The SimFeedback-AC DIY Motion Simulator thread

[sjb266]

Hey guys. Thought I’d create a thread for those taking the plunge into this brilliant DIY project..
I will be starting mine soon and I know there are others thinking about it.. so feel free to share your knowledge and experiences so we can all enjoy this platform to its full potential. A huge thanks to the developers who have really knocked this one out of the park!

Website: https://opensfx.com/2019/02/20/welcome-to-our-new-site/

Github: https://github.com/SimFeedback/SimFeedback-AC-Servo/wiki

For all the internals for the actuator contact Amy - skye@ntl-bearing.com
She can supply everything you need. Just remind her you want the ends of the shafts chamfered and make sure she sends the right sized ball screw - we have had a couple of issues reported. She is very helpful though and the cost is pretty good.


Huge thanks to @RowanH for writing a comprehensive user guide which can be accessed here - https://www.rowanhick.com/sfx-100-build-and-running-guide

In addition, @anton_Chez has contributed a list of post numbers for some of the important settings etc..
Post #320 SFX-100 thread
Post #327 SFX-100 thread for Discord correlation
Post #339 SFX-100 thread
Post #418 SFX-100 thread
Post #424 SFX-100 thread
Post #439 SFX-100 thread
Post #449 SFX-100 thread
Post #517 SFX-100 thread
Post #554 SFX-100 thread
Post #580 SFX-100 thread
Post #826 SFX-100 thread
Post #837 SFX-100 thread
Post #864,866,867,868,870,887,889,897 SFX-100 thread
Post #911,914 SFX-100 thread
Post #988,992,998 SFX-100 thread
Post #1147 SFX-100 thread
Post #1492 SFX-100 thread
Post #1511,1517 SFX-100 thread

I will try to keep this page updated with links to source the parts in other parts of the world. Just post whatever links you have and i'll add them here.

Please note: Not all the parts listed below are essential for the project. For the essential parts refer to the original shopping list.

Australia:

• O-Ring - https://www.ebay.com.au/itm/Kit-419Pcs-O-Ring-O-Ring-Black-Rubber-32-Sizes-With-Case-3-50mm-W8D7/223152697816?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
• D-Sub breakout board - DB25 25pin Female Adapter RS-232 Serial Terminal Module Breakout Board Connector
• Emergency Stop - https://www.ebay.com.au/itm/Reliable-Emergency-Stop-Push-Button-Box-600V-Switch-for-Elevator/192115082001?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
• Arduino Wiring - https://www.ebay.com.au/itm/40-pcs-Dupont-Cable-20cm-Jumper-Wire-for-Arduino-RPi-breadboard-AU-Stock/202436863098?ssPageName=STRK:MEBIDX:IT&var=502467628096&_trksid=p2057872.m2749.l2649
• Breadboard - https://www.ebay.com.au/itm/Mini-Solderless-Breadboard-400-Contacts-Tie-points-Universal-Available-New-lemon/123145741183?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
• D-Dub Cable - https://www.ebay.com.au/itm/Black-D...h=item3f6ace6403:g:038AAOSw9mpaSsU2:rk:1:pf:0
• Screw Shield for Arduino Leonardo - https://www.ebay.com.au/itm/New-Scr...h=item25a9d471a4:g:5BgAAOSwraJbc9rC:rk:1:pf:0
• Arduino Leonardo Replica - https://www.ebay.com.au/itm/DIY-Eduino-Leonardo-Module-with-USB-Cable-for-Arduino-ATMEGA32U4-Blue-Black/132719951279?epid=916281063&hash=item1ee6b9bdaf:g:2QUAAOSw5iNbWv6b:rk:123f:

Thanks to @AussieSim for the following links:

10A power lead(s) * 4
https://www.jaycar.com.au/2m-black-mains-extension-lead/p/PS4152

Top quality wire stripper
https://sydneytools.com.au/product/boxo-cutws205-multifunction-wire-stripper

RCD/safety switch power block
https://www.bunnings.com.au/arlec-4-outlet-heavy-duty-portable-safety-switch_p4420028

WD-40 lithium grease for the ball screws
https://www.bunnings.com.au/wd-40-specialist-300g-high-performance-white-lithium-grease_p6100408

Vibration pads
https://www.bunnings.com.au/whites-on-site-100-x-12-5mm-rubber-anti-vibration-mat-4-pack_p3961547

WD-40 Dry PTFE spray for the slider (free shipping)
https://au.rs-online.com/mobile/p/lubricants/7577134/

Arduino Leonardo (free shipping + frequent 10-15% off discount)
https://www.arrow.com/en/products/a000057/arduino-corporation

DB25 cables * 4 (free shipping)
https://www.arrow.com/en/products/ak401-2/assmann-wsw-components-inc

PETG * 3 (free shipping)
https://www.arrow.com/en/products/petg17bk1/mg-chemicals

WAGO-like connectors to avoid a breadboard (perhaps use genuine ones if you are doing 240V AC)
https://www.aliexpress.com/item/32906719488.html

D-Sub breakout boards * 4
https://www.aliexpress.com/item/32297675967.html

3D printer Creality Ender-3 Pro
https://www.aliexpress.com/item/32918302452.html

Wires from Arduino to D-Sub breakout (remove black plastic from the WAGO end)
https://www.aliexpress.com/item/32887680826.html

Crimp connectors for AC wire leads
https://www.aliexpress.com/item/32813550981.html

 

[o Tiger Feet o]

However, I should note that my rig extrusions arrive tomorrow and I will be bolting it together and firing up my motion rig for the first time.

If you want a small bit of advise, wear some loose fitting pants. You will get a boner the first time your rig lifts

 

[saxxon66]

High Pitch Tone

It's a shame that you guys are going to help in this regard, but not having all the info, we found out about this before.

I think if someone is going to address this issue here, he is in charge to inform you about all what we (a lot of people tried helping before) did found out. This did not happen so I will do it now.

Sound level

This System produce a high pitch tone in the 10 kHz frequency.
We have proved this by using PC and mobile applications to record and analyze the spectrum and pressure. It shows the tone is spot on 10 kHz and about 30 db.
Most of us can hear the tone, but even it is not not comfortable, we can ignore it while using our motion simulator, because of the low sound pressure, sound coming from our games and the simulator mechanics.

I do know two (2) people (this is 1-2% overall) who can not stand this tone, and therefore can not use their simulator, as they like, because of this.

Sound origin

The Servo Controller is using a current control loop to control the torque in a servo motor by manipulating the pulse-width modulator (PWM) outputs that drive an inverter.
The motor currents are monitored and fed back to the current-loop controller and the controller updates the PWM outputs if necessary.
Typically the PWM carrier frequency is in the 10 kHz frequency range.
See: http://www.ti.com/lit/wp/swpy031/swpy031.pdf for more information about this subject.

This is the frequency you will hear if you enable the Servo Controller we use.

It is not related to the Arduino controller, because if you remove one variable out of the equation (Arduino) and the result (tone) is the same, you have proofed that it is not related to this one variable.
This is what we have done. By using the position control Jog method of the Servo Controller, you can hear this tone w/o any Arduino attached to the Servo Controller.
Btw. the Arduino uses PWM too but in a much higher frequency range (~200 kHz).

Sound emission

We opened the Servo Controller to find out what part is going to produce this tone.

By measuring the sound level by holding a mic near to the components, we found a relay to be the most likely cause of this tone. A quick test by wrapping this part with some tape for isolation showed a change in the tone.

The next step would have been to desolder this component and re-solder it via cables to prevent the transmission of vibrations.
At that point, we stopped further investigation because we exceeded a point that could lead to serious injury if anyone were to follow these steps.

We are of the opinion that even if we were to identify the component, it would not be a solution to change the internal structure of the servo controller for safety reasons.

Am I affected?

Like I said before, most of us can hear that tone.
People that are sensitive to higher pitch tones have stated that they can hear the sound even watching videos.
So try to watch videos showing the SFX in action, find a reference sound level (spoken words, ...) and tune the volume. By listing to the video you can estimate if you are effected or not.

Solutions

There is no real solution to stop the Servo Controller producing that tone.

Easiest solution: Use headphones

Other Solutions:

- Use in ear filters
https://www.racedepartment.com/thre...simulator-thread.159524/page-200#post-2948113

 

[saxxon66]

Hi, I'm also in the process of building the SFX100 and I've a question about the Arduino to be used. Would it be possible to use an Arduino Micro instead of a Leonardo? They are technically identical only the footprint is different...

You have given the answer yourself.
They are technically identical, so yes you can use an Arduino Micro.
If the USB power is not stable (too many peripherals) it is easier to have an external power supply connected to the Leonardo and you can use the awesome SFX-100 Shield.

 

[anton_Chez]

Thank you Saxxon. That post explains a lot of the technical reasons behind the whine and why users are best advised to find alternative solutions to minimise the noise, rather than looking into the drivers themselves.

 

[saxxon66]

...
Actually this is interesting...https://servotechusa.com/faq-items/minimizing-noise-on-your-servo-system/

The "noise" the linked article is talking about is something total different.
It is about electrical interferences, not sound.

 

[anton_Chez]

Just on the external power for the Arduino, mine did not like that at all. It wouldn't allow the USB connection until I removed the power brick. Then all was normal.

 

[mouse1]

You can call it series, bridged, cascade, as you wish ... Looks like you understand me

I know how to deal with electricity don't worry, I am even wiring it on a dedicated line with according protections but my question was just for wiring convenience.

I am just wondering if the last 2 controllers are not gonna "overheat" with all the total current flowing through them ?

I assume, what you want to do here is putting 2 wires in each terminal of the servo controller, right? Because there's no power "input" and "output" on the controller. The current will not flow through the controller itself, and so it cannot "overheat" it.
What you should pay attention though, you should select a proper wire for this. Those are 750W motors (although we are not using those on max.), so on a 230V, the max. current consumption is ~3.3A. Which means, between your 4th controller and wall socket, there could be 4*3.3A = ~13A. The wire, you are using there, should be thick enough to handle it. So planning for like 15A, should be good enough. I think, a 1.5mm2 copper wire should handle that well. (I'm not that familiar with AWG, but that's probably equals to 16AWG.)
I used the same wire, as far as I remember.

 

[dedraro]

Guys I participated in the group buy, for the awesome board designed by Pyronious, but I was wondering however which DB25 connectors I have to take to solder them on the board, some links? thank you

 

[Crashtappen]

I assume, what you want to do here is putting 2 wires in each terminal of the servo controller, right? Because there's no power "input" and "output" on the controller. The current will not flow through the controller itself, and so it cannot "overheat" it.
What you should pay attention though, you should select a proper wire for this. Those are 750W motors (although we are not using those on max.), so on a 230V, the max. current consumption is ~3.3A. Which means, between your 4th controller and wall socket, there could be 4*3.3A = ~13A. The wire, you are using there, should be thick enough to handle it. So planning for like 15A, should be good enough. I think, a 1.5mm2 copper wire should handle that well. (I'm not that familiar with AWG, but that's probably equals to 16AWG.)
I used the same wire, as far as I remember.

I was planing to use 2.5mm2 so it's okay

Guys I participated in the group buy, for the awesome board designed by Pyronious, but I was wondering however which DB25 connectors I have to take to solder them on the board, some links? thank you

You don't have anything to solder mate, everything come complete and ready to use.

 

[pass-low]

grease gun and grease arrived today, blimey talk about overkill the grease gun is huge and plenty of grease spare

so if anyone is near Leeds England UK wants to borrow a greasegun and grease message me! bring your own nipples

 

[JohnnyV]

Yes, never share your nipples with random people on the internet

 

[HugoB]

High Pitch Tone

It's a shame that you guys are going to help in this regard, but not having all the info, we found out about this before.

I think if someone is going to address this issue here, he is in charge to inform you about all what we (a lot of people tried helping before) did found out. This did not happen so I will do it now.

Sound level

This System produce a high pitch tone in the 10 kHz frequency.
We have proved this by using PC and mobile applications to record and analyze the spectrum and pressure. It shows the tone is spot on 10 kHz and about 30 db.
Most of us can hear the tone, but even it is not not comfortable, we can ignore it while using our motion simulator, because of the low sound pressure, sound coming from our games and the simulator mechanics.

I do know two (2) people (this is 1-2% overall) who can not stand this tone, and therefore can not use their simulator, as they like, because of this.

Sound origin

The Servo Controller is using a current control loop to control the torque in a servo motor by manipulating the pulse-width modulator (PWM) outputs that drive an inverter.
The motor currents are monitored and fed back to the current-loop controller and the controller updates the PWM outputs if necessary.
Typically the PWM carrier frequency is in the 10 kHz frequency range.
See: http://www.ti.com/lit/wp/swpy031/swpy031.pdf for more information about this subject.

This is the frequency you will hear if you enable the Servo Controller we use.

It is not related to the Arduino controller, because if you remove one variable out of the equation (Arduino) and the result (tone) is the same, you have proofed that it is not related to this one variable.
This is what we have done. By using the position control Jog method of the Servo Controller, you can hear this tone w/o any Arduino attached to the Servo Controller.
Btw. the Arduino uses PWM too but in a much higher frequency range (~200 kHz).

Sound emission

We opened the Servo Controller to find out what part is going to produce this tone.
View attachment 300744

By measuring the sound level by holding a mic near to the components, we found a relay to be the most likely cause of this tone. A quick test by wrapping this part with some tape for isolation showed a change in the tone.
View attachment 300745

The next step would have been to desolder this component and re-solder it via cables to prevent the transmission of vibrations.
At that point, we stopped further investigation because we exceeded a point that could lead to serious injury if anyone were to follow these steps.

We are of the opinion that even if we were to identify the component, it would not be a solution to change the internal structure of the servo controller for safety reasons.

Am I affected?

Like I said before, most of us can hear that tone.
People that are sensitive to higher pitch tones have stated that they can hear the sound even watching videos.
So try to watch videos showing the SFX in action, find a reference sound level (spoken words, ...) and tune the volume. By listing to the video you can estimate if you are effected or not.

Solutions

There is no real solution to stop the Servo Controller producing that tone.

Easiest solution: Use headphones

Other Solutions:

- Use in ear filters
https://www.racedepartment.com/thre...simulator-thread.159524/page-200#post-2948113

Or about the same dBA as a 1080Ti card:
https://www.guru3d.com/articles-pages/geforce-gtx-1080-ti-review,10.html

 

[ScottSonder]

My parts came early today but again the spec is all over the place, the screw housing is longer so won’t fit flush inside the slider which caused another one to split. Starting to get a little pissed off with it now! Back to the printer and this is why buying one is super useful.

I thought I was unlucky with the Kinetik shipment that passed through Wonderland, but I think you win mate. How do you ship out replacement parts out of spec ? I really wonder what the inside of their warehouse looks like..

Great post by Saxxon too, if only we could sticky it. Reading threads like these will make it seem like any small issue is a cataclysmic build stopper, play the tone at 10kHz and 30dB as specified while listening to music or something. I just did that test, and it seems very comparable to the experience with the SFX.

 

[dedraro]

You don't have anything to solder mate, everything come complete and ready to use.

oh great news! I had missed that one

 

[Pyronious]

High Pitch Tone

Typically the PWM carrier frequency is in the 10 kHz frequency range.

Note: I am not an expert in servo motor controllers. However, I will share what I have learned from doing some research in this area.

Audible whine is a common property of PWM drives. Our controllers are not "broken". As saxxon66 mentioned, this is a result of the 10kHz frequency at which the controller is switching the motor back and forth to hold a position. I would be surprised if that relay on the PCB is the only component responsible for the noise - it is simply the most noticeable. With this much power being switched, there are likely going to be sympathetic vibrations throughout the system, including the motors, cables/chokes, etc. Very difficult to isolate.

One way to address the issue is to source a new PWM drive that supports a higher frequency. Getting a PWM drive that supports 20kHz would make it out of the audible range for most people. Some PWM drives have programmable PWM frequency; I looked through the documentation for ours and don't see any obvious way to adjust it.

Unfortunately when you start getting into higher end servo drives the cost goes up accordingly. I would expect to pay around $1000 per controller.

So the search for a cost-effective DIY solution continues. In the meantime, I just wear headphones.

 

[Crashtappen]

Today I have finished the actuators assembly but I faced a problem on all 4 of them.
When tightening the bolts of linear and fixed bearing mounts the parts starts cracking as soon as the bolts started to bite harder.

The result is I can't screw them tight enough or I am scared that the part will crack under pressure.

Has anyone experienced those cracking noise before ?

I'm printing with PLA since 3 years with my Prusa and used the recommended Simplify3D setup. PLA rolls from Prusa as they never failed on le.

 

[Furnace Inferno]

Well ****, I reprinted a slider with an adjusted deeper linear bearing hole mount to accommodate my longer one, everything now up and running and mounted fine.

Fire up my Accuforce, fire up the buttkickers, press start on the six profile rig lifts up to correct height, oh yes. USB disconnect sound , Accuforce wheel has disconnected .

Played it with an Xbox controller on the projector to my right but couldn’t really get a feel for it driving like that!

So what is the best way to resolve this I’ve seen on the previous page about ferrite cores, where and how many? What else can I do?! It only seemed to be the Accuforce having issues and the power/data cable from the motor goes right past the the front left actuator so perhaps that is th issue.

I was also having major issues with WiFi but not sure if that was the them or an internet issue at the time but it miraculously was fine once I turned off the servos at the plug.

 

[ThugUK]

Oh, I have the AccuForce too so hope I don’t have the same issues.
How did the motion feel?

Have you tried going through the basics, removing everything USB except the things necessary?
Try different USB ports.

I had a strange issue with my AccuForce. When I ran VR (Rift) it would work ok unless I took my VR headset off then it would cause the AccuForce to disconnect. I didn’t even have to stop the VR, just lift it up off my head was enough.

 

[PandaNL]

Hi All,

A few days ago I made the following post: https://www.racedepartment.com/thre...simulator-thread.159524/page-198#post-2947207

Those boards are now in, and have 5 more left. So if you live in the EU and missed out on the first group buy hit me up.

(*some flux remover is on its way to remove this nasty no clean flux mess)

The other PCB's is something I designed to connect 4 PWM fans controlled by an Arduino Micro via Simhub/ShakeIt.

 

[Tim Palmgren]

@PandaNL I was thinking of doing the same until I tried metalnwood's Boat blower setup and realised I was going to need something with a lot more current output to be happy. This is the lazy link for the motor shield but gives an indication on how much current you need to get moving to power 2 x Boat blowers https://www.sparkfun.com/products/10182