DIY Linear Actuator design

Great start Good luck to you!

HI @SeatTime , im still getting to grips with my AMC128USB card , needed some more option to test operation . there are 4 jog buttons up/ down -- left /right on the controller that im unsure of in terms of their correct use or function , my Board was one of the original so I need to do a hardware mod ref potential pot noise , but have been able to load the latest firmware so not all bad.

Quite like the function of the SMC utility to run the actuator using the pre-defined signals ( triangle , sine , Square etc for testing ..

one things for sure im only running the motor at low voltage while I check the safety stuff before cranking things up , but already im aware that there will be some good results but that all depends on the Motor for now , a video of weight testing will be proof as it were..

Once the design is optimised i'll release my Cad drawings for all to see , this is not my work but an interpretation of a great project so , its rough around the edges for now but will be tided up soon .. Cheers for the encouragement guys , more to come


I may have missed the correct size of the Carbon Tube , as this on is only 20mm OD with 18mm ID , so will need to make sure any load is vertical for these tests, until It fails and then i'll change it for the Steel tube version or the next size up ref Carbon Fibre Tube ...

What size did you end up with , I ask because I cant seem to find 25mm OD which is weird because they seem to do 24mm but then I cant easily find 24mm Igus Bearings or Linear ball bearing type for that size .. ( guess im looking a wrong places again )

My tubes are dual walled, 25mm + 22mm bonded together. Super strong.

Aha LOL now tha makes sense @SeatTime , really appreciate sharing the inof , so nw a new direction to consider , I have never worked with Carbon Fibre , Heard all about its great properties but when I saw the 2mm wall thickness I had my doubts LOL , Hence the steel tube back ( Just in case or now it more of definetlly the case

A nice confidence booster this evening , all bits checked and AMC fired up and have to say ( A ) she moves and returns to center after using the wha t call jogging buttons on the card ) & (B) the limit switches catch any over travel when the get to near the max travel limits are , Phew and Sigh of relief .

Made a quick video but now have to upload it to you tube so watch this space , and remember this is the baby steps phase nothing cranked up yet

back again , 2 Quick snippets to show 1st baby steps
&

Are you using Fabi's configuration software for testing?

Hi @SeatTime . goes t show how much I need to learn quickly now, I thought Fabis stuff was for the AC guys , will have to download it and have a play , Thanks for the Pointer , at the moment I just did the basic test to confirm it works , at slow speed ,

Not looking for performance yet , just safe wont break itself Operation , tha being the case I was using the 4 buttons on the AMC but Fabis utility may well be the answer ..

once im happy then I'll hook it up to Simtools and have the option to also run Ians BFF Software for gaming ..

Long way to go yet , but gotta say thanks , to all you guys on this forum Inspiration in just about every project, so hell yeah this place is a great resource , roll on Simtools V2 , Money being chucked at the screen already & Waiting

Hi guys another of my mini update..
Been gradually increasing the test loads and so far I have come across only minor issues , but all in all things seem to be going well.

Actuator anchored to the ground and test program allows me to manually move form min to max Positions and any point in between with good repeatability with a 15Kg car battery as my 1st test load ,

Lessons learnt so far are that I found out that the unit will backdrive slightly at this stage with this 15Kg Load ( but remember is not all tuned and tweaked yet or fitted with correct motor ) so had to alter the Pot range and limit switch position to allow for slight overrun during weight load testing ...

The scooter motor seems ok at the moment but not fully stressing things so will see how well it holds up,

The dual Server Power supplies ( 24Vdc connected in series @ 50amps ish ) were tripping out with rapid direction changes , so I had to fit a 3 ohm high wattage resistors too the Sabertooth to absorb the current generated during direction changes ( power supplies don't like that apparently )

This feature of the new Sabertooths worked a treat but the resistors got KIN hot ( heat sink and fan mod coming up as well as sticking a few of these 3ohm resistors in parallel to share the wattage ( er I think that's the right description anyways I stand to be corrected )

Need to get an option to cycle the actuator up and down automatically so I a can concentrate making sure the test load wont go through my ceiling LOL @RufusDufus not Gotten round to trying you code but could be the answer to that issue

Speed will improve but no complaints at the moment , early days testing but good news is , so far no magic smoke and no mechanical breakages ,

Oh oh almost forgot , need to fit current meter so I can see how much this motor is drawing under real world loads ....

Tis only me again with some more parts , Ebay was my friend again and picked up 6 of these Brand spanking New Parvalux PM90 Motors , Brand new , So looks like im gonna have to make 6 Actuators after all,

Specs parvalux . 12VDC , 4000 RPM
Will Need to print link to data sheet for the Proper Info ( will do that later )

So Seem even at this early stage , i'll have to make a Mk2 version for back to back testing .. so 2nd ballscrew order needs placing and design update ..

New Cad Draft Update Guys , Some minor tweaks for the current build standard , the Mk version will follow ... Note i'll add the dimensions for the Individual parts with the next cad update , but these drawings are for general overview and are meant to be tweaked to suit individuals DIY skills, Materials and equipment at hand.

Hi, I don't have any Sabretooth's myself so the code was just written to the interface spec. I seem to recall someone saying it worked but I'm not sure what testing they did. If you try it and need some tweaks let me know and I'll see what can be done.

Hi @RufusDufus thanks for the offer of an assist , im trying a few control schemes at the moment as I would like to get to the stage where I can cycle the motor back and forth automatically to assess its load carrying range,

Your software offers that option, so what with my preferred controller being the DE stuff, it would be great for me and a great option for the community as well, if we could verify that this works as a combination ..

Will have a play today already got the program on an Ard just waiting so i'll let you guys know how it went later hopefully . Cheers

I looked over the sabertooth sketch from RufusDufus when it was first released and it looked viable but I didn't test it myself. I think @ericRacer has tried it though and reported it worked.

The only thing I noticed is it uses the sabertooth in simple serial mode which only has 64 speeds and SMC was designed for 256. The sabertooth sketch divides by 4 to bring it into range. Therefore, I believe that you must also make adjustments with the SMC utilities in multiples of 4 for it to make an effective change but I may be incorrect about that.

Hi Guys . Been playing in the Man cave some good news , Thanks to @RufusDufus and @BlazinH i now have a means of Cyclic Load testing my Version Of @SeatTime Linear Actuator ,

i needed a method of running the actuator backwards and forwards while i kept a beady eye on the load , Great news , Even the MY1016 scooter motor im using seems to be able to lift the 30KG weight i had balanced on the actuator during the test cycle ..

I used Rufusdus's SMC Utility and with the Sabertooth Controller Code ( ref Mode 3 ) , Happy to say it's all working great so far , im pushing my luck with the actuator in so far as i have not tidied up all the elements but great to report that so far she's performing well , Trying to set up the camera so you guys can see the unit in motion ..video hopefully later today ..

Im a Try it and see type of builder and so ignore the clutter , the main thing is i seem to be on the right track , so i expect even better performance when i use my new motors on the Mk2 Version .. Once again guys thanks to all that contributed to me getting this far Happy Chappy ( dont car if its pissing down out side ..in this Man Cave the sun is shining LOL )

Quick Vid as promised Stop laughing i can hear you ....well i can imagine i hear you LOL

Well done, your on your way - just 5 more to build .

Thanks for the feedback guys and specially @SeatTime the inspiration , Just waiting for the second 1605 ballscrew set to turn up , not sure how much customs charges will be if I order the next 4 at the same time ( just wish we had UK supplier at Chinese Prices LOL ) , so will have to wait and see...

This Test Version is considered the MK1 model , the next and possibly final build before making all 6 the same will be based around my new PM90 Motors ,that being the case the performance should be even better ...

I have some updated drawings but will release them once I have ironed out some of the current design options ...

Cheers Crew and some pricing info

Well The second Actuator Mk2 is almost complete just need to print some GT2 Gears for Feedback Pot range trials ... with any luck i'll have more Progress info Tomorrow

I'm really interested in your work, do you have any news with the 12v 4000rpm motors?