Hoernle's Belt Tensioner - Detailed Build Instructions

[Hoernle]

@Andy J I just installed the Mcsetupctrl extension. For me it works perfectly. Just unzip the folder into the "extension" folder in the Simfeedback main directory. Then activate the plugin (see screenshot). Make a restart of Simfeedback and then you should see it in the "Extension" tab (see below).

 

[Andy J]

@Hoernle I took your advice and ran the remove blocking several times and then restarted and it has worked !!!! I need to spend some time figuring out how to use it but it has now installed. Thank you for your help - hopefully I can figure this out from here !!!

 

[Hoernle]

@Andy J fantastic . The plugin is super simple. Just click "add" to generate another controller. Each arduino needs one controller. Afterwards, just assign the correct COM port. In the device manager you will see which COM port belongs to your second arduino. Obviously, don't forget to click the green check mark to save. Probably you have to do a restart to see the second controller in the effect menu.

 

[Andy J]

So I have got the second controller connect, and the servo motor I am using starts up just like the main ones on the SFX100, but I cannot get any movement out if during a simulation. I am NOT using the same servo and controller as the SFX100, but a NEMA 32 and servo controller (open loop) - perhaps this is the issue ? but I would have thought that the simfeed back software is pushing out PWM signal so either should work as there appears to be no feedback loop to simfeedback judging by the wiring (only pulse/step , direction and enable).

The fact that the NEMA servo goes to the mid position using controller 2 when starting up had me hopeful - but now I am not sure .....

 

[Hoernle]

I have never heard that someone uses NEMAs with simfeedback. I guess there is a high chance that those motors are not supported.

Maybe someone else knows more?

 

[Andy J]

It looks like they are not - so I am off programming my own code now - strange that it calibrates like the others do but then nothing. Still getting to do it with my son - so that is a good time together although his coding skills are better than mine !!!

 

[Hoernle]

Ambitious project! Why would you prefer the NEMA? Are they significantly cheaper?

 

[Tronicgr_6DOF]

NEMA is a dimension specification for flange size, not a servo brand...

Is it NEMA32 flange? NEMA34?

 

[Hoernle]

Learned something again .

He is mentioning NEMA32.

 

[Kaj Rosenqvist]

I want to thank Hoernle again about making such great diy simracing product. First its very good belt tensioner, second it has also lap belts, and most importantly it can be made with basic tools and really basic skills.

I had have one constant problem. I am running belts higher force PN8 at 200, which which brakes smaller pulley quite often. Has anyone tryed metal pulley?

 

[Insert Coin]

I want to thank Hoernle again about making such great diy simracing product. First its very good belt tensioner, second it has also lap belts, and most importantly it can be made with basic tools and really basic skills.

I had have one constant problem. I am running belts higher force PN8 at 200, which which brakes smaller pulley quite often. Has anyone tryed metal pulley?

Print the small pulley with 100% infill (solid). Or with a high wall (vertical shell) count and at least 50% cubic infill.

 

[Hoernle]

Hi @Kaj Rosenqvist,

You are not the first one reporting this issue. Could you post a picture of the broken small pulley that I can see what ultimately failed? Did the teeth brake?

Despite having this issue only very rarely with high P8/P9 settings, I took the chance and designed a new version (1.4) of the belt tensioner that also addresses this issue by using a 1:3 gear ratio instead of the previously used 1:4 in version 1.3. I also reworked some other things and made a dual axis belt tensioner on top of the single axis. I didn't manage to write a build guide of this version yet but a lot of information is already available in the Good Vibrations discord in a dedicated channel.

The tips from @Insert Coin are potentially a quick fix.

 

[Kaj Rosenqvist]

Hi @Kaj Rosenqvist,

You are not the first one reporting this issue. Could you post a picture of the broken small pulley that I can see what ultimately failed? Did the teeth brake?

Despite having this issue only very rarely with high P8/P9 settings, I took the chance and designed a new version (1.4) of the belt tensioner that also addresses this issue by using a 1:3 gear ratio instead of the previously used 1:4 in version 1.3. I also reworked some other things and made a dual axis belt tensioner on top of the single axis. I didn't manage to write a build guide of this version yet but a lot of information is already available in the Good Vibrations discord in a dedicated channel.

The tips from @Insert Coin are potentially a quick fix.

Its always breaks between layers. I have printed both ways and even 45 degrees tilted. Now best result is petg, 100% infill, slow 20mm/s speed and without fan. 1:3 ratio would be great, because little more plastic will make it more robust. Mostly when printed upwards pulley brakes between teeth and 45 degree section. So point where twist force is highest. And let me remind that I am really pushing it.

 

[Hoernle]

1:3 gear ratio has the advantage that more teeth are gripping. You would need a longer timing belt (64 teeth, HTD 5M, 320mm long, 15mm wide).

Could you let me know if your small coupling has 2 or 3 jaws?

 

[Kaj Rosenqvist]

1:3 gear ratio has the advantage that more teeth are gripping. You would need a longer timing belt (64 teeth, HTD 5M, 320mm long, 15mm wide).

Could you let me know if your small coupling has 2 or 3 jaws?

3 jaws. I ordered 12t steel pulley to try first. Of course steel isnt gonna break, but is it going to slip without hard measures like welding?

For everyone reading... 80st motor geared down is very capable to even hurt you, so it is good to have physical fuse on system like this. Printed right that original pulley is more than enough for P8/P9 75, and even quite bit more. I hope everyone puts emergensy stop button on their motion rigs, including any diy belts.

 

[Hoernle]

Let me know if you want to try the 3d printed small pulley.

For the belt tensioner design I didn't choose a metal pulley on purpose since it makes the assembly bulkier but obviously everyone can decide what they would like to have.

Emergency stop is very much recommended. The version 1.3 of this belt tensioner can develop a theoretical peak torque of 72kg per belt which is obviously dangerous.

 

[Kaj Rosenqvist]

Used This aluminium pulley and now its perfect. First I thought are set screws gonna slip, but they are holding perfectly. I suggest anyone with pulley breaking problems to try this.

 

[Hoernle]

Hoernle Belt Tensioer is now available as version 1.4. Check out the first post in this thread to get more information. Of course feel free to let me know your thoughts and questions.

 

[stas80]

I'm in the process of building this project and am really looking forward to playing with it. I'm curious why this can't be used with SimHub/Thanos? I have SRS as well but have recently switched to using SimHub for motion control and it would be nice to use the same app for belts.

 

[Hoernle]

Hoernle belt tensioner can be used with Simhub motion as well since Simhub recently got the motion plugin. This BT works with all controller/software combinations out there like the motion actuators.