[in progress] 6DOF compact and small footprint

Just in: 360° hall sensors, they fit my couplers perfectly, which will be mounted directly on the backside of the customized shaft. I have no levers for the shaft yet, but have a friend that can probably design and cnc this at his company. But that's for a later time.

I also made some progress on cabling yesterday. I must say I underestimated the work/time this takes. But it's coming along nicely.

So I tested the PSU, all seems to be working fine, however the fan is quite loud and I think it's spinning at 100% duty cycle all time. I made a video about the noise compared to a mouse button click. But I am not going to upload it. It's very loud just trust me I do not have decibel meter (unfortunately). With headset on and some race sound it won't be an issue I suppose but still I think it's way to loud and should not have to be this loud. So that's not so nice in my opinion about this PSU. I opened the back of the PSU and
there is the factory default fan named NMB - 3110KL-04W-B79 (3 pin connection) and specs say it's 40.0dB max. Will have to replace it with a quieter one.

@Rens Just make sure it has the same (or higher) air flow.

You think it's going to be issue otherwise?

Hmmmm....I searched the specs for both and the airflow is almost identical so... you should be ok.

I looked at the specs myself I found this:
Old one: 45.9 CFM (1.29m³/min) 77.40m³/h
New one: 26.3 CFM (0.74m³/min) 44.45 m³/h

Where did you get specs from?
Personally I am not to concerned about it since the thing runs at 100% and there will be plenty of airflow in my opinion. But perhaps I can find another fan that does not go above 20dB. I havem't ordered the fan anyways, was planning to do after dinner today.

@Rens
https://www.bequiet.com/en/casefans/506

I don't know exactly how to read it but it states: 26.3 PWM / 44.45 CFM


Edit: Never mind. I was reading it wrong. You are right

I decided to order a couple of fans from different bramds (see below). They all come with different specs so will see which one is most quiet compared to good airflow.

Old fan replaced with new fan. I went with the NF-A8 FLX, because the others had not enough airflow in my opinion. This one does, and it's plenty quiet You can clearly hear the difference in the before and after video's.

Before:
https://drive.google.com/file/d/1Xt0bRnmd8g-57E26JD_VWKrW5MjWz5Bu/view?usp=drivesdk

After:
https://drive.google.com/file/d/1XopHUVLacVb8lGkGLsavrtPuJ9mYVyrc/view?usp=drivesdk

Your timing for small dc rig is just perfect. I had to abondon plans of servo drive 6dof, and get back to 6 wheelchair motors, wich are around 200-240w so thats really close to your power specs, I thank you for your detailed shopping list since I couldn't find hall pots for decent price it helped me a lot. Before making mine I will start my thread on it since Im not sure how to calculate dimensions to give motors easiest work load and still have to do some research in that regard

Hi, perhaps I am indeed (I don't know). Regarding the dimensions I am guessing you are referring to the levers for on the motors? I guess you will have to try this out. I probably start with a 50mm lever or something like that and see how that goes. I can't give you any advice since I am a noob at all of this myself. This is my very first rig. Will see how it goes, I still haven't received the motors yet, I hope I will soon

Still haven't received motors... (after 2 months of ordering). I had contact with Sunrise motors. And they asked me to pay another 90 dollar for shipping due to covid or something. They said that the motors are now finished and ready for shipment. I have paid the extra 90 dollars. But honestly I am not happy with the way they do business since their terms stated that the motors would be shipped within 25 days after first deposit.

Anyway, I figured I should just get started with the top frame already, and not wait for the motors, because who knows how long I have to wait.

A week ago I received my racing seat, the simucube 2 sport, Heusinkveld Ultimate pedals, and shifter and handbrake. So I was able to create a new design from scratch with exact measurements. I then ordered all the steel with the correct measurements cutted in the correct length. I have been welding, cutting and drilling holes for a couple of days. The result being that I have completed the top part of the rig. My initial measurements where not completely satisfying when seated. The steering wheel was too close and to hight. So had to alter it a little bit. But now it's pretty much perfect I already have done some races (way to much fun honestly).

Yesterday I connected the VR headset (HTC Vive around 4 years old by now). When I bought it 4 years ago I only used it a couple of times to play "Onward" (FPS game, also a blast). But other than that never really used it ever since. Now it comes to good use again! I installed KartKraft yesterday and man, what a ton of fun that was. Very realistic. Because since 4 years the technology for VR has improved a lot, I might consider upgrading to a better headset, but for the time being the HTC Vive still does a great job!

Below some pictures of the progress of the build itself, and the result so far

@Rens
Sorry to hear that you had problems with the motors.

Your build is starting to look great.

I received motors today, that's really fast shipping. So I am happy about that . I am trying to find a good way to attach hall sensors right now. Some pictures for now, as you can see the shaft was customized to fit the coupler/hall sensor nicely

Great to hear that.

I cutted a round steel plate with 4 holes that go to the side of the motor to fix the sensor.

Could you share some pictures with me, for better understanding?

Something like this

Oh that simple he, that's probably the easiest and best way to go about it. Very solid, thanks for the tip/share

So I have been making good progress. Worked f9r 2 days on the code to improve it. It all seems to be working quite good/smooth (without any load that is). Regarding pot attachments, I used "beer" coasters. Theybseem to be doing a perfect job. They were round at first but had to cut them of, otherwise the plates that connect/hold the motors together wouldn't fit. But otherbthan that I didn't camr accross any unseen/unplanned issues.

I have tried to put pressurebon the motor with my feet/leg amd the amp measured was max 1.5 if I remember correctly. The motor driver was warm after some time under load but you coukd easily touch witj your finger.

I am still planning on adding gas springs to help with load. And maybe add some heatsinks to the drivers and maybe a fan. But will have to see how the test goes with the rig without a person in it before I add more weight. I probably have to adjust PID a little bit too based on the total load.

Here are some pictures and some videos:

@Rens

Looking great!