New 6DOF Initial Planning

Hi all. I have been coming back to this site every couple years for a while now dreaming of being able to put together my own motion simulator rig and I think it is now time to start some dabbling with some of the components to see where it takes me. I have always had a 6dof in mind. I prefer to shoot right for the top instead of putting something simpler together and being disappointed. That is probably why it has taken me so long to get started. The good part of delaying is that the components and designs have evolved to make things easier and cheaper. My original thought was to go with a motor/gearbox setup with lever arms (aka a rotary configuration), but I am now leaning toward a DIY linear actuator configuration. Other than the potential for a super compact setup, I currently am not seeing a benefit to the rotary option, but please correct me if that is a more appropriate option based on my wants list. It currently appears to offer an easier way to get more displacement and good linear speed at a relatively low cost. The elimination of the gearboxes is a big plus in my mind. With that said, I am planning on a ~500mm displacement actuator using a fold-back design to limit the length of the actuator. I am planning on designing for a fairly large load to hopefully future proof the setup and maximize the life by not pushing the limits of the components. I am currently looking at this AC servo motor/drive combination:

It looks like I am unable to post a link, but it is a "1.8KW 110ST-M06030 220V AC Servo motor 3000RPM 6N.M. servomotor Single-Phase ac drive permanent magnet Matched Driver AASD" from aliexpress.

I am hoping that I can get a confirmation that this will work with the @Thanos AMC-AASD15A. I plan to couple this with a 2020 ballscrew using a timing belt and pulleys to set the available torque/speed. The prototype actuator housing will be a 100mmx100mm aluminum extrusion and I have a mill and lathe to make the parts required to get it all attached. I am looking to have a payload capability of about 1000lbs, or more, meaning that a passenger could be possible, or just a lot of structure and controls to make it more realistic. I would like it to work well for both driving and flight simulation.

If anything sounds out of line so far, please feel free to comment and make suggestions. I still have much to learn and prefer to do as much of that as possible prior to laying out a bunch of cash.

Now for some big questions. I would like to make my upper platform using aluminum extrusion (80/20 type, but using 45/90 dimension materials for the current design), but I am not sure how to evaluate whether or not it will be strong enough. I am not planning to have a separate base platform with the 80/20 cockpit just sitting on top. I would like the whole upper cockpit structure to be 80/20 type extrusions. The only exception would be some custom actuator mount brackets that would be welded aluminum or steel. I don't believe that I have seen anyone do this yet, but easily could have missed it in the wealth of information here. The second big question I have is how to size the relative upper and lower platforms. It sounds like each wants to be an equilateral triangle, but I believe that they need to be different in relative size to allow for the full 6dof effect. The real question is how do I size the two to get a good mix of displacement/rotation in each degree of freedom?


This has gotten pretty long, so I will stop there for now, but I will certainly have more questions and I appreciate everyone's time in responding with help and criticism.

Thanks all,
Chad

Trying again to post the motor and servo drive link:

https://www.aliexpress.us/item/3256....0.0.1beeICjZICjZwn&mp=1&gatewayAdapt=glo2usa

Thanks,
Chad

Chad
I’m just starting my 6 DOF build, put a Ali Express order in two days ago for 7 motors and servo controllers. I also ordered a Thanos control box. I was 100% sold on linear actuators but space is an issue and I thought a rotary design might be better. Have you settled on a design layout yet? If you are going with linear actuators how you are going to construct them, round tubing, square? Inverting the motor with belt or inline with ball screw etc..
Cheers
Robert