Repair motion rig

Hi,

Over the years i build an nice motion rig, based on 2 systems i bought seperately from the dutch marketplace. Part 1 is an seatmover, running on arduino system with 2 motors and using simtools. Unfortunately is cannot retreive the building plans of the system, but as long as it works, im happy. Underneath the seatmover i have build an 3 actuator frame running on an arduino controller and using flyptmover.

After several months of an break i just started the system up again and the lower system (3 actuator) is causing problems. The start up procedure is so that the whole system goes up, and al the way down after that. That works, until the actuator on the backside starts making an terrible noise once the actuator is on his lowest level.

To determine what could be the cause of this i tried connecting the back actuator on an other output chanel and 1 of the front actuators on the back connector: result was that the actuator connected to the 'normal' back actuator channel would show the same weird knocking sound. Besides that i tried disconnecting the back actuator and then start of the motion system, but that also isnt working. Motion rig is connected to the pc, com port is recornigzed. Flyptmover is setup like normal, is able to connect, but no movement what so ever.

First conclusion would be that the channel for the back actuator would cause an error or the arduino is causing an error ?

My questions are:
-given the fact that im not able to contact the builder of the rig, is there an possibility to recover the data from the arduino? Is it even possible to assess backwards?
-it would be a shame to trow away perfectly working actuators etc. Can someone help me out in the progress of rebuilding the kit for e.g. simtools or open sfx?
-can i use the actuators and e.g. redesign the rig to be used with simtools or open sfx? Using the equipment which i already own?

If needed i can make pictures of the inside of the whole rig.

I live in the netherlands btw.

Kind regards,

Can you show the output window of flypt mover. I want to see the type of controller.
Also, is the actuator using a limit switch?
It could be damaged and the actuator keeps moving making that noise. While the calibration is not performed, there's no movement. That's why I talk about the limit switch.

Edit: Damaged can be just the wiring to the controller

Ok, I saw the pictures. Who sold you that? Seems similar to my controller...

Edit: But it's not, it's stepper motors. So, show me the output module just to see what the board expects to receive.

I will upload the flyptmover asap. The actuators do have 2 switches. 1 for max level and 1 for min level. I switched the actuators from controllersside, an still the weird noise is coming back, even though i have changed the actuator.

See pictures of the setup in flyptmover.

Ok, it's kind of a clone of my controller, but using steppers. I have no idea of what is inside the ESP32.
I don't see anything wrong with FlyPTMover. Check for the limit switches cable if there's one. It might be damaged and it doesn't allow the calibration to conclude. So it doesn't start receiving data while in that state.

It was wworking with that setup before?

Arent the sensors on the side of the actuators the limit switches? If not, were could i find an limit switch?

So if i understand correctly, it could be that the rig is getting stuck in an calibration phase due to 1 actuator nog working through the whole calibration program.and therefore will not accept data cq. Movement? Once i completely remove all cables from the back acuator it still will not do anything!!

I thing though, i can recall from the past that once i initiate the serial connection, the rig would also react slightly by making some noises, like humming noises, etc. And maybe even some small movement.

Since i started the rig up again after months of not using it, it does nothing at all, besides starting up..going up and down, and ending with some sort of crash. Could it be an setting in the comport seting which are faulty?

And on the other hand: could i reflash the esp 32 easily, or is that only possible if i know exactly how it is wired and setup wrt the controllers?

Or as an last resort: can i tottally dosconnect the back actuator from the esp32 etc and go further with only 2 actuators at the frond and just an support behind (without movement)

If it was using BLDC motors and drivers (with same specs) like I do, you could just flash it, but I don't know what is inside.
All the rest behaves like I have in my rig and no data is received until the calibration ends if they mimic my code.

Are you sure the ESP32 is connected to the COM7? Sometimes it's something stupid... You might be swapping the ports of both controllers. Don't take it bad, but I do many of those and loose time with things like that...
Some weeks ago I burned one of the USB ports and thought I had the hardware malfunctioning and it was the port on the laptop.

The setup in the output seems ok. That's what I have in mine and it's good for the ESP32.
In my case I use limit switches if you have them, they can be inside the actuator, but the connection cable to the controller box can be damaged.

If the code in the ESP32 is like mine, it will always wait for the 3rd actuator to end calibration. So disconnecting is not a solution.

Note, I'm saying this thinking they might have used parts of my code in this controller.

Im sure that its not the wrong com port. I checked system devige manager with and without connecting the usb. Windows is clearly stating the correct com port. I assume the bitrate set in flyptmover and the port setting should be the same, but does both has to be set at an specific setting?

Given the fact that switching actuators to another controller does not help i would almost conclude that something isnt wrong with the actuator or the limit switch, but something wrong with the connection in the last controller unit for the back actuator.

Given the amount of wiring now i dont know were to start. Do you have any suggestion, knowing electrotechnical im far from an expert.

In my opinion (and I can be wrong), the problem is on the cables connecting that rear actuator.
Can you swap the cables to another port to test?
Instead of swapping the actuator try just the cables. If the problem follows the cable, then check the cable and connections in the cable. Soldering in the connections?
Can't help much more...
I don't think the problem is software.

Mescaline,
The top 2 posibilities are cables connecting and limit sensor fail. Either of them is easy to validate if you have a multimeter and you have basic electrical knowledge(important!).

I'm an servo system expert myself and with my professional tools&instruments can find out where the problem is in 20 minutes. Unfortunately I'm living in China......


---------------------Appendix----------------------
The limit sensors in your actuators are inductive limit sensor.

An inductive limit sensor is a type of non-contact sensor that detects the presence of metallic objects using electromagnetic induction. It operates based on the principle of changes in an oscillating electromagnetic field when a conductive (metallic) target approaches the sensor's sensing face.

Oscillator Circuit: Inside the inductive limit sensor, there is an oscillator circuit that generates a high-frequency electromagnetic field via a coil wound around the sensor's face.
Field Distortion: When a metallic object (the target) comes close to the sensor, it enters this electromagnetic field. The presence of the metal distorts the field, causing a change in the inductance of the coil.
Detection and Output: This change in inductance affects the oscillation amplitude or frequency, which is detected by the sensor's internal electronics. Once the change exceeds a certain threshold, the sensor triggers an output signal, typically switching an output transistor on or off.


You need test the output of inductive limit sensor to validate whether the sensors are good or bad.

Hi 'supporters',

By having the cables fixed to the actuators i first connected an correct actuators to the port in the controller box which shows failures: result: that actuatorr shows same behaviour as the other actuator. Pre conclusion would be that its not the actuator which ia causing the errors, but the area between the connector of the cables of the actuator towards the controllerbox, see pictures attached. Is that an correct assumption?

Given above, how would i be able to test the controller side of the mition rig? Any ideas?

Grllkr

test the controller is complicated process. You need multimeter.