custom pedals

[Johand]

Hi There , i am starting with simracing again.
I bought a secondhand fanatec csw v1 wheel just to get started and ordered alu profiles to build a rig.
In the time i am gathering all the stuff that i need (seat ,pc , monitors etc.) i started to build my own pedal set

I want a solid set of pedals , hydraulic and with a realistic clutch feel.
I'm still working on it , now working on the electronics and ordered different springs for the throttle and clutch.

some pics:

master cilinder and slave


alu stock

 

[asteroulis]

Amazing piece of craftsmanship. keep us updated. Well done also for the thorough photograph record.It looks like you could document the whole procedure and sell blueprints if you feel you succeeded.

 

[Johand]

Amazing piece of craftsmanship. keep us updated. Well done also for the thorough photograph file.It looks like you could document the whole procedure and sell blueprints if you feel you succeeded.

Thank you , will update when i have more finished

 

[Moxley6969]

Very impressive. how is the clutch action feel ?

 

[3ller]

You sir have some awesome machining skills, this pedalset is pure work of art, love the bearing mounted pedals what bearing size are those? they look so slim, and what sensor are you going to use for throttle and clutch?? and last how do you hold the bearings inside the pedal arm holes?? just by pressure?? how you prevent them from sliding out?

ive sent you pm also

 

[Johand]

Very impressive. how is the clutch action feel ?

clutch feel is verry good , but not perfect now the little spring between the bearings is way to weak (small homedepot spring), i have ordered springs that should arive today to try some combinations..

the idea is to make a new rear plate and fix the spring between the delrin block and alu plate , i want to make magnets in the delrinblock for a hall sensor.

for the throtlle i don't know if i will use a hall or potmeter , with the potmeter i can only get about 30 procent of the 4095 steps.

i use a bodnar board.

 

[Johand]

You sir have some awesome machining skills, this pedalset is pure work of art, love the bearing mounted pedals what bearing size are those? they look so slim, and what sensor are you going to use for throttle and clutch?? and last how do you hold the bearings inside the pedal arm holes?? just by pressure?? how you prevent them from sliding out?

ive sent you pm also

Thanks , the bearing i use is a flange bearing , the flange is on the outside and the assembly is mounted between 2 12mm shaft supports , a shim is used to space them correct.
In the end i could use some loctite to lock them in place , altough it woul not be necesarry..

bearing is 12x24x6

 

[Flying Kefran]

That's very impressive.
Do you plan to do other parts of your rig yourself ? (shifter ?)

 

[Johand]

That's very impressive.
Do you plan to do other parts of your rig yourself ? (shifter ?)

I already made a sequential shifter , full alu


solidworks drawing for a H-shifter , still needs some redesign

 

[AussieStig]

Great stuff mate, fantastic workmanship and design. Looking forward to seeing how you finish this project

Cheers AussieStig[/QUOTE]

 

[Flying Kefran]

Excellent.
I think I recognise the sequential shifter that inspired you

 

[Johand]

Excellent.
I think I recognise the sequential shifter that inspired you

lol , don't they all look the same

 

[Johand]

this is what i have now

 

[Johand]

I finished the clutch assembly


and after testing with the hall sensor or potmeter i made this test setup and was able to get almost the full 4095 steps on the full range of the throttle


and the final version


also made a plate to fix my wheel , for a test fit i mounted the pedals to the rig



here you can see the new spring and the adjuster knobs i made

 

[Moxley6969]

I highly suggest ditching the wheel plate and mounting 100% direct to the wheel base.

PS pedals look freekin awesome.

pps what are the slide bushing's on the clutch pedal ?

 

[3ller]

Simracing porn is this!! top job done there!!

How is the linearity with the magnet configuration you got right now? I know that if the magnets are not located correctly the hall sensors have some linearity problems, i see you use two magnets on a slide by configuration, it is normally used the bic pen configuration where the hall effect sensor in inside a bic pen body and sandwiched between 2 magnets that rotates from the outside, to get the best linearity you cant exceed maximum 45º 30º preferably, cause the magnetic field changes following a sine cosine curve that is not linear but if you choose the apropiate part of the curve the response is pretty linear.

 

[Johand]

I highly suggest ditching the wheel plate and mounting 100% direct to the wheel base.

PS pedals look freekin awesome.

pps what are the slide bushing's on the clutch pedal ?

i have drilled the plate for the wheelplate and also for direct mount , but i wanted a small angle
Under the wood are 2 40x40 alu profiles..

the bushes are from iglidur from a lineair guide system , i will see how they hold up, might be changing them to lineair ball bearings on a steel shaft in the future

 

[Johand]

Simracing porn is this!! top job done there!!

How is the linearity with the magnet configuration you got right now? I know that if the magnets are not located correctly the hall sensors have some linearity problems, i see you use two magnets on a slide by configuration, it is normally used the bic pen configuration where the hall effect sensor in inside a bic pen body and sandwiched between 2 magnets that rotates from the outside, to get the best linearity you cant exceed maximum 45º 30º preferably, cause the magnetic field changes following a sine cosine curve that is not linear but if you choose the apropiate part of the curve the response is pretty linear.

I dont really understand your bic pen configuration , but i tried different setups and magnets too.
I have 6x6mm magnets and in this setup it decreases the travel of the magnets.
This way i could space the magnets only 12mm from eachother , therefore the linearity is pretty good.

For the clutch i wanted to put the magnets in the white bearingblock , but the travel of that block is about 25mm. when spacing the magnets to that there is indeed a big linearity problem , in the middle it hardly response so have to come up with something.

another idea is to make the hall sensor work only in the range where the clutch is starting to bite ?
or maybe it would be better with bigger magnets..

if anyone has a good idea please let me know!!

 

[3ller]

http://simhq.com/forum/files/userga...107610741072_1084107210751085108010901072.jpg

This is bic pen config the magnets rotate around the sensor. imagine a bic pen body around the sensor and the two magnets.
And then you have to restrict the angle you are going to use cause and select the right portion of the curve cause it acts as a sine or cosine wave.

http://www.gmw.com/magnetic_sensors/sentron/2sa/images/Angle_pos_chart.gif

The trick is to search for the sensor center 2.5 volt (half of steps) and try to get the 0 volt (0 step) 20 degrees back/before so you have a 40º sensor on the right portion of curve, you need to saturate the sensor in less than 45º for good linearity, look how in the middle always the curve flatens, your linearity problems could be cause you are on top or bottom of the curve.

 

[Johand]

http://simhq.com/forum/files/userga...107610741072_1084107210751085108010901072.jpg

This is bic pen config the magnets rotate around the sensor. imagine a bic pen body around the sensor and the two magnets.
And then you have to restrict the angle you are going to use cause and select the right portion of the curve cause it acts as a sine or cosine wave.

http://www.gmw.com/magnetic_sensors/sentron/2sa/images/Angle_pos_chart.gif

The trick is to search for the sensor center 2.5 volt (half of steps) and try to get the 0 volt (0 step) 20 degrees back/before so you have a 40º sensor on the right portion of curve, you need to saturate the sensor in less than 45º for good linearity, look how in the middle always the curve flatens, your linearity problems could be cause you are on top or bottom of the curve.

Thanks for the info

I will look in to this , i tested te throtle today in game and the linearity is not good , the response on half throttle is not the same so i have to change the setup.

Maybe i will change it to the potentiometer , it will be much easyer and i now doubt that less resolution will be a problem..