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

 

[Furnace Inferno]

Okey, thanks seems like its A tittel i whount play then

After some runs with the sfx 100 its hard to play without motion

Its one of the games I play with a controller, I can only imagine how destructive a motion profile for it would be on your body and surroundings.

 

[Jean-Paul Lanaux]

Has anybody had issues with the 110 to 220 transformer tripping a 20 amp circuit from a cold start? This only happens when the transformer has not been used, and only when I click start in Sim feedback and attempt to raise the platform. after the breaker trips, and I reset it, no problems whatsoever until the next time.

4 Reasons Why Circuit Breakers Trip

In rare cases, the breaker may be damaged. But in most cases, the breaker or fuse is just doing its job when it pops. Circuit breakers are designed to trip and turn off the power when any of four dangerous situations occur.
Overloaded Circuit When a circuit breaker regularly trips or a fuse repeatedly blows, it is a sign that you are making excessive demands on the circuit and need to move some appliances and devices to other circuits. Or, it may indicate that your house has too few circuits and is in need of a service upgrade.
Short Circuit
Ground Fault
Arc Fault
To test for circuit overload, the next time the breaker trips, turn off all the switches in the affected area and unplug all appliances, lamps, and other devices. Flip the breaker back on and then turn on the switches and plug in/turn on devices one at a time. Wait a few minutes in between to see if the circuit will remain on. Each time you turn on a light or run an appliance, you’ll be drawing more electricity through the wires. If the breaker trips before you turn on all the appliances, try the experiment again, this time turning on the appliances in a different order. You may need to go through the process several times to get a good idea of how many appliances you can operate at one time before overloading the circuit.

 

[Lebois]

Hi ! As I am planning to use my stepper motors that are weaker than servo motors, I would like to invert the actuators so they don't have to lift their own weight...(it allows a better cable managment too).
My question would be : Will the weight of the simulator rest on the motor shaft or on the motor case ? Because the motor shaft doesn't like axial load at all...

(The picture above is just here to explain, I am thinking about using end joints)

 

[ThugUK]

Good question and it think that unless you have some kind of pivot you may put unnecessary stress on the shaft, bearings or couplings. Especially as it’s at the extreme ends all the time.

 

[metalnwood]

The design of the SFX, the weight will go on to the case, the shaft of the motor will not take any weight.

On a practical note, I think it will be a spectacular failure

Well, the last comment has a lot to do with how you mount everything.. I dont think endjoints mounted on to the frame will be enough. I assume that the actuators will not be standing freely as in the pitcure but mounted to their own frame. I dont think that will give them the freedom to move as the will need to

 

[Lebois]

The design of the SFX, the weight will go on to the case, the shaft of the motor will not take any weight.

On a practical note, I think it will be a spectacular failure

Well, the last comment has a lot to do with how you mount everything.. I dont think endjoints mounted on to the frame will be enough. I assume that the actuators will not be standing freely as in the pitcure but mounted to their own frame. I dont think that will give them the freedom to move as the will need to

I am still thinking about, so don't hesitate to tell your mind

Hm I am thinking about using the following system, it gives the roll freedom :

 

[Lebois]

I assume that the actuators will not be standing freely as in the pitcure but mounted to their own frame. I dont think that will give them the freedom to move as the will need to

Yeah I figured out that it would even give too much freedom, giving the possibility to the rig to globally "fall" on one side...
So I will fix the hollow shaft like this (with something stronger eventually), anything bad ?

 

[Michal Burisin]

I'm building SFX100 with additional G-Seat, the build will consist from 4x SFX100 servos + 6x 60ST servos, so total of 10 servos + controllers.

I'm starting to solve the power connection / cable management.

a) Custom approach

I was considering to connect all the controllers to some single point and from there, there would be just one power cable to the outlet. But this would probably require some custom work / advanced electricity knowledge if there is not some product, that could do this.

I saw nice installation from @GeniFx - link to post here. @GeniFx could you please share how is the connection done? And what is inside these 2 boxes?

b) Power hubs approach

I found this product: APC Essential SurgeArrest, link here and with english description here.

Then I would buy 10 of these cables and plug each servo controller individually to SurgeArrest.

For 10 servos, I would need those 2 APC SurgeArrests. Those would be probably stashed in some control box, that would not be easily accessible. So I thought, I would plug these 2 APCs into another power hub (image below just for example, I will try to find another Surge Arrest with individual outlet power buttons), that would serve as main one and would be easily accessible. When starting the rig, I would manually switch on all systems one by one to avoid possible overload when powering everything up at once.

I saw somewhere before that these hubs shouldn't be connected one to another, but I cannot find this info anymore, maybe it was related to specific product, but I cannot remember.

In APC manual, I found just this: "1. Plug the surge protector into a grounded outlet only", which I think is ok with it connecting to another hub, because I think every outlet of that hub is just another normal grounded outlet, am I correct?

What I found interesting is that APC provides EMI filter:

EMI/RFI Noise rejection (100 kHz to 10 MHz)
60.0 dB

Is that something, that could possibly help with EMI issues?

c) General power supply overview

The complete rig will be very power hungry:

1) 10 servos (4x 750W + 6x 600 W)
2) 6x Buttkicker Units (6x 1500 W) + 2x TST Units (2x 150 W) powered by 4 iNuke 3000 DSP amps
3) DD Wheel (1000 W)
4) computer (800 W)
5) other accessories

I know these max power limits are only theoretical and in real usage, the max power peaks are much smaller, but I would be worried to plug all this into single branch of the power supply to the appartment as it could overload the breaker for that individual branch. I have 3 different power supply branches in appartment I can use via extension cord from another rooms.

Is there some recommended way how to split the load in order to avoid EMI issues in general or it doesn't matter how I split it?

For example if the servos + DD wheel + computer with VR should be on one branch and I could power the tactile from the other branch or something else?

Many thanks for any insights!

 

[Tim Palmgren]

@Michal Burisin I will preface by saying I'm not an electrical engineer but if you plug the two surge arrest units into an external power strip you might have to check the total amperage it can handle. Most power strips only have a 10A or 15A max fuse in them so you might run into that limit potentially. You would rarely see it using peak though. When Rowan measured current draw on the SFX100 it has been topping out around the 500W area, also your DD wheel is unlikely to use 1000W. My power supply is only 470W and I never run the motor on much more than 50% max so you should have some headroom on these figures.

That said due to the loads you are thinking of running you might want to check what your fuse in your power box is rated for on that circuit and figure out what your total power load might look like on that end as well.

 

[metalnwood]

@Michal Burisin Those two boxes look like an EMI filter on the bottom and a junction box at the top, the junction box will just put the 220V coming from the emi filter on to some sort of rail so you can wire up the 4 drives easily.

 

[Michal Burisin]

@Michal Burisin I will preface by saying I'm not an electrical engineer but if you plug the two surge arrest units into an external power strip you might have to check the total amperage it can handle. Most power strips only have a 10A or 15A max fuse in them so you might run into that limit potentially. You would rarely see it using peak though. When Rowan measured current draw on the SFX100 it has been topping out around the 500W area, also your DD wheel is unlikely to use 1000W. My power supply is only 470W and I never run the motor on much more than 50% max so you should have some headroom on these figures.

That said due to the loads you are thinking of running you might want to check what your fuse in your power box is rated for on that circuit and figure out what your total power load might look like on that end as well.

I have checked it and on the main appartment breaker, there's written 16A on the fuse for each power line (I have 3 separate ones available I can use).

I used calculator:

I'm not sure what is the Power factor, but it would probably lower the limit further.

3520 Watts seems like a lot, but I'll probably try to put at least tactile on another power line.

PS. I'm considering Fanatec DD, but couldn't find wattage in spec, so I just guessed how much it could be, so I was off quite a bit

 

[metalnwood]

The single circuit breaker is probably connected to all the power points in your room, possibly ones in the next room as well. You will have to start plugging in lights to sockets and turning off the breaker to figure out which sockets run off which circuits.

Those multiplugs are probably not rated for more than 10 amps either, so while you may be able to pull 16 amps from one socket you will have to check that the multiplug can handle it. DOH, I see Tim addressed that..

PS, the multistrip/plug is different than the circuit breaker, they may not be rated for the same, in fact unlikely.

 

[Michal Burisin]

@Michal Burisin Those two boxes look like an EMI filter on the bottom and a junction box at the top, the junction box will just put the 220V coming from the emi filter on to some sort of rail so you can wire up the 4 drives easily.

Ah, I see, thanks, so I could probably use something like this:

I would need 3 of them for 3 separate cables from power line. Then I could just use individual cables to lead power to controllers, so I would need just one power cable, which would be much cleaner / less bulky installation.

Then, I would connect it to that APC with EMI filter. Will be all the servos protected from surge with connection like this, or would there be some advantage with each controller having it's own power cable connected to SurgeArrest?

Is there some advantage to dedicated EMI unit compared to that one built in APC power hub?

 

[Michal Burisin]

The single circuit breaker is probably connected to all the power points in your room, possibly ones in the next room as well. You will have to start plugging in lights to sockets and turning off the breaker to figure out which sockets run off which circuits.

Those multiplugs are probably not rated for more than 10 amps either, so while you may be able to pull 16 amps from one socket you will have to check that the multiplug can handle it. DOH, I see Tim addressed that..

PS, the multistrip/plug is different than the circuit breaker, they may not be rated for the same, in fact unlikely.

Yeah, I have 3 power circuits on different breakers available in appartment - living room, 2 other rooms together on another and last one is bathroom + kitchen. I'll need to make sure, I'll use some light and try switching breakers on / off to make sure it's like how I remember it, thanks for the tip.

I checked that APC multiplug has 10.0A and 2300.0W limit in specifications, I'll keep that in mind.

 

[Tim Palmgren]

@Michal Burisin It is not best practice but I have a cheap 4 plug with a 10A fuse inside my rack case and each driver is wired to a normal plug and inserted. Then that 4 plug is inserted into another power strip outside of the case on the floor with either a 10 or 15A fuse (cant remember exact amperage but it is a more expensive one with individual power switches per socket). That allows me to power the drivers on and off with the flick of a switch and I also have a few other things on there that I use selectively (not at the same time) like chargers for Vive Wands and a heater / fan (definitely not running heater simultaneously so these are shut off when the actuators are running).

For the Fanatec DD I doubt it would be drawing more than 200-300W, but you may want to wire the actuators for the G-Seat so you can separate them to another power circuit if you start tripping fuses/breakers on the same wall socket/power strip as the SFX100.

 

[GeniFx]

I'm building SFX100 with additional G-Seat, the build will consist from 4x SFX100 servos + 6x 60ST servos, so total of 10 servos + controllers.

I'm starting to solve the power connection / cable management.

a) Custom approach

I was considering to connect all the controllers to some single point and from there, there would be just one power cable to the outlet. But this would probably require some custom work / advanced electricity knowledge if there is not some product, that could do this.

I saw nice installation from @GeniFx - link to post here. @GeniFx could you please share how is the connection done? And what is inside these 2 boxes?

View attachment 321848

b) Power hubs approach

I found this product: APC Essential SurgeArrest, link here and with english description here.

View attachment 321849
Then I would buy 10 of these cables and plug each servo controller individually to SurgeArrest.

View attachment 321850

For 10 servos, I would need those 2 APC SurgeArrests. Those would be probably stashed in some control box, that would not be easily accessible. So I thought, I would plug these 2 APCs into another power hub (image below just for example, I will try to find another Surge Arrest with individual outlet power buttons), that would serve as main one and would be easily accessible. When starting the rig, I would manually switch on all systems one by one to avoid possible overload when powering everything up at once.

View attachment 321851

I saw somewhere before that these hubs shouldn't be connected one to another, but I cannot find this info anymore, maybe it was related to specific product, but I cannot remember.

In APC manual, I found just this: "1. Plug the surge protector into a grounded outlet only", which I think is ok with it connecting to another hub, because I think every outlet of that hub is just another normal grounded outlet, am I correct?

What I found interesting is that APC provides EMI filter:

EMI/RFI Noise rejection (100 kHz to 10 MHz)
60.0 dB

Is that something, that could possibly help with EMI issues?

c) General power supply overview

The complete rig will be very power hungry:

1) 10 servos (4x 750W + 6x 600 W)
2) 6x Buttkicker Units (6x 1500 W) + 2x TST Units (2x 150 W) powered by 4 iNuke 3000 DSP amps
3) DD Wheel (1000 W)
4) computer (800 W)
5) other accessories

I know these max power limits are only theoretical and in real usage, the max power peaks are much smaller, but I would be worried to plug all this into single branch of the power supply to the appartment as it could overload the breaker for that individual branch. I have 3 different power supply branches in appartment I can use via extension cord from another rooms.

Is there some recommended way how to split the load in order to avoid EMI issues in general or it doesn't matter how I split it?

For example if the servos + DD wheel + computer with VR should be on one branch and I could power the tactile from the other branch or something else?

Many thanks for any insights!

Its Just A EMI filter and A box for the wago connections over to one cabel that go to the EMI filter.

Think you have to make 2 "boxes" for this if you are Running all those servos. I have A cabel rated for only 10amp from my servo controller. Not recomended but after seeing the power draw i used what i have Just to get IT up and Running. But its still cold after Running for 3 houres.

 

[Michal Burisin]

@Tim Palmgren Thanks, that's my secondary option to do it like that it would be easiest to do I think, but little more bulky and expensive.

@GeniFx If I go this route, I will definitely do 2 boxes - I will separate servos fro SFX100 from G-Seat. I'll probably just use the EMI filter inside that APC SurgeArrest to not overcomplicate it.

I will stop at the electric supplies shop and see what they will recommend me to do with my particular skills with electrics .

Thanks everyone for help!

 

[Eric Bergeron]

@saxxon66 I know you probably talked about maintenance of the actuators, but I was wondering if it was possible or a good idea to add a timerr to Simfeedback, so it would be easier to do lubrication periodically after say 50 or 100hre or other ... What do you think ?

 

[SixDegreesOfFlight]

Powered up my actuators on the floor for a test tonight - everything looks good.

Just need to mount the actuators and box up all the electrical and tidy up the wiring - sorry had to tell someone

Great job! They look exactly like mine. I am almost at the same stage. Let us know how the testing goes

 

[saxxon66]

@saxxon66 I know you probably talked about maintenance of the actuators, but I was wondering if it was possible or a good idea to add a timerr to Simfeedback, so it would be easier to do lubrication periodically after say 50 or 100hre or other ... What do you think ?

Nice idea, perfectly suited for an Extension.

Start here:
https://github.com/SimFeedback/SimFeedback-AC-Servo/tree/master/Src/extension