DIY Linear Actuator design

Hi @motiondynamics as mentioned yesterday this is the option im introducing to my Actuators to make use of off the shelf Ball Nut carrier , I will need to drill and Tap an additional 3 x M5 ( 15mm deep holes) to the purchased block I think they are less than £5.00 each ..

The photo shows the 3D printed Rod Mount and there will be 2 Adjustable sliders to dial out excess ball nut carrier rotation.. also while I have the Actuator apart i'll had the Optical encoder GT2 40T pulley to the Motor Shaft .

Hi wannabeaflyer2,
congratulations for the idea you had, in this the Ballnut replaces the piece that you would have had to print in 3D, shorter waiting times to create the piece in 3D and print.
Two curiosities:

1) I read that the diameter of the steel tube is 18 mm inside and 20 mm outside (1 mm thick metal), so I suppose the diameter of the Ballnut attached to the ball screw is about 18 mm, which the Ballnut extra, it has an internal hole with a diameter of about 20 mm. Is it so?

2) The 20 mm tube, how was it fixed with the two Ballnut? I saw on the photos a piece of blue color attached with the tube, but I didn't understand the method of fixing (a passing screw? Or glue?)

Thank you

Hi @motiondynamics I just today did a drawing of the revised Adaptor which can be 3d Printed or |Made out of Ali / HPDE plastic .. Gimme a mo to photgarph the drawing and i'll add it to this post later , 9 Gotta find camera as I forgot to e-mail it to myself at home LOL ) .

My Steel tube has a 25mm od and the Ball nut is 28 mm The clamp has a hole reduction feature to match the chosen Tube ( Carbon Fibre . Metal whatever ) centrally to the ball nut and is locked in place with a Pinch clamp feature built into the adapter ,, ( as most of the force is applied vertically ) this pinch clamp idea should be Fine ..

the one shown in pic was done on cnc Lunch time so bit rushed but the idea is there , its clamped to the ball nut holder by x M5 screws and has a 6mm Nut and bolt at the base to clamp onto the tube to prevent tube rotation or being pulled away from the adapter block ..

Tomorrow i'll clean up the sketch and show a cutaway section of the assembly .. the loaded platform weight is transferred directly from the rod to the top face of the ballnut . well that's the theory ..

so the 3d printed version in blue was proof of concept the Black ( Delrin -Acetal Co Ploymer ) CNC version I think will be my choice ( mainly because I have access to this machine at work in free time .. my Home cnc is in bits ... making it bigger) but missing its use for stuff like this .. Cheers

you keep reinventing the wheel... my friend, you need to enjoy your 6 DoF more than you do building it @wannabeaflyer2 !!!

LOL @hannibal you have a very valid point , im a tinerer and love the making bits , But need to get on with getting the platform with these upgrades running , these were little upgrades that I had inn mind so I'd better get back to assembly after these last bits are made im missing the fun
So order was placed yesterday for AMC103 Sensors ( plastic took a hit ) and 3D printer will now be working and earning its keep Cheers Crew.

Hi Guys , As a master tinkerer and general I can try that kinda guy , I have decided to embark on a 5 DOF simulator using these ever popular AASD15A AC servo Motor Drive / Motor Kits .. always had this bee in my Bonnet about using encoders and this system looks like it will fit the Bill ..

I'll start a New Post for this new Endeavour so this is just a teaser , The new actuator I just built is a Derivative of my Trusty ol 6 DOF unit ( just scaled down to allow 150mm total travel ..

Cad drawings are now in last stages before release but those familiar with the MK1 version will see no major changes other than the Motor used and some small tweaks .

If these Motors Perform as well as they seem to , then im looking to swap my DC units out and replace them with these AC servos . Some changes will be needed to the New Motor Mounting arrangement but totally doable so I'll still Have 6 DOF setup and running and a 5DOF Car racing sim with Traction Loss..

Basically this new system will be Wannabe's version of the SFX unit but with my Tight arsed trying to save money mods LOL .

So without further ado here are a few teaser Pics ..

Doh Forgot the 1st Draft Cad Pic

Happy to report the 1st round of manual testing went greta actuator works a treat ,
Using my Barebones AMC128USB with AASD15A firmware and connected to AASD15 Controller via a Bread boared Lash up ..all ggod
Self Homing Works ,
No Limit switch required ( But these can b fitted if user needs them )
Next Step Simtool V2.04 Control Then I will be cooking with Gas as they say ..

Currently Only bought one controller / Ac Servo Set as test assembly, But looking good so far IE "does what it say on the tin " just like the advert

Just need to tidy Up the last few Bits on the Actuator .. NEW POST coming guys

One mor LOl then i'll bugger off for the day
Note speed turned down for these initial test ...This puppy will go a bucket load faster once I get brave enough

Soon you'll be here:

you are going from 6dof down to 5dof and a reduction in movement to 150mm

what were you reasons for these decisions

how much are the ac motors - they look like a nice unit, what is rpm ?

hi @Gadget999 sorry only just seen this post ,
you are going from 6dof down to 5dof and a reduction in movement to 150mm
after all this time messing about i sortta convinced myself (and wallet ) that seeing an nicely priced ac servo motor inc controller and built in encoder would make for an almost plug n play setup , all i need to do was conver my actuators form DC to these New AC servo motors and coulf still use my AMC128 usb setup it worked well enough for me and now bought AMC-AASD15 dedicated servo controller made by @Thanos .

what were you reasons for these decisions
i got seduced by the 4DOF darkside LOL ..been doing to much tweaking and not enough simming and i have now verified that i can upgrade my 6DOF actuators to AC with simple mod ( best of both worlds ) 6dof for flight simmimg and 4-5 DOF for cars ( that the Plan till may i have to sell one

how much are the ac motors - they look like a nice unit, what is rpm ?
well the AC servo motors and controller were each set at circa £195.00 + shipping and Buggering import duty LOL . can post a link next time and have to say they are great value for money one parallel port cable required and either sfx or preferably Thanos AMC-AASD15a and with simtools or FlyPT mover you'll have a single axis system up and running in no time .. just need to change a few parameters on Servo controller and your good to go

been messing with kartkraft and cant wait to get the cockpit made and mount my new sfx derivative Actuators..

Cheers

Oh Oh forgot to add ,as a warning i guess , only downside that seems to have been flagged up, is when using these ac servo motor and controller , there seem to be a high pitched noise (whine) in the background that annoys a lot of users

Lucky for me im deaf LOL and Old so this wont be an issue .. thought i'd mention it as you'll come across a few users that this issue spoils, what would otherwise be for them a great sim system/setup..

One hopes that with time someone will figure out how to work around this ( different people get affected and for some like me its a non issue ) cant guarantee what any visitors might hear though so it may well be an issue for people demoing the simulator when its finished ..

great work

Hi,

what a wonderfull piece of ARTWORK !!! Respect.

I am also dreaming and planing to build an actuator like yours.

Which motors are you using right now? I am wondering if nema 23 is strong enough or
did you use nema 34? Also, why not choose closed loop stepper for position signal? That would
have reduce your problems with the pot. Or does that not work?

I was wondering if wiper motors without gear directly mounted at the T16 Rod would also work
as a motor or are they to weak without gear? Did someone have experience with that?

Again, great work.

Regards
Rock

Hi @Özden Büyüksanalan i am currently using the ASD15 servo motor/ driver setup that most diy guys are using for SFX100/150 Type builds , moved away from DC motors as the price came within the acceptable level and a lot easier to configure and use . there are pro's and cons for any motor choice but for me the clincher was the encoder incorperated in the servo motor . even though its mains driven my 6 Actuator only pull < 10 amps so far and to be honset ive not looked back to dc . Still have all the gear but now will be selling stuff before long to buy more AC gear

I do understand your point.

I will try to customize a wiper motor to connect to a T16 rod. And for the positioning i will use
a 125 mm Fader if thats possible and enough movement range. Just designing a clamp for the
Fader to put on the main assembly of the Motor and Rod Shaft. Maybe it will work.

If, then we can set up a very very cheap setup.

Hi @Özden Büyüksanalan we all star somewhere in this DIY hobby and your in the best place for advice all over this forum . i have been through wiper motors , Wheelchair motors and gearboxex , and DC motor driven ballscrew etc and the only thing id say you need to bear in mind, is the weight , speed capability of your intended motion system, . pound for pound the ballscrew combo delivers but can be a bit noisey ( im deaf noise is not an issue LOL ) hey good luck with your project and welcome to the forum , i mean it when i say this is best place for info and feedback , its all good stuff and great sharing experiance

Hello, I am using linear actuator based on DC motor. For me, the price of servo motor is still too high! I feel that the linear actuator of DC motor is the perfect combination of price and performance! I don't know if my statement is correct, because I haven't used the linear actuator of servo motor, so I can't distinguish the specific performance difference between the two actuators.

Having used both, IMO the performance/easy of use difference is great. AC servo motors FTW. For a non balanced Rig (Stewart Platform etc) a good DC setup is actually not that much cheaper, once you factor in good quality motors, drivers, feedback and power systems. Don't forget that the price of a AC servo motor normally covers also the matched power supply/driver, fitted encoder, cables and connectors.

I am located in China. On Taobao, I can buy a cheap and stable DC motor driver board to drive my 24V 400W DC motor (the motor price is very low), as well as linear potentiometers with various stroke and low price. Moreover, the price of an 800W DC power supply is only 200rmb. So the cost of DC motor is lower! And this low-cost performance can fully meet my needs.