Herein lies the first project ever produced by motion simulation technology leader SimCraft. This complete DIY project represents the first application of the SimCraft architecture for motion simulation; the architecture for motion sim pioneered by SimCraft and launched in 1998. To read more about what makes this architecture more compelling than seat mover or “platform” type systems, click here.


This project is an extensive DIY project that will require fabrication of actuators, pneumatic valves, and many other technically complex components. It is not for everyone. Some of you may be interesting in adding motion to an existing flight sim cockpit, or simracing setup. A more desirable option may be the electromechanical motion simulator development kit :: STAR :: also from SimCraft :: which incorporates a commercialized and robust system designed to tackle the hard part of motion simulation and leaves the chassis and cockpit building to you. STAR also allows for seamless system integrations to other flightsim and simracing titles other than Microsoft Flight Simulator.


If you are interested in building the first SimCraft motion sim project from the ground up, read on.



SimCraft DIY


The main premise(s) behind the development of the SimCraft DIY™ motion platform was that it should be possible to develop a design for a motion system that would provide a major motion-enabling enhancement to home-based simulations and would be:



          1. SimCraft DIY 3.0 Installation and Usage.pdf

          2. SimCraft DIY Weight & Balance.xls

          3. SIMCATT7.GAU (USB Based attitude interface gauge for USB-ERB24)

          4. ISARELAY.SIMCATT7.GAU (Deprecated ISA Based attitude interface gauge for Acrosser AR-B2103)




SimCraft DIY Motion Platform Requirements

The requirements of the DIY system are:

· The SimCraft DIY Assembly and Instruction manual (part of this project)

· SimCraft DIY Interfacing Software for MSFS/MCFS (part of this project)

· 7' x 7' of physical space (minimum)

· A PC or laptop with a USB port available. (hardware spec sufficient for running Microsoft® Flight Simulator)

· Microsoft® Flight Simulator (MSFS) 98 or 2000 or 2002 or 2004 or Microsoft® Combat Flight (MCFS) Simulator 1 or 2

· One (1) canister style household vacuum cleaner

· Measurement Computing® Relay Board (USB-ERB24) - Available here:
http://www.measurementcomputing.com OR equivalent relay board

· Common hand tools such as screwdrivers, circular saw, hammer, etc.


1.1 Measurement Computing® USB-ERB24


The Measurement Computing® USB-ERB24 is a USB based rlay board equipped with 24 electromechanical relays of which 16 will be used for DIY. Please refer to the Measurement Computing® documentation for complete installation details, product function and configuration.


Technical information on the internal operation of the USB-ERB24 as well as several test software applications may also be found on the Measurement Computing® website. (http://www.measurementcomputing.com)


1.2 Modified Flight Instrument Panel – the SimCraft DIY enabled Attitude Gauge


The SimCraft DIY enabled attitude gauge file, SIMCATT7.gau, provides output data to the USB-ERB24 relay board based upon attitude (i.e., Pitch and Bank) information extracted from Microsoft Flight Simulator®. It encodes positive pitch attitude from MSFS into the 4 most significant bits and negative pitch into the 4 least significant bits of the byte used to command the pitch digital valves. Similarly, the bank attitude data from MSFS is encoded into the upper and lower 4 bit "Nibbles" of the byte used to command the roll digital valves. As detailed below, this gauge must be called out in the panel configuration file of every simulated aircraft that is to be SimCraft DIY Motion Enabled.


1.3 Weight and Balance and Inertial Loading Spreadsheet Model (Excel Format)


The DIY Weight and Balance Spreadsheet model contains a complete model of the SimCraft DIY motion prototype. The spreadsheet cells are color coded for easy identification of input data (Green), constants and assumptions (Yellow) and, calculation cells (Blue). The spreadsheet can be used to determine the effects of changing the position or weight of any element of the SimCraft Motion Platform or any other platform similarly suspended (i.e. like a physical pendulum) Study and understand the green coded cells and change them at will to reflect the design of your particular platform and setup. Be a little more careful about changes to the yellow cells before changing. Unless you completely understand the calculations within the blue cells, do not alter other than to copy or duplicate (entire rows) to add a similar element to the model. Note that you could build the entire platform without even referring to the spreadsheet and rely on trial and error to get the balance and CG location correct. The model simply helps in that process and helps to understand the inertial character of the platform also. Observing the spreadsheets calculated results as you change things can add to your intuitive understanding of the expected response of the platform to control inputs.


1.4 Use of the balance weights


Pitch Frame Weights

The configuration of SimCraft DIY with respect to the location of counterweights – (pictured on simcraft.com) is the configuration that have had people ranging from a an eight year old child to 200 pound adults maneuver the platform using the same setup without need to rebalance. This is because the design constrains the center of gravity of the pilot to closely match the CG of the Platform just below the Pitch Pivot Axis. On the other hand, the weight of a given monitor, because it is substantial and located well forward of the Pitch Pivot axis could require use of counterweights on the shelf behind the pilot or, if it happened to be very light, weights mounted on the bottom of the monitor mounting shelf as would probably be the case for an LCD style display. The flexibility of the design will accomodate both of these situations.


Roll Frame Outrigger Weights

The Roll Frame Outrigger has 10 pound weights mounted at the extreme ends with the outrigger positioned in the full up (+30 Degrees) position. This position will raise the CG somewhat and make the platform easier to maneuver (Roll) Also, by positioning the weights outboard the roll rate is slowed in proportion to the square of the distance of the weights from the roll axis. Obviously, there are many, many combinations of weights and positions which can be used to alter the response of the platform to suit your simulation preferences.



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2. INSTALLATION NOTES

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2.1 Computer Hardware and Software Requirements

There are no special computer hardware or software requirements for use of the various DIY™ components. If you have a PC with Microsoft Windows® running Microsoft Flight Simulator® software successfully, the additional resource requirements for the SimCraft DIY™ related applications are not significant. An unused USB port will be required for the interfacing to the USB-ERB24 relay board.


2.2 Installing the Measurement Computing® USB-ERB24 Relay Board


The SimCraft DIY application software as supplied for use with DIY is compatible with the same default configuration that the USB-ERB24 is shipped with. This default install initially configures the USB-ERB24 as Board #0, unless other Measurement Computing® boards are present on the same system. To ensure that the board number is - Board #0 - install and run the InstaCal® software that was shipped with the USB-ERB24 relay board.


The USB-ERB24 relay board will plug into a USB port on the computer that is also running Microsoft Flight Simulator®. Refer to your computer's documentation to identify the USB ports that it provides.


2.3 Installing the SimCraft DIY Enabled Attitude Gauge in MSFS


Copy the SIMCATT7.gau Microsoft Flight Simulator® gauge file into the "GAUGES" Directory. Under a default installation of the Microsoft Flight Simulator® software, this directory is normally located as follows in the hierarchy of directories:


Program Files

|

Microsoft Games

|

Microsoft Flight Simulator

|

ADV (Adventures)

Aircraft

*

*

*

Gauges <-----------SIMCATT7.gau in this directory

*

*

Weather

Then callout the gauge in the panel.cfg file of each aircraft in MSFS that you want to have SimCraft DIY Motion Enabled:


Program Files

|

Microsoft Games

|

Microsoft Flight Simulator

|

ADV (Adventures File)

Aircraft

|

C182 (Using the Cessna 182 as an example)

|

Panel

*Panel.cfg <--(Callout gauge here)


EXAMPLE:

Panel.cfg file:

// Panel Configuration file

// Cessna 182


[Window Titles]

window00=Cessna 182

window01=Bendix/King Radio Stack

window02=Compass

window03=Minicontrols


[Window00]

file=cessna182.bmp

size_mm=600

window_size_ratio=1.0

position=7

visible=1

ident=0


gauge00=Cessna_182.Suction, 49, 81

gauge01=Cessna_182.Fuel_Quantity, 23, 117

gauge02=Cessna_182.Oil, 23, 179

gauge03=Cessna_182.Timer, 88, 60, 52

gauge04=Cessna_182.EGT_CHT, 85, 116

gauge05=Cessna_182.Manifold_Pressure_Fuel_Flow, 85, 178, 59

gauge06=Cessna_182.Airspeed, 155, 45

gauge07=Cessna_182.Turn_Coordinator, 155, 148

gauge08=SIMCATT7, 243, 45 <-------------------SimCraft Attitude Gauge Callout

Typically, you may simply want to replace an existing Attitude Gauge with the SimCraft Gauge as shown in the example above where gauge08 used to be"Cessna_182.Attitude, 243, 45". In this case, we replaced the Cessna_182.Attitude name with SIMCATT7 and made no other changes. When MSFS is run using the C182 aircraft, the new gauge will appear on the 182 panel at the location of the original gauge. Attitude data will be sent to the relay card corresponding to the pitch and bank attitude of the C182.


Note that the two integer numbers following name of each gauge in the panel.cfg file are the panel coordinates of the location of that gauge. The third integer that appears in some gauges is a scale factor that can be used to control the size of the gauge. You could use the coordinates to locate the SimCraft as a new gauge (gauge09 for example) in a vacant area of the panel. You can use the scale factor to make it as small and unobtrusive or as large and prominent as you wish. A little experimentation with coordinates and scale factor will quickly reveal the relative effect of changes to these numbers. Be careful not to disturb the sequence of gauge numbers when adding gauges. If there is a gap in gauge numbers, gauges after the gap will not be displayed. Note also that gauge numbers always start at gauge00.



2.4 Installing and Running the Spreadsheet Weight, Balance and Inertial Model


The Spreadsheet is a Microsoft Excel® Workbook Document created with Office 97 Excel SR-1 and should be compatible with subsequent versions of Excel. Refer to the product description above for more information.






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3.0 KNOWN PROBLEMS AND OTHER ANNOUNCEMENTS

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There are no known or unresolved problems with DIY as of the date of this publication.