Showroom 2 Dof DC Motor Rig with Item Profile

Hi,
i had many years a stady rig and some time ago i build my first simulator out of wood. It was a lot of fun at building phase, but it didn't worked very well. NowI thought about building a new one, because I have all of the parts.

This time I want to make nice so that the result is som fun in gaming too
I decided to make the rig out of aluminium Profile, because i think it's a great system. I never build something with this Material.

I've made a simple sketch in setchup to show you what I want to build.

Pictures and Videos of the Rig:








1. Electronics

The Sim is driven by arduino nano and one Monster Moto per Motor. Software I used is Smc.
The box is designed to quickly plug of the sim to take it to the workbench for service. All parts are exchangable very quick.
The Killswitch can be mounted on top of the Platform as Emergency shut down button and also will Provide 12v for other Dashboard applications.



Shopping List:
2x HP DSP 600 PB Powersupply
http://www.ebay.de/itm/2-Stuck-HP-D...3-001-575-W-/321498985600?hash=item4adad53480

2x Monster Motor
http://www.ebay.de/itm/310780916584?_trksid=p2057872.m2749.l2649&ssPageName=STRK:MEBIDX:IT

2x Xsilence Coolers mentioned py Pit
http://www.ebay.de/itm/Xilence-Nort...sink-Cooler-/121101706990?hash=item1c323966ee

2x DC Motor (In my case the one from Motion Control Products, 60:1)
http://www.ebay.de/itm/12V-DC-Geare...805?pt=LH_DefaultDomain_3&hash=item1a02b18bdd

2xHal effect pot
https://hbe-shop.de/Art-2319662-HALLSENSOR-02V-20V-BIS-10V-PIN

2x Relays 12v min 30A
http://www.ebay.de/itm/Hochstromrel...0A-Wechsler-/151617106861?hash=item234d1573ad

1x Killswitch
http://www.ebay.de/itm/Kill-Switch-...70?pt=LH_DefaultDomain_77&hash=item5662179ac2

1x Arduino Nano
http://www.ebay.de/itm/Arduino-Nano...-RS232-Chip-/331614631556?hash=item4d35c5b684

1x Fusebox
http://www.ebay.de/itm/4-Fach-Siche...en-Schraubb-/121668761016?hash=item1c5405f5b8

1x Box to store electronics
https://www.luedeke-elektronic.de/p...use/Gehaeuse-Kemo-G108-210-x-160-x-66-mm.html

2x Connectors for Pot wires 3 Pin ( I used Binder 711 Series)
http://www.esto-stecker.de/binder-flanschdose-serie-711.html

http://www.esto-stecker.de/binder-kabelstecker-serie-711.html

5x Cable screws (I don't know the word in English)
http://www.ebay.de/itm/1-10-20-50-S...ter-PG-/121474599978?var=&hash=item1c48734c2a

Some Cable shoes in different Size
http://www.ebay.de/itm/480er-Kabels...stecker-Set-/171400603599?hash=item27e845a7cf

4x EC5 Connector
http://www.ebay.de/itm/5-10Paar-EC5...-Plugs-/191611139603?var=&hash=item2c9ce9f613

2x Pair of connectors 6 pole
No link avalible i had them laying around


Also you need some soldering tools, Shrinktube, Saw to cut the case etc.
I also used some mtal mesh for the Fan holes and some Carbonfoil to wrap the whole box up.

Everything is connected like shown in this schematic.


There are no connection from Arduino to Monster Moto or pots included. This depends on what Method you use your MM. I used mine like descriped very well in the Post from Pit.
http://www.xsimulator.net/community...cts-as-a-single-motor-driver-more-power.5482/
The 6 Pole connectors are used for connection between each MM and arduino.

For more Information about Arduino and Monster Moto take a look in the Faq
http://www.xsimulator.net/community/faq/motor-driver-for-arduino-compatible-controller.11/category

The Psus are prepared like shown in the Picture. The cables are soldered to the contacts and little jumpers making the connection to bring the psu alive.



2. Metal works

If made some Motorholders out of Aluminium. There is a lilltle bar welded on one side to prevent the holder from bending. I used 6mm thickness , 100x100mm aluminium profile. The lever is made out of steel and allowing multiple mounting points. The pot holder is made out of 6mm plexiglass bended 90° with a heatgun.



For the Ujoint I used a cardan joint from a Bmw and welded some steel plates on.

Overall design is not bad at all mate.

Centre pivot you will find may need to move backwards towards the seat, I would make that section adjustable, profile allow you to do this too.
Motors in current position will have to be fairly strong , wipers wont cope for long.
You CG is very high from the centre of the pivot too, I would advise lifting the centre of the pivot to as close to the base of the chair as possible or even equal or higher than the base of the top, this means less work for your motors, meaning better movements once in motion.

Sorry to seem picky but a nice start.
P.S there should be some pics on here on several profile rigs, if I remember I will post back.

Hi,
thanks for your reply.
Take a note that this is a basic scetch. I didn't look carefully at point of Gravity. I'll make this adjjustable later to find the right point.
Also the u joint is an example where to place.
By CG you mean center Gravity? sorry but i don't know. I now have a ujoint out of a ne Bmw f10 cardan unit I made both ends in equal length. But i take your advice and cut the upper section that will be mountet to the seatbase. So like in picture the joint is 180 rotated. thn the lower part will be longer.

I'll try to get some motors but it's harrd to find some for a moderate Price in Germany. I contactet Telfel here from the forum because he sells 2 motors that would be right i think http://www.xsimulator.net/community/threads/motion-rig-hardware-for-sale.6057/

or would this ones be better http://www.ebay.de/itm/380956910371?_trksid=p2060778.m1438.l2649&ssPageName=STRK:MEBIDX:IT

If someone knows a good Motor source in Germany let me know.

For the design, i want to make it very stable. But for me it looks very heavy in the front section and i have a small room. So something looking lighter would be better

Cool did take note its a basic sketch so was just portraying a couple of ways to bring it to reality for you.

For you configuration I would use the second ones - 12v at 60:1 meaning you can run Jrks or the Ard .
The other to gain the power needed to lift the whole rig and you , you will need to run them hard at 24V.

A member has built one like yours in the past , will post back his link on his build, will help you.

Found it :: check this out, and I think if you read through you will find he changed his motors for higher ratio. http://www.xsimulator.net/community/threads/diy-2dof-simulator.4793/

Hi,
thanks for pointing me to this thread. Very informative. Also it let's me think about wheel holding again. in his thread this solution looks very nice and stable too.
So i will definitly use the 60:1 ones but than i need some extra time to get the money. Maybe i'll need a second Hbridge for these motors. Or maybe directly some new controllers but this is out o price range.
How much current is such a motor ratet? Currently i use this H bridge http://www.pololu.com/product/2502
Will 30A per motor be enough?

So i got bad news. The shipping Cost for the Motors are so High that i can't afford it.
the 2 Motors will cost something about 300€ with shipping and import taxes =(

So i need an alternative. On ebay i found a reseller of wheelchair Motors. He's loctated in Germany would be much better for me. Someone got any experience with wheelchair motors? I just contacted the seller if he has any more infos for the motors.
This label is on the motors

http://i.ebayimg.com/t/2x-AMT-Invacare-10kmh-Getriebemotor-Winkelgetriebe-Magnetbremse-24Volt-TFS952-/00/s/Nzg3WDE2MDA=/z/q0MAAOSw0vBUiVs7/$_57.JPG

http://i.ebayimg.com/t/2x-AMT-Invac...00/s/MTA0N1gxNjAw/z/smUAAOSwAL9UiVs3/$_57.JPG

but nothing about gear ratio and rpm. On manufacturer site there are some infos. Not about this spezific model, but about the series.

Rpm will be 105 - 170
300 Watt
24V
Gesamtbelastung bis max. 160 KG (i try to translate, Max weight that motor can handle)

http://www.amt-schmid.com/de/produkte/winkelantriebe/srg_01/srg_01.php

So you think they can do the job too? I'm really unnshure and don't want to spend hunrets of Euros for something not working.
Or maybe you can give me some data for good motors?

Also i'm not shure about the Aluprofiloe, becuase there are 3 types like light,medium and strong. Which one would be the best.

After no one was replying for the other motors i bought the 60:1 90zyt at Motion Control Products. The arrived today.
I wasn't able to test them with controller, because my Monster Moto arent arrived. I hope one per Motor will be enough.
Als after having Motos in my hand i've seen trouble in mounting pots and Leaver, because i don't want do drill wholes or something to void warranty.


I thought about a tube going over the shaft with a welded leaver on It. The whole is 8mm so i decide to screw the tube with m8 screws. I hope thiss will be stable enoigh.
I also changed my rig design.


It's a common rig uses by many people.

I'll update if new parts will arive.

so for the lever a steel tube or square tubin that fits the outer diameter of that shaft with a bolt through both should do you fine, weld the actual lever on the end. Would be cleaner to drill a hole on the other side for you POT shaft mount bout you could put it oin the other side of your lever arm.

sucks that they dont have a hollow shaft on the end through. I would prob drill and tap. Did you make sure that would void the warranty? And if it does, is it just on the gear box and no the motor? The gear box is the lesser of the expense if that helps. Havent heard a lot of stories of the 90zyt going bad though.

I'm planning to build pretty much identical sim as you are. same motors, build out of aluminium profile and front mounted motors. you're a bit ahead of my build so I'm keen to see how this turns out.
If you're still in the process of planning the physical form of the rig, I found really good software to use when using aluminium profile. It is for May-Tech aluminium profile, but I think other aluminium profile manufacturers can use things that are planned with it. It even calculates the material costs as you design your simulator. You can download it from here if you're interested http://www.maytec.org/maycad_e.html

@tombo , try not to get confused with info you asked for on the "other" forum

Hi,
wow thanks for all the helpfull Posts. After reading all your posts and links carefully, i think i have no more Issues with leaver and Pot mounting.

@shannonb1
I hope you are right and my Motors didn't fail I'm just a little bit worried because for me it is very much mo0ney i spend on the Motors.

@Ville Pesonen
Thanks for the Link to the Programm, very easy to use. I wish had this before messing up witch sketchup

@noorbeast
Thanks for the Link. For the potmounting i thought about something like you did. It looks very nice. And also Thans for the detailed Information and Pictures of Potmounting. I think i'll di it like you but will use some Flexcouplings to protect my Potentiometers.

@bsft
srr I not really understand what you mean, because my englsih isn't the best. Maybe you mean my Post on the Gs4 Thread about motors surcing up to 70A?

I found my spare Motomonster and hope I'll get some cables and Connectors today to test everything. Did you think 6mm² Cables will be enough? Or should i take 10mm² ?

And again thanks for all of you beeing so helpfull.

yes that thread......

no problem, I also started the planning with sketchup but found the software by accident while searching for aluminium profile sellers.

Today i organized some Cables and cableshoes. Will crimp them proberply on monday at work.
I thought a little about the motor brakets.
Here is my final design.


I will make this out of aluminium Profile with 130mmX80mm with 6mm width.
http://www.ebay.de/itm/141309789006?var=440429649031

In the back the Motors will be holded by some clamps. They have 90mm diameter. The will be also screwed to the base to make the motor more stable.

@Ville Pesonen
i made some sketchup files to print out, to put it on top the metal for exact drilling wholes. The measurements are very acurate. You said you'll be using the same motors as me. Let me know if you are interested, then i will upload them.

I'm going to build motor brackets based on my previous version exept this time the motor will be placed horizontally.



The bracket is made of steel 3 mm thick, folded and welded for a perfect fit. The steel will be laser cut which will ensure a very high accuracy.
I will show you the final version soon.

Tombo The Motor's Do NOT need to be supported by anything other than the gearbox itself. Completely not needed.

@Nick Moxely
Thanks for that information. But since these Clamps are very cheap and easy to install i think i'll do it anyway to reduce the force on the 3 M6 bolts.

Today while searching for some coolers for my Monstermotos i find some nice one at ebay
http://www.ebay.de/itm/Kuhlkorper-A.../311028291360?pt=Bauteile&hash=item486abb1720
This one should be fitting perfect.
I know it's better to use 2 coolers for each chip because theay are not plan. But all coolers i can find in such a small measurement are really low in hight.

For what its worth, I hang my 2 motor's off 2 1/4" bolts as seen in the pic, so 3 bolts is plenty

that would be much appreciated. My motors are on their way and this way I can probably get something done until I get them.