Another compact 2dof - seat mover

After weeks of reading various threads, I’ve finally decided this project is worth pursuing and have already ordered most of the parts. Many threads lack detailed guidance for beginners like me who have no experience with hardware, electronics, or programming. My goal is to provide more in-depth details than those other threads—especially since I spent considerable time researching even small items like which bolts to use.

I’ve decided on the following components:

• 4040 aluminum extrusions
• 1× Arduino Uno R3 clone
• 2× IBTS 7960 clones
• 2× 90° Hall sensors
• 2× 24V 250W 75RPM wheelchair motors
• 1× inexpensive power supply (0–24V, 50A, 1200W)

I read in one thread that a 90° Hall sensor provides four times the resolution of the more common 360° sensor, so I opted for it since I won’t be using more than +/-40° anyway.

If I understand correctly, a 1:1 pulley ratio is required. This means one pulley would be 40 teeth with a 17 mm bore and the other also 40 teeth but with a 6 mm bore. I guess a 120mm belt?

I’m wondering if 3D-printed pulleys would work well, or if I need metal ones?

Also, why is it considered better to use 90° or 180° Hall sensors instead of 360° ones? If I understand correctly, you could utilise the full resolution of a 360° sensor with a 3.5:1 pulley ratio, since it’s the ratio between the pulleys that ultimately matters, not just the sensor resolution.

Finally, I’ve decided on a 50 mm lever to maximise torque. This design is the most compact I’ve seen so far, and I’m hopeful that the motors will deliver enough power. I’m also considering what type of aluminum to use for the levers—likely something stronger than 1050 to be safe.

My simcalc data.

The idea of Hall 90st sensors is wrong , you will easily exceed the values read from the movement of the motor and shut down the motor, buy a standard Hall 360st sensor its resolution is sufficient, do not buy an IBT-2 bridge at 24V they are easily damaged, buy a controller https://www.xsimulator.net/community/threads/reasonably-priced-100a-motor-controllers.17638/page-5 tested works without a problem, zebatki you can print , I have a design of zebatki without a belt, it works properly for a few months, unfortunately my computer died temporarily, I will try to post stl files as soon as possible

I bought almost everything already.

I have 4 cloned ibt2s and 2 cloned arduinos. I saw a lot of people had problems with them but I will give it a try. Hopefully it will work

But I will buy the 100A driver as well just in case. I need just one?

Below is what I have in mind for IBT 2s. They will be cooled by strong 40x40 pwm fans 12w each. I've got a pwm fan controller which will cool them based on temperature. And a step down power converter. I'm planning to use the main power supply for them.

Regarding the hall sensors I'm still considering what to do. Please share your stl files, maybe it will give me new ideas

100A driver 1 for two motors