DIY FFB Wheel Arduino Leonardo. 3 3

[Sieben 2]

DIY PWM+DIR DC Motor driver with DPDT Relay & MOSFET IRLB3034.

Schematics: PWM-pin11, DIR - pin10

Ai-Wave 2016, some desktop effects on slight set ups. ) 

 

[Sieben 2]

Find out the config with aiwave 2016 to work. The "constant force" slider, should not be zeroed. And that's it.
The relay driver works!

test run)

 

 

[Sieben 2]

SOLVED.

The DD config with 540 dc motor was too fast. It works but if gonna make a drift with it, or a like, i.m. release the wheel out, the motor runs away. Made the gear ratio smth like 1:6, and here we go)))

 

https://youtu.be/dMeOD56qgVw

https://youtu.be/CVFK2zGWokk

[Sieben 2]

And 100% ffb gain. That one was 80%.

[Sieben 2]

EMC 0.9. Wheelcheck 300 ms.

Constant should be checked) 

 

 

https://youtu.be/dkmy-lq6eL4

 

Figured out that the ffb greatly depends on this slider. EMC is alright for all the other games, with this slider being active) 

Edited June 16, 2019 by Sieben

[Sieben 2]

The relay module is assembled in such a way.

 

  

 

Test.

 

              

 

 

Determination of the freewheeling diodes locations and connection. Just with ordinary 1N4007.

 

  

 

 

And schematics for them.

 

[Sieben 2]

Advanced pwm+dir driver version is assembled. Got to test with MY1025.

 

 

 

                       

 

Capacitors.

 

 

Capacitors ripple current.

220uf50v x24 + 2200uf50v x2 + 3300uf63v x2

19A

 

220uf50v x24 + 2200uf50v x4

16,5A

 

Total

35,5A

 

 

Flyback diodes 30u60DN ~ 60A

 

Mosfets.

 

IRLB3034 x3pc.  Total allowed power should comprise  ~ 90 / 120A.

[Sieben 2]

And test with MY 1025 motor 

 

          

 

Cycle test.

 

https://drive.google.com/open?id=18xhuRHq46gW4J--yL3UAsAJd2QK6TINt

 

Wheel rotation rate - 220 rev/min. Wheel weight - 1,4 kg.

 

 

 

Step log 600ms

 

 

 

 

Checking  the MOSFETS temperature during the test run   PWM frequency - 16 khz.

 

Edited July 8, 2019 by Sieben

[Sieben 2]

Made some adjustments with min force for the wheel for the step test 2. To eliminate the zero responce zone. 

For the game have got some other set ups on it. 

 

And new link to encoder. 

[Sieben 2]

Made some corrections on the "gear to the shaft connection". 

[Sieben 2]

Noname wheel from oklick. 240mm  0.4 kg weight. )

 

Step test.

300/600

 

 

 

 

 

https://youtu.be/UwYMtKqMirE

 

Some current limiting tests with bulb 60/55w H4 12v. 

And linearity test with it. May be someone can find it useful) The FFB is less with it, but no motor overheat etc. 

 

[Krassi 692]

I follow this interesting project... Can I ask you why you choose chain instead of belt? As Motorbiker I know that to operate proper need to have some loose, if you tight too much it will become too hard and will kill the FFB effects, but in the same if it is too loose it will have some gap I think....There is a reason nobody to produce chain FFb wheel:) But will be happy to hear what you think and have in mind?;)

Cheers!

[Sieben 2]

I can give a number of builds with bike chains and sprockets, and can, may be even bet, that the only main reason, if the builders switched to the belts drive, is a chain noze, compared to belts ofcourse. On the other issues it is quite a good actually, as it appeared to be later on)

But generally, it's the most quick and dirty simple way to get everything work and be tested) Many aspects underwent under this scope. But ofcourse I too prone swithing to the belts, if build another base, with cars steering rack, i posted here before.    

Yea i made a bit loose to the chain, by adjusting the nuts on the motor mount. So that's not an issue. It do can have the right tension by that. 

Thank you Krassi for following this build) 

[Sieben 2]

Checked the torque test and a wheel under 12V12.5A Power supply appeared to be of having - 3.67 Nm of force. I made units conversion of the obtained data measured not with 1 meter lever of force, but with 7.5cm force lever. That has 5 kg at that applied point of measurement, fastened just right on that gear sprocket)    

Edited July 23, 2019 by Sieben

[Sieben 2]

Switched to 4khz PWM, and the driver works perfect. The 4n35 optocouplers, are not good for the 16khz pwm frequencies.  Any other optos can be chosen ets for the frequency that is out of the hearing range. But, 4khz is good too in that aspect. It's quite,  a quite one)))

 

The force linearity test)

 

12v12.5A

 

 

https://drive.google.com/file/d/1H-qEs65xWk0l8TBFCWeGutuWyR7YCI6J/view?usp=sharing

 

 

 

https://youtu.be/cosZzNbbOf8

Edited July 26, 2019 by Sieben

[Sieben 2]

With 12v33a - 5.5 Nm of force.

 

 

 

Step test is not set on full power with constant force. With just a bit of it. And it has a direct input on the results over here)   

[Sieben 2]

Checked the torque amount the wheel produce. I recalculated it before according to the lever it was measured, right on the sprocket, and that was 7 nm. Then checked with 1m lever and all the same results) A bit more then 0.7kg gives - 7Nm of force) 

 

https://youtu.be/pYQ6gguGLU0

 

And changed the wires in relay. Now it is a high amp one) 

 

[Sieben 2]

 

Some changes with flyback's connections. That should be a right thing. )

[Sieben 2]

By having directly cut out the relay from the driver, and having an idea of replacing it with a first bridge circuit there, instead of the relay, a quite reasonable question arose, why not actually give a chance to one BTS7960, together with the idle diodes and capacitors in a team. )

 

Driver with relay.

  

 

As a short summary, experience in using relays. To be honest, I don’t know what kind of assessment to give, because replacing the BTS and unscrewing the FFB 100% Gain, Constant and a feature in the form of Scale up to x2.5 times Constant in EMC09, I got almost the same steering wheel vibration in the center, as with the relay, but at much lower FFB values when there was a relay. For BTS, I left everything in a hundred and reduced Scale x1.5 Constant. If x2.5, the BTS chips get heat up more, so it is set in more “cautious” modes so far (Scale x1.5 Constant.)Again, can repeat that with the "relay driver" it pumped much more strongly at much lower values of force. The switching moment, by changing the direction of rotation, is also not noticeable, with a relay, as it may seem. The same thing in the center. But in short, if it were not for the "oscillations" in the center, as a result of a forced decrease in the strength of ffb, to eliminate it, an absolutely adequate and powerful playable driver would be obtained. If this is of course it's problem at all, i.e. see paragraph above. One can of course connect it to the bridge circuit, from the beginning of the experiments, and see what happens. ) Maybe even the first version of the diy driver will go, but with the correct binding for diodes, and condencers. It may even be possible to score on the need for deadtime s for the bridge. 

 

BTS7960. As it was announced earlier,https://www.xsimulator.net/community/threads/diy-force-feedback-steering-wheel-using-dc-motor-based-on-mmos.13019/#post-174094

the chip numbers in this bts are sort of from the correct series. (617)

   

 

The linearity of the base with a wheel of 1.4 kg

 

This curve, it seems even due to the fact that it is not MMOS that is used, but EMC. Arduino, and not an STM32. Presumably. Since, in the comparative test, one run was enough, and you get an even linearity curve, in MMOS, with EMC apparently has its own small issues, in this regard. But let me remind you that it was even too, when experimenting with the diy driver of the first version and with EMC09)

  

 

BTS7960

https://youtu.be/jNGLFM-X2Uo

 

 

Some sort of countersteering etc

https://youtu.be/GYLofjQ3jWE

 

 

And with relay.)

https://youtu.be/lVKL4GdzkJM

 

Edited August 12, 2019 by Sieben

[Sieben 2]

 

[Sieben 2]

 The power arrangement with caps and flyback for bts7960 used. The caps nominals and quantity is for example. Should be picked in accordance of the total amount of the ripple curent specs. 

Edited August 13, 2019 by Sieben

[Sieben 2]

Hi there!)

 

Some connections clear up with the power section to the schematic above) I can say that, the freewheeling diodes are an option, with BTS7960 usage. But also can be used for good with it. And, it is quite an obligatory to use this schematics, with complete diy controllers for powerfull motors.

 

 

 

 

Edited August 21, 2019 by Sieben

[Sieben 2]

Switched to mmos.

 

Made enclosure for STM32 & Arduino. Axis are connected via usb cables. 

     

[Sieben 2]

 

Level of Ai 120%. Low agression.

Powerfull FFB, motor takes 12A, with rated 14A. Good result with no super cooling of the motor to run it.

Edited March 4, 2020 by Sieben

[Sieben 2]

Made up the H-Bridge with IRF3205 and Ir2101 gate drivers.

 

Based on this.

http://tahmidmc.blogspot.com/2013/01/using-high-low-side-driver-ir2110-with.html

[ATTACH]71500[/ATTACH]

 

With such revision with IR2101

https://blog.avislab.com/ir2101/

[ATTACH]71499[/ATTACH]

 

        

 

Now to Relay driver.

Made some minor changes to the schematics of the diy gate driver component nominals with wires layout may be too, and found out that the mechanical relay driver is completely and fully corresponds to the needs of the motor driver for FFB. There is no lags or any of the kind due to the relay itself. No thouse oscillations and so on. Can be used with no problem may be except for the relay sound a bit. )

 

40% FFb with no extra min force etc. The mosfet is cool but the motor can be boiled with full settings) So works great really.

  

Compared to BTS with all the same force but with 2% of min force for BTS.

   

 

For low voltage mosfets with flaybacks, and high voltage mosfets with no flyback diodes.

 

 

Edited April 13, 2020 by Sieben