x3 inch steel rectangular tube, to lift the platform off the ground


Mocking up the bottom feet area,.


Gear/motor in place on base for first time -- Giggidy,..


Needed the base to be higher than the rectangle tube would allow, thick steel tubing for an extra few inches


Pre welding mock up


Welded and painted


Gear bracket support added so no flex occurs


More Brackets


More welding


oh snap,..This is pretty


Rust protection!


First swing arm in place 7 1/4" long


Got a tiny server case to use to mount all of the AC Servo power supplies.. now to figure out how to stuff it all in there...


Running the wires for 220v and distribution blocks


Filling it UP!


Swing arm production line...


AC Servo control box all wired up and TURNED ON!!!!


All motors mounted for first time


Adding threaded bungs to the swing arm for attaching the chassis platform/arms


Lifting the base onto the threaded anchors in the cement floor. using a car jack...


By this time I needed to mod the wheel area for a new Fanatec wheel,... so I hacked of what I did to start over


Welded a extension on to chassis for Fanatec wheel


Blower Fan with 90 degree (car air intake) tube for wind feels


Rear surround speakers


Oh look,.. its almost done,... Giggidy...


Monitor bracket, welded to chassis. (Universal Vesa mount, then I took a angle grinder to it to get the piece i wanted...)


Magnetic limit switch installed


Beauty shot of the motor base


"My muse my flame"


Green screen room!!!


Needed a room for the rig, May as well make it green!


Small monitor attached below the main monitor for SimHub, or video recording display

Nice!! Welcome!

I'm working on a linear 6dof setup, but this looks good too! Nice video's!

Be sure to mention that the platform is bolted on the floor...

Lol, post updated!

I recently added a solid monitor bracket to the motion rig, made a time lapse of the process.


I have ordered 2 new 50:1 gear boxes to replace the 2 gear boxes I have in the rear. They are older and have more backlash than the rest, 12 arcmin vs 5 arcmin... its enough of a difference ... to get me to spend 500 on replacing them,... in the name of perfection.

Congratulations , very nice achievement , Thank you for this sharing

GT Legends tuned up and ready to go.

I want to build a Cobra kit car,.. so I am getting my practice in

You have really created a fantastic piece of hardware. Congratulations!

I also love your green screen videos. My favorite is the rollercoaster ride in this post, where I get the impression that your rig does indeed sit on the rails. Amazing!

Thank you!, compliments never get old!

Love the sim! Was wondering how you liked the reclined position for your rig, is it optimal for you or would you prefer a different geometry if you did it all over again? I'm considering doing a similarly reclined rig only with actuators and your rig looks like a good place to start copying =)

Thanks!, The reclined position was intended to balance the load out as much as possible when a rider is in the seat, to counter balance the mass of the monitor/pedal box area. Once you are in place, the reclined position feels natural, and I would do it the same or similar if I was to do this again.

good job

IMO your cranks are a little long,dont you have any problem with your motors power for lifting.
anyhow nice setup mate...

Not at all, the longer the swing arm, the more movement I could get out of it. I first did quite a bit of testing to make sure that a motor/gear could handle the weight... I found that a single motor/gear could lift a rider ~14 inches in less than a second, with a 7.25 inch swing arm. I am a skinny guy @ ~180lbs, but I have had dudes ~250lbs in the rig and it handling just the same.

good mate.i calculate you have more than 715 N turq at the tip of any actuators,

nice green box.i think this is the first time in this community such a video to show clear rig motion with the game