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Project AC Servo Motor - 15nM MiGe - by Beano, Based on Bernhard Berger API, MMos HID USB
Invité_mrbean_phillip_*
posté 31-08-2014, 12:00
Message #1





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Hello Everyone,
Firstly, apologies for the English Language, unfortuntately I do not know much French other then a few words... I hope you will enjoy reading this as much as I am working on the project.

Thank you also to Racing Mat for inviting me to open this WorkLog.

Whilst waiting for a few big players to release their latest versions of Force Feedback Wheels (FFB), I decided to have a go at doing my own wheel to tide me over.

Whilst hardware is important in such endeavours, especially when it comes to reliability and indestructability, even more important is the software and/or firmware to make it all work.

My wheel will be based on work done in this field by Bernhard Berger (API) and MMos (HID USB) both from Virtual Racing eV Forums

All credits to them for both the API and HID USB implementation of the soft- and Firmwares.

Also, I would like to try out the French version based on LPC board and firmware by you Guys (IMG:style_emoticons/default/happy3.gif)

With that done, let us get to the hardware list for this exercise.

1 -> AC Servomotor

Motors generally used in the DIY versions are mostly sourced from AliExpress, Hangzhou Mige electric Co. is the manufacturer -> talk to Lisa Zhan (Chunjin Zhan) -> http://www.aliexpress.com/store/100742
Get in touch with Lisa Zhan directly via email (hzmgdjzhan@gmail.com)

I have selected the MiGe 2.3kW version -> 130ST-M15015 with 30NM peak torque-> http://www.aliexpress.com/snapshot/6179659453.html

Using this will require a few minor changes to the controller settings, as the file provided by Bernhard is for the smaller 1kW motor. The 1kW version is more often used by most DIY’ers, and with its 10nM nominal and 20nM peak torque rating, should be sufficient for everyone! Unless you have a very sturdy racing frame, a nice 5-point harness and go to the gym for pretty extensive workouts, I would recommend the 1.0kW version, link below.

MiGe 1.0kW servo motor -> 130ST-M10010 with 20NM peak torque -> http://www.aliexpress.com/item/PM-Servo-Motor/267482883.html

Below a photo of the massive motor I got, metric ruler for scale - I wasn't kidding about the 5-point harness, Boyz.....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0515Large-1.jpg)


2 -> Drive-lock

After all the cabling is done, and before your first drive, you will need to mount a wheel-rim to the Servo, trying to turn this thing by hand won't work during extensive gaming sessions - oops, sorry iRacers, racing sessions.....for that part, I have sourced a split-bush at 22mm id to marry the two -> http://www.beltingonline.com/drivelock-13-22x47-dl13-9694

You will still need to make an adapter plate to mate your wheel's mounting holes to the split-bush, I will post CAD files shortly of two options, a simple adapter plate, and a nice eye-pleasing hub - designed by moa....below a pic of the bush next to a small electronic board, this for use with the drive controller....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0522Large-1.jpg)



3 -> Argon Drive Controller

Onto the part that will act as a driver controller for the motor, again most commonly used and open source with custom firmware for this application, done by Granity in Tampere, Finland - the venerable argon Drive Controller -> http://granitedevices.com/digital-servo-drive-argon

There are a smaller version sold by them too, the VSD-E, which will work fine for the smaller motor listed above - take note the 'smaller' motor will be on par with Leo's and Berney's consumer Servo Wheels, give or take a few ounces here and there...

A photo of the Servo Controller next to the HID USB interface controller, more on that below:

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0518Large-1.jpg)

and the back side, where you can mount an optional heatsink with a fan to provide even better current capacity, but this will not be needed in almost all applications - I will fit a custom heatsink though.

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0520Large-1.jpg)


4 -> HID USB Controller

If you only ever play iRacing then you can use the API version (by Bernhard) and you would not need this USB device – if however you also play other racing sims, it is advised to use this controller, the FW was developed by user MMos as mentioned before. This controller will be the interface between your pc racing sim of choice and the Argon or VSD-E drive controller.

STM32F4DISCOVERY -> http://www.digikey.com/product-search/en?K...eader=search_go

Anyway, I will be providing a layout schematic, as well as wiring diagram, and CAD files for the parts I design, feel free to use them for non-commercial purposes. Hopefully this exercise and many others like it, will bring an affordable solution to hardcore racers.

Update: Please find here the link for a schematic I have made for the Argon drive, Discovery controllers and motor.
https://www.dropbox.com/s/ug0y9gg80ctx7d3/B...202010.pdf?dl=0

Cheers,
Beano

Connected the drive controller to the Computer and flashed the latest firmware, both the Core and IO firmwares were done - versions in the screnshot below, firmwares from links in first post.

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/NewOSWFWflashed.png)

Onto the mechanical side of things, I will use a nice hub on this to connect the wheel rim to the motor shaft, I did this design which will also use only the inside part of the split bush, as I have tapered it to the correct ratio....so nice and simplistic, relatively lightweight also.

These have been passed to our CNC guy in the Orient, should be with us in ~3 weeks or so....ordered a few extras, just in case...

Let me know what you think:

front:

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/Front.png)

and Back:

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/Back.png)

Time to fit a few bits and pieces together, first the bush/adapter to the motor shaft, snug the bolts up in a cross pattern, like you would do when torqueing cylinder heads....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0531Large-1.jpg)

and

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0530Large.jpg)

Then proceed to mount the wheel to the adapter, short a few bolts, but this is just a testfit, no worries, final version will come without any empty holes.....

In use here is a spare Momo wheel I have, I would rather not use my spare new Mod 30 for this, as I like it more, so this one will be the sacrifical offer....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0532Large-1.jpg)

Do not worry also about the long screws used, again, this being a temporary plate only, the final solution will sport a very neat mounting hub...

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0535Large-1.jpg)

You guys reckon it is starting to look like something we could use for racing?

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0533Large.jpg)

As I have mentioned, photos don't always give you an idea about scale and size, so picture this one, here next to the 330mm Momo rim - it is a pretty big animal, as the Yanks would say, there is no substitute for cubic inches (IMG:style_emoticons/default/2501.gif)

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0523Large-1.jpg)

a close-up of the motor specs....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0534Large-1.jpg)

these bits I will put away for reuse later if I decide to use a smaller motor with lower inertia, let's first see how this is going to go, I would suspect pretty decent anway...

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0540Large-1.jpg)

Here are a few shots of it next to another pet project of mine, almost completed Tilton Hydraulic pedals - again you form an idea about the size of the motor.....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0542Large-1.jpg)

and

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0543Large-1.jpg)

then, once I am done with this wheel project, next on the list is this beast....

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0538Large-1.jpg)

A close-up of another bit of gear I fitted recently, this will be used to machine my heatsink for the Argon servo drive...

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0539Large-1.jpg)

designed in Germany and made under license in dearest 'ol China, is my Optimum Vario BF46 Mill....It is a pretty big machine in itself, weighing in at 500kg's and around 2.2M high sitting on its stand, this will soon be CNC'ed by me, myself and I.....blah, to many projects, not enough time, but it will get done.

I have 3x 750W DMM Tech servo motors and their tuned drives sitting in a box here somewhere, need to order the ballscrews....but another project for another log, soon...

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/IMG_0537Large-1.jpg)

Ce message a été modifié par mrbean_phillip - 9-11-2014, 23:39.
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Invité_RacingMat_*
posté 31-08-2014, 12:26
Message #2





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Really wonderful job! and detailed post!
(IMG:style_emoticons/default/arf.gif)
Thanks for your contribution Beano (IMG:style_emoticons/default/rulaiz.gif)

PS: I'm warning you: guys around here LOVE videos!
Je te préviens que les types d'ici ADORENT les vidéos !
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Invité_mrbean_phillip_*
posté 31-08-2014, 12:43
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Hey Mat,
Thanx for the welcome (IMG:style_emoticons/default/happy3.gif)

I will need to get a small vid-cam, I will soon go to Tokyo again, end of September is my next visit there, then I can get a good one at a nice price. My old one is quite bad after the cat jumped on the table and it dropped on the floor, now images all fuzzy.

But soon I will rectify the situation, so vids will come!!

I will also contact you wrt the LPC board, as mentioned, I would like to try that version also, will be quite simple to make the switch from the STM32 to the LPC, a few wires and not much more!

Cheers,
Beano
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Invité_Sweed_*
posté 31-08-2014, 13:19
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Hello and welcome MrBean (IMG:style_emoticons/default/salut.gif)

It's really a great project, impressive (IMG:style_emoticons/default/+.gif)

A good wheel, Tilton pedals (IMG:style_emoticons/default/love.gif) but what about the shifter? (IMG:style_emoticons/default/lol5.gif)
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Invité_mrbean_phillip_*
posté 31-08-2014, 13:59
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Hey Sweed, thanx for looking, and the feedback!

The Hyper comes with a really nice seq shifter, and I use paddle shifters on all my wheels, plus I have a Ligthning SS H-shifter....but I guess one if these days I will do a DIY version too, let me see what my few remaining brain cells can come up with.

First to finish this project though!

(IMG:style_emoticons/default/happy3.gif)
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Invité_thecures_*
posté 31-08-2014, 17:16
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nice project....it's possible to know all pedals feature!! where did you buy the componets...various element...electronic..... .ecc ecc !!! tks again
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Invité_mikethebike71_*
posté 31-08-2014, 20:31
Message #7





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Welcome Beano (IMG:style_emoticons/default/lol4.gif)
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Invité_mrbean_phillip_*
posté 1-09-2014, 11:25
Message #8





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Hey. Guys,
Thanx for the welcome, appreciated (IMG:style_emoticons/default/happy3.gif)
I will post a list of the pedals parts during the week sometime, most of it was bought from Summit Racing during a recent trip to the USA....

Anyway, I just ordered a nice enclosure for this DIY setup, I will house the Argon drive and other parts inside this -> http://www.ebay.com/itm/200938397133?_trks...K%3AMEBIDX%3AIT

Quite a nice price from Ebay, let us see what the quality is like once it is delivered, hopefully good....but it will take a few weeks to arrive, usually these free postage items are really on snail mail. I hope this will be a little quicker....

Onto other news, recently I have ordered another small servo drive, very much the same as Leo was using, brand new from the USA....I will need to fit an encoder, because it only had a resolver, but no issues, will also test that motor if the MiGe is to big. I will post more details later.

Cheers,
Beano
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Invité_rider63_*
posté 1-09-2014, 13:02
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Citation (mrbean_phillip @ 1-09-2014, 12:13) *
Hey. Guys,
Thanx for the welcome, appreciated (IMG:style_emoticons/default/happy3.gif)
I will post a list of the pedals parts during the week sometime, most of it was bought from Summit Racing during a recent trip to the USA....

Anyway, I just ordered a nice enclosure for this DIY setup, I will house the Argon drive and other parts inside this -> http://www.ebay.com/itm/200938397133?_trks...K%3AMEBIDX%3AIT

Quite a nice price from Ebay, let us see what the quality is like once it is delivered, hopefully good....but it will take a few weeks to arrive, usually these free postage items are really on snail mail. I hope this will be a little quicker....

Onto other news, recently I have ordered another small servo drive, very much the same as Leo was using, brand new from the USA....I will need to fit an encoder, because it only had a resolver, but no issues, will also test that motor if the MiGe is to big. I will post more details later.

Cheers,
Beano


Welcome mrbean_phillip! good work!

can you tell me more about this small servo drive please, do you have a link to order this?
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Invité_Stef Bord_*
posté 1-09-2014, 13:16
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+1, Welcome mrbean_phillip, good job and great pedals.

I see just one little problem to use the Mige 130ST15015. To have 15Nm constant torque, you must have 9,5A, but the Argon can deliver only 11A Peak of sine continuous, about 8A continuous (11A/1,41)...

Explication here :

http://granitedevices.com/wiki/Peak_value_of_sine

Ce message a été modifié par Stef Bord - 1-09-2014, 13:17.
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Invité_RacingMat_*
posté 1-09-2014, 13:20
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@stefbord : Maybe Beano will confirm what I have read on the german forum: the founder of Granite Device developed a custom Argon firmware to deliver up to 19A.

Citation (RacingMat @ 5-08-2014, 11:48) *
il utilise un firmware pour améliorer/adapter l'argon fournit par Granite Devices (Tero Kontkanen) :
- l'argon peut alors fournir jusqu'à 19A
- il peut "régler la vitesse" alors que sinon il faut augmenter le voltage de l'alim (comme Rider63 !!)

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Invité_Stef Bord_*
posté 1-09-2014, 13:22
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Ah ok, with this custom item, it will be ok... (IMG:style_emoticons/default/happy3.gif)
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Invité_mrbean_phillip_*
posté 12-09-2014, 14:04
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Hello Everyone,
Thank you again for the welcome, nice to see so many guys interested in the DIY projects (IMG:style_emoticons/default/happy3.gif)

@Stef: yes, as Mat said, Tero made a new core firmware available for the Argon. It is capable of 19A peak, of course I need to add a nice heatsink and force-cool it with a 120mm fan or something similar, but it will work very well to drive the larger motor.

Anyway, if the big MiGe will be troublesome, I also have a spare Danaher AKM52 motor as well, similar to Leo's one, so then I can use that one, which has a continuous torque of around 8Nm.....

But I will try this one first and see how it goes!

Will talk soon again, thank you for feedback!

Beano

Hey Guys,
word is just in that the hubs I have designed have been finished in the CNC shop in China, looking pretty spiffy....should have them by some time next week (IMG:style_emoticons/default/happy3.gif)

Let me know what you think!

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/imagejpg2-1.jpg)

(IMG:http://img.photobucket.com/albums/v329/MrBean_PM/imagejpg1-1.jpg)

Ce message a été modifié par mrbean_phillip - 12-09-2014, 14:03.
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Invité_Tortue G_*
posté 12-09-2014, 15:43
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Les pièces usinées sont très jolies et doivent être légères, par contre si je comprends bien elles se fixent en face avant du moyeu de serrage, je ne suis pas convaincu que ça soit la meilleure solution, il vaut mieux utiliser les capacités de serrage du moyeu qui travaillera ainsi comme il faut (IMG:style_emoticons/default/help.gif) .
Ca marchera certainement très bien ainsi, mais tant qu'à utiliser un moyeu de serrage expansible, autant le faire correctement (IMG:style_emoticons/default/happy3.gif) !

Le pédalier est très joli, par contre j'ai regardé le prix des éléments, et ce n'est clairement pas dans mes moyens (IMG:style_emoticons/default/lol5.gif) !

Ce message a été modifié par Tortue G - 12-09-2014, 15:44.
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Invité_Ponch'_*
posté 12-09-2014, 15:58
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Non, non je pense que son montage est parfait :

Citation
I did this design which will also use only the inside part of the split bush, as I have tapered it to the correct ratio


dit-il dans son premier post.

Great job Bean !
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