My 2DOF simulator with sew eurodrive geared motors

[pyrana18]

Hello,

THis is the actual status of my simulator, mechanical side finished after 3 months work.
My friend has a lot of job on electrical side... good luck !!!

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[motiondave]

now THATS motors!

[vicpopo]

Hello,

THis is the actual status of my simulator, mechanical side finished after 3 months work.
My friend has a lot of job on electrical side... good luck !!!
[

Hi everybody,
I'm the lucky friend who will help him finishing his simulator .

We will use the configuration as follow:

- sew inverter type Movitrac B ( to power the motor with 3 current phase and for the frequency motor driving)
- amc1.6
- RC filter for converting the pwm signal to 0-10 Volt
- a board made by us for driving the rotation sens (p1d1 p1d2 etc) from 0 5 Volt to 0 24 volt.
-xsim 3 for the game interface.

You can find in this topic the driving solution we want to implement :

http://www.x-sim.de/forum/viewtopic.php?f=39&t=132&start=110#p1681

Geard motor specifications:
0,37 kW 4 poles - gearbox output rpm : 48 ( a little bit high but we will see)
My young friend want touch the moon with his simulator !!! We could make his dream a reality !!

That all for the moment

Best Regards

[Riton]

nice work, good luck for the future!

[vicpopo]

Bonsoir Riton,

Merci pour le post , si j'ai besoin je ne me priverai de te contacter .J'aurai des questions aussi si un jour on passe à la version 3DOF!
Connaissant mon jeune ami impatient cela ne tardera pas !Mais on commence par faire un 2 DOF pour se faire la main.

Hi Riton , thank you for your post.If I need some help I will contact you for sure !When we will pass in the future to a 3 DOF I will have some questions too.
As I know my unpatient young friend that will happen soon, but first we have to finish the first in 2 DOF

@+

[tronicgr]

This a a very good looking simulator!! And really strong motors too!

How much is the cost for the motors / sew eurodrive inverters? Can they work with single phase too? Not everyone has 3phase power available for home use.

Best Regards,
Thanos

[Roadster2]

Hi Thanos.

It's the Frequency Inverter that supplies the 3 phase to the motor. It has a single phase input and a 3 phase output. The motor is wired in Delta connection (as opposed to Star).

[vicpopo]

Hi Roadster2,

You 've absolutly right !
Better explaination as me.For the price I will check and give more information.
Best regards

[vicpopo]

Hi Everybody ,

I go a little bit forward in this project.
The parameters I will use are the same as those I talked about on this post.
Link : http://www.x-sim.de/forum/viewtopic.php?f=39&t=132&start=160#p2011
First of all the pictures :

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simuarrière

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backsimiu

Inverters :

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inverter

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Output shaft :

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output shaft

I not finished to wire all the material .I have to finish the sensors positioning , the box where I will put the amc1.6 and all stuff for connecting the current net.
It will take me about 4 or five hours and after I can make the first test.

Update 15/09/2012
I just want to share how I build the magnets for using the hall effect sensor ss495.
I found this idea on a french topic for a flight simulator joystick.
Below the pictures from the french topic.

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Magnet

So I used this idea taking a pen wiich has an hexagonal form to glue the magnets parallel !I confirm that I used magnet with 2 mm thickness and external diameter from 4 to 8 mm. I bought some magnets which have just one millimeter thickness, I puted
2 parallel for,each side.
As I mount the magnets at the end of the output shaft which is taped,I glue the magnets to the pen and the pen into a screw.
Look at the basic mounting for this.

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Pen glued into the screw

To have a good finishing I make some more operations.I wrap around the magnet a epoxy glue.To maintain the epoxy I wrap before around the screw a double face skotch(it's like molding).After I glue into it the epoxy taking care not to full up the pen complitely with epoxy.

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Epoxy glue

The final result with epoxy

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Screws with epoxy glue

The last work is to drill into the pen to have more space between the hall sensor and the magnets.I use a 7,5mm dril to rework the inside diameter.
The final result.

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Final result

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Finished

UPDATE 2/11/2012:
After several weeks trying to make a suitable h-bridge for bigworm dc motors I found the time to finish all electrical stuff for my friend's the simulator.
First a picture from the electrical box ( I promise to make a good finishing in an another life )
It's a wine wood box ... Hope that it will be a very good vintage wine ...Bordeaux I believe!

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Box

And 2 litle video showing the first tests:



@Thanos:with the allegro 1302 hall sensor I measured this values:
Mini lcd display 89 for 1,68 volt
Maxi lcd display 165 for 3,13 volt
The third pot was on 70% for 90° angle course
The multiturn pot was turned on max on amc1.6 to give the full range voltage sensor.

UPDATE 3/11/2012

I posted a video showing the startup for the inverter MovitracB coupled with SEW Gearmotor with the movitools Motion Studio Software given free with material.
It's really simple for a startup setup , it takes one minute.If you want to change a parameter just redo this procedure.It's really easy to use.
If you don't have a SEW motor the menu launch a motor test for knowing its parameters.


UPDATE 7/11/2012

Hi ,
After several tries for finding the right parameters I present the first suitable test for the simulator 2DOF.
I decreased the speed motor to 30% from its nominal speed.That means a speed 14 rpm ( max value) on output shaft .
The ramp up,and down is fixed to 0,2 s and in xsim3 USO parser a refreshing rate from 5ms.
The Inverter drive each motor in Vector flow control mode.
It's a good compromise between speed , acceleration,smoothness and not too much brutal!! but a little for more sensations
The next step is with me seating on the simulator !!!
Don't worry about the screw falling from the simulator !!! Ouah !
You can watch the video below Enjoy :


UPDATE 8/11/2012

Hi ,
Below the first test on the simulator loaded!! And full loaded ... My weight humm I can't say ... ok about 100kg
The new paramaters , I had to decrease the motor speed to 400 tr/min max and I set the ramp up and down to 0,1 s.i changed also the arm (decreased) .I will give the lenght after.
The video of the test :

NB : the other noise than the car is water falls.I have fish in my garage!


UPDATE 14/11/2012

First test with all stuff ,shifter, pedals,wheel,screen.The simulator is very dynamic.The Thanos amc1.6 FW g is very good, fast response, good accuracy in positioning .

The youtube video:

UPDATE 17/11/2012

One another video trying to see the track and the motion .Hope that give a idea of motion because the quality video isn't very good.



UPDATE 24/05/2013

You can fin attached the files for making the adapter pwm to 0-10v and 0-5v to 0-24v

The symbol M in the pcb is Micro for capacitors 0,1 MicroFarad and 1 MicroFarad.

NB: in this post you won't find this board because it's 2 boards .One is the old board given per Tronicgr to convert pwm signal to analog 0-10v and the other the board made by a friend to drive the directions signal from 0-5v to 0-24 v.
My job was to compile both boards in one board with this 2 functionalities.

adapt.zip

Adapt.zip

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Best Regards

[vicpopo]

This a a very good looking simulator!! And really strong motors too!

How much is the cost for the motors / sew eurodrive inverters? Can they work with single phase too? Not everyone has 3phase power available for home use.

Best Regards,
Thanos

For one inverters about 450 Euros and the gearmotor 500 Euros.My friend didn't pay the gearmotors because he knows someone who build motorized bands.
He gave him for free !! (lucky guy).
Best Regards