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Thread: Project BruteForce2 - IONI-based DIY DD FFB Wheel

  1. #1
    Newer Member Beano's Avatar
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    Project BruteForce2 - IONI-based DIY DD FFB Wheel

    GENERAL INFO

    Please do not copy any of my work to other web-sites without prior approval and give credit where it is due.

    Hello Guys,
    After a rather short wait, here is the new Bruteforce2 project log, based on the newly released IONI Drive, by Granite Devices. This log will be a work-in-progress WIP, and I will consistently update the first few posts in this thread, to keep the information easily accessible. This work is a direct copy of my worklog at iRacing, and after request I have decided to share it here too.

    Here are the links to the original Bruteforce Wheel project, based on the Argon drive, also by Granite Devices. (note these links are at iRacing and I will create a new Bruteforce1 Argon thread here too.)

    Part 1: http://members.iracing.com/jforum/po...t/3282974.page
    Part 2: http://members.iracing.com/jforum/po...t/3293316.page


    Credits:

    Bruteforce2 will be the first wheel based on the IONI drive, and whilst I had a direct interface to Granite Devices in guiding the development of the IONI drive, to suit our DIY DD FFB wheel needs, there are a few key-players that make this build possible:

    Tero Kontkanen (Granite Devices): For listening to our feedback and incorporating them into the final design:

    1) IONI was originally planned as capable of driving ~8A Peak of Sine (POS), whist our minimal requirements called for ~13A POS. Due to this, the original 4x ‘PCI Express’ form factor was changed to 8x ‘PCIE Express’

    2) A simple 1x Cube motherboard to make the overall project affordable and easy to implement

    3) Provision for an external MOSFET driver stage that will allow us to drive large motors without any concern. With this feature, the sky is literally the limit , as it would be simple to design boards that can drive 100A POS. For practical use, however, we will be looking at ~30A POS. Lenze, large MiGe and others will be no problem.

    4) Further to point 3 above, the capability to run 2x IONI drives in parallel on a 4x Cube board, which will allow higher current to those not wanting an external MOSFET driver stage – this feature is currently untested though

    5) Encoder connector pin compatibility with Argon, as well as a simplified connection to E-Stop and Drive Enable interlocks

    6) PWM+DIR control based on Argon PWM+DIR principles – thank you to Bernhard and Michael for your efforts with this!

    7) One Granite software interface compatible with both IONI and Argon, soon new DIY DD FFB specific functions – the first I am testing, which will allow us to adjust current/torque on the fly


    Michael MMos: For his HID USB Interface based on the STM32 Discovery Controller, and continuous efforts in developing the firmware, finetuning it all the time as well as adding new features. Thank you, without you, this would have not been easy. MMos (HID USB)

    Bernhard Berger: For your original Argon API interface, it was you that got me started on Argon some time ago. I am hoping that at some point in the future, API mode will be available on IONI too, as I know you have very exciting things in development with the API interface. Bernhard Berger - API

    Ben Darley, Phil Berry, Brett Stiles: For your continuous research into components and producing parts-lists that will make prospective DIY’ers life so much easier, Ben and Phil, and Bretto, for tweaking my hub-design to something special - you can tell I am not artistic, lols


    Late 2014 IONI discussions between Beano and Granite Devices – narrated

    Meeting with Granite Devices, 17 November 2014
    Argon and IONI FW: Tero and Timo was keen to explore the option of creating a smaller footprint firmware dedicated to FFB-based direct drive wheel applications. They will simplify the UI, as well as remove unnecessary parameters, for example, if we only use torque control, they could take away velocity and position modes. Also, parameters that can simply be calculated will be done and hidden from the UI view.

    The new firmware will also have some other soft interlocks that will be selectable, something like preventing the wheel from exerting max force in an oscillatory fashion, like when you hit that damn wall after Eau du Rouge at Spa in the DW12 and the front wheels are caught at a bad angle, then the wheel will very violently do a few left-right movements, hanging off the wall there...so that can get quite scary...

    The main idea is that if the drive encounters that behaviour, it will be able to terminate the signal to the motor....of course; the degrees of rotation and interlock will be user selectable for those that will this added safety feature.

    IONI: Tero confirmed the first prototypes based on 4x PCI Express form-factor (not electrically compatible) are being delivered by the end of November and he doesn't foresee any delays, the first commercial boards will be ready around the middle of December.

    This is where things got really interesting. We discussed power stage and capabilities, and some here know the ION will be coming with a 10A driver stage. Well, after some brainstorming, Tero will be looking at making different versions of this, maybe something like basic, intermediate and advanced, not only in hardware capabilities, but also FW.

    He agreed it will be relatively easy to use the full 8x PCI Express form factor (note again, not electrically the same pin config!!) instead of the current 4x length, and could very easily have the output stage provide.....wait for it.....~20A! Far out, that is better than the VSD-160E, and in par with Argon.

    I also requested a feature that will allow us to use 2x IONI’s in parallel -> I was bowled over when Tero indicated that there will be selector on the pcb that will allow you to drive an external high-current driver...wow.....almost spill my beer all over the floor...

    So in essence, Tero will produce a high-current driver, probably in the 25-35A range, that we could buy off their web-shop.....and that will be driven directly by ION, something I was dreaming about someone would do for us.....at the flick of a switch or jumper, you can revert to onboard MOSFET driver, or external driver stage....

    Tero may eventually also provide the information to any drive manufacturer (as well as us geeks) that will allow them to design their own external MOSFET driver stage, to suit whatever you want to do.

    I cannot help to think the ION will redefine drive controllers for FFB wheels, and come at a significant lower price-point than Argon.

    Although the footprint of this controller is insanely small; it will more than adequately fill a pretty large gap in the current direct-drive portfolio
    DISCLAIMER 1: I accept no responsibility for anyone doing a project based on this information, I provide the following as a worklog of my endeavours and as information only. Should you decide to use this information for any purpose, the RISK IS ENTIRELY YOURS. In any such an event you want to use this information, please make use of certified and qualified electrical and mechanical engineers to support you.

    Also please note the legal implications wrt patents should you set out to gain commercially from this exercise! I provide this information with the full intent that this is for personal use only, no more, no less.


    DISCLAIMER 2 - SAFETY: Please keep in mind that the forces that the DIY DD FFB will generate is significantly higher than any available commercial FFB wheel, direct or otherwise driven. If you lose control during racing, or you have a wheel that behaves erratically, keep your hands away from it and rather hit the E-Stop or Drive Enable button. You have that wired, right? Also, note if you are using any USB cables connected to the wheel rim, secure it well!

    If there is a risk that the wheel might dislodge the cable, you don't want it near your face or eyes. Take precaution and rather wear safety goggles then when using this wheel. Safety first people.

  2. #2
    Newer Member Beano's Avatar
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    HARDWARE AND PARTS NEEDED

    -> Ben Darley have made a very comprehensive list of the hardware required for this and Argon projects, I will await his email and post that in pdf format when I receive it.

    -> For the ones in a tight budget, a big thanx to Phil Berry for the list below, please download the (Phil Berry Cheapskate Parts List) PDF file - sorry Phil I could not resist!!

    With that said, my components and bits and pieces below, I will update and complete the list to suit the components used in the Argon build, that will allow me to use the same enclosure and buttons, glands, etc....

    This first part of my build will be based on the IONI 4x Cube and Single IONI drive, as we are still awaiting arrival of the 1x Cube Motherboards.



    1 -> Servomotors

    MiGe Servo

    Motors generally used in the DIY versions are mostly sourced from AliExpress, manufactured by Hangzhou Mige electric Co. For the best pricing, talk to Lisa Zhan directly, you can email her at hzmgdjzhan@gmail.com or visit them -> http://www.aliexpress.com/store/100742

    For the IONI single drive based on either 1x or 4x Cube, the best motor to use would be one that would not exceed 15A POS (10.6A RMS), hence the small MiGe 130ST-M10010 with 20NM peak torque will be the best fit -> http://www.aliexpress.com/item/PM-Se...267482883.html

    For those that will be using the external Driver Stage once available, and would like more torque, not that it is needed btw, you can go for the larger MiGe 130ST-M15015, it is a shoulder-killer with 30NM peak torque available -> http://www.aliexpress.com/snapshot/6179659453.html

    A photo of the 20NM small MiGe, it is not small by any stretch of the imagination, weighing in at ~11kgs...attached is my old-style hub, the red part at the front an adapter by Brett Stiles, as well as my temporary mounting bracket, which I may develop a little further, as it makes for quick and convenient change-out of different servo motors....



    and another angle



    To give an idea of size, here is a shot showing the Large and small MiGe vs the original ECCI 7000 motor....bloody animals they are, good for a great workout. You can use this as an justification to your Wife, you won't need to pay Gym-fees any longer.




    Lenze Servo

    For those keen on trying a Lenze, contact Dennis Reimer at info@ib-reimer.de -> he might be able to assist with sourcing one - here is the motor specs - please be aware though that the Lenze, as is the case with the large MiGe, will need an external driver stage if you are after the full torque potential of these motors.

    Lenze Id Nr 15336793

    MCS12H15L-C40B0-A19N-ST5S00N-R0SU

    ventilated version would be:
    (230V)
    MCS12H15L-C40B0-A19N-ST5F10N-R0SU

    (115V)
    MCS12H15L-C40B0-A19N-ST5F50N-R0SU

    Here is a photo of mine, with a Martin Ascher mount, as well as split-bush and wheel adapter. Please note these pieces are temporary, I will do a custom mount for this, and we are awaiting the newly designed Beano/HRS hubs below, to round it off nicely.





    Danaher/Kollmorgen Servo

    There also is another servo, the AKM series by Kollmorgen. The one in Leo Bodnar's wheel is by this manufacturer and is of very high quality and might be the best and probably the most expensive one for our application. They are extremely smooth, comes with very decent NM/A ratios, and pack a pretty powerful punch for their size.

    The one in Leo's wheel is the AKM52, whilst Pavan Dendi has used an AKM53 in his DIY built. For those that wants the ultimate torque available, the 53 might be the go, I will buy one and test against the Lenze for performance, and feedback here.

    Part numbers:


    AKM52G-ANCNEJ-00
    AKM53G-ANCNEJ-00
    AKM54G-ANCNEJ-00



    Stepper Motors

    Although I won't be playing with these, IONI has the capability to drive Stepper Motors in closed-loop mode to the tune of over 25k micro-steps, for those that might want to look at really cheap and affordable alternatives. I leave this up to those keen to have a play, and please, if you do find something that works well, let me know, and I can update part numbers and specs here.

    Below a pic of a NEMA 34 closed-loop stepper, similar to that which the Accuforce is using, although that one is 'custom' made to SimXperience specifications. Compared to the 130mm body and 22mm shaft dia of the MiGe, it is indeed compact at ~85mm frame and 14mm shaft dia.




    2 -> Custom Hub and Drive-lock

    For the mechanical connection between motor and wheel rim, I have sourced a split-bush at 22mm id -> http://www.beltingonline.com/drivelo...2x47-dl13-9694





    I have designed a hub for the original Bruteforce build, and I have somewhat refined it for Bruteforce2. First picture below is of the baseline design I have done, using the same Drivelock bush as per above. The good thing about going down this path, is that I can use the same Hub, and fit different versions of the Drivelock 13 series to suit the Lenze, MiGe and Bodnar Servos.....happy with that.





    Sharp eyes might pick up the recess around the center of the hub, this will allow the Inductive Charger Coil to sit snug and cosy - something else I want to play with at some stage - well, better to include it now than to redesign the hub later.





    The next render is after letting Brett Stiles loose on it, I have to say I like the final design a lot, and have ordered a few for my use.

    Last edited by Beano; 06-09-15 at 09:34 PM.

  3. #3
    Newer Member Beano's Avatar
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    3 -> IONI 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 Granite Devices in Tampere, Finland - the newly release IONI Drive Controller -> http://granitedevices.com/digital-servo-drive-ion

    Please note there are the drive Controller, as well as the 4x Cube board that I will use in this project, and then, within the next few weeks, we will have the 1x Cube board available too.

    IONI Drive: -> Link to Wiki Pages -> http://granitedevices.com/wiki/Category:IONI







    IONI 4x Cube: -> Link to Wiki Pages -> http://granitedevices.com/wiki/IONICUBE







    and drive and 4x Cube side by side, the drive is indeed tiny...





    IONI 1x Cube: -> Link to Wiki Pages -> http://granitedevices.com/wiki/IONICUBE_1X
    *Please note we are awaiting delivery of the 1x Cube motherboards, I will update this once information is available. Picture below is the standard original 1x Cube prototype board, there are slight modifications to the release version:



    External MOSFET Driver:
    Please note this is FYI only, Tero and Team will decide if they will do this external driver as an Indiegogo campaign, or make the design files available to us DIY'ers to roll our own. Anyway nice to have such powerful capabilities from such a small drive.






    4 -> HID USB Controller

    This device acts as the interface between your PC (Simulator Game) and the IONI Drive Controller.

    STM32F4DISCOVERY: -> http://www.digikey.com/product-searc...ader=search_go

    The recommended USB interface is the STM32 Discovery.




    Core407V: -> http://www.ebay.com/itm/261045971937...%3AMEBIDX%3AIT

    There is an alternate model, a smaller footprint board, called the Core407V -> this will also work with the MMos firmware, but please note it is not pin-compatible with the Discovery, so be careful to ensure your wires at connected to the correct pins - as said, different on both

    Please note the smaller Core407V also needs an external programmer (to make things easier for most) -> http://www.ebay.com/itm/260922761103...%3AMEBIDX%3AIT




    Since the STM32F4 discovery doesn't come with any mounting holes, I recommend the following mounts for the Disco -> https://www.adafruit.com/products/1116
    Last edited by Beano; 06-09-15 at 09:38 PM.

  4. #4
    Newer Member Beano's Avatar
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    5 -> Power Supplies

    Logic PSU

    A small 24V Logic PSU is required to power the IONI and Cube - the current requirements will be in the 600ma range for every IONI drive - for those looking to use these as a multi-axis CNC controller, please take the above in consideration.

    With that in mind, I got myself some real nice Meanwell 24V 3.2A units, link here -> http://www.ebay.com/itm/131297748945...%3AMEBIDX%3AIT

    For those interested in a single IONI and 1x Cube board, I also sourced a smaller MeanWell unit, 24V 630mA, and they work like a dream -> http://www.ebay.com/itm/141101070242...%3AMEBIDX%3AIT

    Main PSUThe Main PSU will connect to the 4x Cube HV inputs, and will be switched via the IONI onboard MOSFET driver stage and provide power to drive the Servo Motor.

    There are 2 options here, using either a switch-mode or then a linear (preferred) power supply.

    SMPS
    If you opt for the more readily available switch-mode power supply, please note the requirements for a capacitor and beefy DIODE on the output stage, this will act as protection for the PSU against reverse-currents by the motor.

    (An 8000 micro-farad, 80VDC capacitor, together with a 35-40A 400-600A Schottky diode should work well, at least it does for me.)

    Here's a link to the Diodes I would suggest, they work rather well.... -> http://www.ebay.com/itm/140330599103...%3AMEBIDX%3AIT

    Search for MeanWell 48V 600W PSU, this will result in quite many links on Ebay. usually get mine from Taiwan, here is a photo with the aforementioned capacitor, diode and wiring fitted - please note I did a dirty and used the one leg of a 35a bridge rectifier, as my diodes were still enroute from Hong Kong...



    and




    LINEAR PSU
    The second option, would be the preferred one, as Linear PSU's can provide high current for very short bursts....again, please search for 600W or 800W linear PSU, the one below is an (way overkill for small MiGe) Antekinc 50V 800W unit -> I selected the optional 24V option here that will allow me to do away with the need for a separate 24V Logic PSU unit: -> http://www.antekinc.com/ps-8n50-800w-50v-power-supply/

    Please see here for one of Ben Darley's very nice descriptive how-to videos, this time on wiring the Antekinc Linear PSU pictured below, to 230VAC systems - watch this before you do, it is important!! Otherwise. you might end up with smoke and tears. Thanx Ben!!

    [youtube]http://www.youtube.com/watch?v=l5FiyLAgF-g[/youtube]



    6 -> Enclosure

    As I travel to Tokyo a lot, by mere chance I discovered someone at Akihabara Electrical Town selling some pretty decent enclosures, made by Takachi, I am using the MB-25 model for my endeavours, as this is the same one I use for Bruteforce based on the Argon Drive Controller -> http://www.takachi-enclosure.com/data/p_02aluminum.html

    Below a photo of the Takachi enclosure, with my custom CF plates for top, front and back. This unit is my current original Bruteforce DIY wheel, running the Argon, I would like the Bruteforce2 to look the same at the end.

    Attached Files Attached Files
    Last edited by Beano; 06-09-15 at 09:49 PM.

  5. #5
    Newer Member Beano's Avatar
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    SCHEMATICS AND WIRING DIAGRAMS

    To be continued'
    I will update this section as receive the 1x Cube hardware, please note the schematic below is only applicable to the 4x Cube and Single IONI Drive as per my prototype testing.

    Block Diagram of the IONI based on the 4x Cube


    edit: fixed a few cosmetics, use this latest version (7 May 2015)




    4x Cube Wiring Diagram


    Please download the pdf file(s) below, appropriate to your CUBE




    4x Cube Port Config


    Below a few pictures of the location of the ports on the 4x Cube, please note the small white arrows donates Pin 1 in each case. This might save you a bit of time.


    Cube viewed from the top, indicating the X-Axis



    front view, highlighting the Encoder and Servo Motor Output Power connectors:



    Last view of the various connectors as indicated in the schematic:



    1x Cube Wiring Diagram
    1x Cube Wiring Diagram
    Added 3rd of July 2015 - Enjoy!
    Attached Files Attached Files
    Last edited by Beano; 12-07-15 at 01:11 AM.

  6. #6
    Newer Member Beano's Avatar
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    Reserved for 1x Cube updates
    Last edited by Beano; 06-09-15 at 10:21 PM.

  7. #7
    Newer Member Beano's Avatar
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    PROGRAMMING AND SOFTWARE

    To be continued'
    To be updated

    IONI Firmware Updates:
    Latest version 1.1.0 -> http://granitedevices.com/wiki/IONI_firmware_releases

    Discovery Interface
    ST-Link software -> http://www.st.com/web/catalog/tools/...ype=partnumber
    * This is used to flash the MMos FW, downloaded in the link below, to the Discovery board.

    MMos Firmware* -> http://forum.virtualracing.org/showt...ack-Controller
    * Zip Files at the bottom of the 1st post in that thread, to be flashed by ST-Link software above

    For the correct procedure on how to flash the Discovery Controller to MMos FFB Controller, please download and follow the procedure in the 'STM32F4 Discovery Firmware update.pdf'.

    But, for the lazies, Ben Darley has done another superb video on the procedure, might make it easier for you. thanx again Ben, these are pretty darn handy



    Granity Software Suite:
    Latest version 1.6.0 and to be used with IONI FW 1.1.0 v http://granitedevices.com/wiki/Granity
    IONI flashing and setup procedure to follow during the next week

    Basic settings for IONI, this is for the MiGe M10010 (small MiGe)
    *Please note screenshots are in the same order of the 'tabs' in Granity software, from left to right.
    ** You can also download my settings (drc) file and upload it to your IONI for an easy setup.



















    Attached Files Attached Files
    Last edited by Beano; 06-09-15 at 10:18 PM.

  8. #8
    Registered Adrianstealth's Avatar
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    Nice one beano !

    Good to see it in the ISI forum now too
    [SIZE=5][/SIZE

  9. #9
    Newer Member Beano's Avatar
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    All good Adrian, hopefully this helps the community here too.

    Cheers,
    Beano
    Last edited by Beano; 06-09-15 at 10:03 PM.

  10. #10
    Registered DrR1pper's Avatar
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    Good lord, lol. We've struck gold!
    Guide: Optimal FFB settings for rFactor 2 - The key to driving in the zone/flow

  11. #11
    Registered wgeuze's Avatar
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    Thanks for very much for sharing all this information with the rest of the online world

    Quote Originally Posted by Beano View Post
    ....bloody animals they are, good for a great workout. You can use this as an justification to your Wife, you won't need to pay Gym-fees any longer.
    hmmmmmm, excellent





    Now if only someone in the Netherlands or western europe would start pre-fabricating kits as a 'turn key' product for a small but reasonable fee, maybe next year
    I could very well be going for an OSW if there is enough budget left (or at least the year after)

    edit:
    eddy, sounds sexy
    Last edited by wgeuze; 06-10-15 at 04:13 AM.

  12. #12
    Registered Eddy's Avatar
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    Thanks very much Beano. At work right now but tonight I am gonna read this.

    Is it okay to ask questions about the building process?

    @ wgeuze, gonna pm you tonight maybe we could do something together 😉

  13. #13
    Newer Member Beano's Avatar
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    All good guys, I will answer what I can, thanx for your feedback

    Kind regards,
    Beano

  14. #14
    Registered Led566's Avatar
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    Quote Originally Posted by Beano View Post
    All good guys, I will answer what I can, thanx for your feedback

    Kind regards,
    Beano
    Thank you Beano for posting this!
    Much probably I will be one of the first trying to realize the OSW with IONI Pro 1x Kit using your instructions, since I have ordered the driver in the indiegogo campaign (I was the 17°)
    So, if you don't mind, I will post here my progress, doubts, problems.

    1. MIGE 130ST-M10010 will arrive to my house next Tuesday. Total price payed is 404€ (direct order to Lisa Zhan, motor, courier, paypal fees, Custom duties, VAT)
    2. IONI Pro 1x Kit will arrive hopefully before the end of June. Total price payed for the kit is 154€ (indiegogo campaign)

    ...

  15. #15
    Newer Member Beano's Avatar
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    Hey Led,
    please feel free all of you guys to post in this thread, we can grow it the same as at iRacing, one place for all OSW users to share their progress and learn from other's results.

    i have had IONI with 4x cube up and running for a couple of months and it works great! I think at the end of this weekend I might post the 1x cube schematic to make it easier for those guys building with it.

    i have 3 kits coming, so should be quite soon that we will see many 1x cube IONI's

    Talk later again.

    kind regards,
    beano

  16. #16
    Registered Adrianstealth's Avatar
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    Led

    thanks for the post, please post progress ( good & dare i say any bad ) +pics if poss,
    these types of project i find very interesting, this is such high end hardware we are very lucky to have access to it at all for sim racing,
    & at these prices too !!!!
    [SIZE=5][/SIZE

  17. #17
    Banned Spinelli's Avatar
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    I am so pumped. I've officially decided. I'm getting one of these for sure. Done! (just need to do some more research on comparing three MiGes - big VS small VS the "15" version of the small).


    One thing that my CSW V2 has spoilt me with though is all the buttons on the wheels, the tuning of the FFB from wheel (amazing, so useful), and the lights/dash (fanaleds). Are there fairly inexpensive wheels out there with lights and buttons built into them? At the very least I would need buttons, I guess I can always buy those dashes with lights and stuff to mount on the wheel, but I don't think I'd be able to drive without buttons on the wheel...
    Last edited by Spinelli; 06-10-15 at 04:20 PM.

  18. #18
    Registered wgeuze's Avatar
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    That is the thing which most people forget Spinelli, a decent formula style wheel could easily set you back another $1000 at least.

  19. #19
    Banned Spinelli's Avatar
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    That's insane. A $180 Fanatec Formula rim would be fine for me if someone figures out a way to make the buttons work, no?...

    Actually, is the Fanatec even able to handle the power without possibly causing damage/deformity over time?

  20. #20
    Registered wgeuze's Avatar
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    There is truth to that indeed, but you do get what you are paying for. I'd want decent buttons, shifters, clutch, proper display, etc. Not something which still feels (and looks a bit)
    like a toy wheel (despite some cheeky marketing slogans). It just gets expensive pretty quickly and that csw rim, well, it does look good (despite some things I personally don't like about it)
    and is priced really, really well, considering the electronic quick release. But, you generally get what you pay for, the formula V2 rim is creaking already at times, on a V1 base :P

    The ability to change settings on the fly, on the wheel, is something I would give up instantly if there is the wheel I would like to have in the $500 range with all the ingredients I mentioned
    above. Is it impossible? No it isn't, but sometimes things cost what they cost and when a company wants to make a living, well..
    Last edited by wgeuze; 06-10-15 at 05:27 PM.

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