6 DOF compact Sim with rotary actuators

Hello everyone. I would finally like to introduce myself here today with my project. This is long overdue but unfortunately I haven't had enough time.

I started designing a year ago using fusion360. Over the course of time, I constantly improved the design and am now satisfied. It is an amazing feeling to have built such a machine.

The goal was to build a simulator for flying in xplane. But car racing also runs like hell.


Features:
- 6 dof hexapod with rotating actuators
- 750 watt ac servos from china
- 1:50 gearboxes 8 arcmin backlash
- CNC milled receptacles and ball joint rods
- Frame made of welded steel profiles
- Self-marriage does not have to be anchored to the floor
- 180 mm lever arm length
- Base diagonal 800mm
- Surge, Sway, heave + - 175 mm
- Yaw + - 40 °
- Roll pitch + -27 °
- Base weight 130 kg
- No external control cabinet, servo amplifiers are installed in the base
- Controller thanos amc usb aasd15a for the beginning
- Cockpit is the 3rd variant

Later I developed my own servo controller based on the experience I have gained so far. The aim was to improve the resolution for flying and to refine the motion cues to make the experience as real as possible.

Due to its actuator length, a simulator like this does not need a washout for roll and pitch angles and can therefore simulate sloping positions much better. One disadvantage is the non-linear movement due to the rotating actuators, but this is compensated for by the fast servos.

I will add more photos and links to the post soon. There will be a separate contribution for my new servo controller.

I am happy to answer questions. Many thanks to the motion sim community.

Now we have motion for, msfs2020

Thank you @flypt for mover Source





I think motion data output in xplane is still better.

Ok for comparisation here is a example flight with xplane motion cueing

feels much better

https://youtu.be/dpdCNX4XNXA

Hi
I have designed new rods with bigger joint eyes, there is no need for it but with the cnc milled adapters i get more moving space. 10° more angel .

There is a video with mover running and the phyphox Source. Aasd15a servos running at pn 98 with 02 so there is a Resolution of smaler than 0.01 mm at the end of the crank.

Have fun

Here is a picture with all parts i used to build this sim

Thx for contributing your project. As a fellow flight simmer, I’m always interested to hear views from people as to how authentic a feeling it is between rotary and linear actuators in flight simulation. So any feedback you can provide on that would be great , including the things that didn’t meet your expectations.
At some point if you are willing to share your Details and design of the sim, it helps people like me see what’s possible and achievable . Thx again for a very good looking rotary sim.

greetings, it's a shame that I can only answer now. at the beginning i asked myself what kind of actuator i should build for my simulator. The idea was decided by my bach who said rotating actuators would be easier to build. i can't make a comparison because i haven't had the opportunity to test a simulator with linear actuators. i think linear actuators would be better for short actuators. I hope I could help. i don't think that it would feel better to have linear actuators in my sim. my sim definitely feels insanely real. i had some fligths as learning pilot in the meantime.

Thx. The videos look awesome. Especially the landing effects. I would definitely like to explore more detail of your build and code when you have time. I think I have come to the conclusion that a rotary platform is best for my needs. I was sold when I saw how you could house the amplifiers and motors within the size base that you did. The platform also offers a sim that appears more realistic for flight than a seat, but I’m not sure. You also seem to have good resolution on your movements. So thx again for sharing

Hello Turbominer ! I have been steadily working on my 6dof project here in the states. I have replaced the motor cable (now 300mm) and redid the encoder cable to make it about 300mm long also. I bent my rods and I am making good progress.

Regards that looks very good you are on the home straight. Because of the code ask in us you can take the thanos controller which is very good for racing motion. i have developed my own which i would like to present in a new post here. I started development in January 2020 and can now present the 1st stable firmware and the associated pcb.

watch this

https://www.xsimulator.net/community/threads/new-6dof-aasd15-servo-motion-controller.15356/

@Motion4Sim Hi Turbo.....
Yes I am definitely in the home stretch of the project.
I have been highly motivated by Flight Sim 2020 .
I had to disassemble my 3dof rig to reuse the motors and stuff.
I am watching your commercial controller thread here also..
Thank you for your help

Hello,
I am following your project with attention, because I am also thinking about making myself a 6DOF like you. Could you tell me where you found the motors and especially the gearboces.
What do you think of the controller supplied with it?

thanks

@coyote
The motors should come with the AASD15 driver.
There are a series of servo drivers with different power ratings.
example: AASD15 is a 15amp controller AASD30 is 30amp.
A motor rated for 1KW and under would use the AASD15.
This is the motor / drive I am using.

https://www.ebay.com/itm/1000W-AC-S...CNC-Milling-/392911210990?hash=item5b7b5549ee

I am using a 20:1 speed reducer although the 50:1 seems to be more popular.
The specification you might look for is the backlash tolerance.
The ones I use are rated at under 10 ARCMIN.
https://www.ebay.com/itm/Nema32-Ser...t-19mm-/254686349503?var=&hash=item3b4c7d48bf

You should expect to pay about $300 USD for the motor/controller each.
And about $250 for a good planetary gearbox.

Good Luck !

Hi,
Thanks for your reply
Can you explain me why did you choose the 1kW motor ? isn't it too much power ?
2500 rpm with torque 4Nm and 20:1 reducer give 125 rpm with 400 Nm
Thanks, because i'm looking to chose my motors ;-)

I chose that model because of a thread on this forum from 2018. Grigory is the poster and he was one of the first people to use this type of motor. He also published the software that did work.. Not knowing anything about the AASD / 90st motorsystem I just copied his project.
https://www.xsimulator.net/communit...ct-and-no-linear-actuators-220v-servos.11839/

I believe 4 Nm through a 20:1 planetary gives 80Nm.
I think that 6 motors will lift 354Kg with a 125mm lever.
If I remember correctly Grigory calculated the speed at 1500mm/second
I am not sure how meaningful the 1Kw rating is.
I don't think it actually draws anywhere near a Kw in practical use.
The Thanos controller does moderate the "speed" of the movements other wise these motors could cause some serious injuries.
Hope this helps..

Sure you're right 4 Nm through a 20:1 planetary gives 80Nm , it's because i was looking at 100:1 planetary .
The hardest part now is finding the right supplier....

thanks for your help.

@coyote
These are the people I bought all my motors/driver/ and gearboxes from.
They were honest and I was able to get free shipping on stuff.
You can negotiate the price somewhat if you desire.
Sylvia seems to be a real person.. lol
Latest E-mail I got from them...
Dear friend,
If you need this servo kit, or other servo kits, please get back to me, I will offer you good price
My Email: service@fasttobuy.com
Mobile &WhatsApp: +86 157-682-52057
Thank you!

Sylvia
Fast To Buy Limited
Tel: +86-755-82546545
Mobile & WhatsApp: +86-15817450438
Email: service@fasttobuy.com
Skype: Ebayfasttobuy
Main Service: CNC Industry Solution; CNC Parts: HMI, PLC, Servo system, Stepper system, Spindle&VFD, Ball Screw&Guideway and so on
Check more on www.fasttobuy.com

thank you, i just wrote to him.

Hey yeah these motors are very powerfull.
i got them from alie express.

https://de.aliexpress.com/item/4000793515498.html?spm=a2g0o.cart.0.0.4a613c00nQ0bpQ&mp=1

please remember the specified torque is the nominal power 750w 2.37 nm and 1000w 4nm. the peak power at 750w is around 6nm - 7nm !!! my platform with 750 watt motors and 1:50 is 600mm / s fast and lifts 1200kg believe me that's enough for everything. but faster is always better. lol

edit :
but please note that the gears do not keep the power in continuous operation. only approx. 60-80 kg per axle

@Motion4Sim
Hi Turbominer.. I got the 6dof working nicely.
How is the controller board coming?
Here is a short video I made of my project