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The current state of the motion rig project is still clearly in the design phase, but recent iterations have led to a fundamental insight: the previous approach to the axis drives has been completely discarded and is now being rethought from the ground up.

The focus is no longer solely on mechanical implementation, but specifically on the dynamic behavior of the axes. The goal is to achieve motion characteristics in the mockup that are as close as possible to the later full-scale, human-carrying version. In practical terms, this means high travel speeds, short response times, and a direct, responsive system behavior.

A key decision is the clear separation between mechanics and function. The mockup is not intended as a simplified model, but as a functional platform for electronics and control systems. The objective is to develop and test around 90% of the final electronics — including sensors, signal processing, and control logic — already at this stage. Ideally, scaling up to the full-size version will then only require adjustments to motor power, power supply, and mechanical dimensions.

To maintain maximum flexibility, the system is designed to be modular. The mockup is intended to support configurations as a 2-, 3-, 4-, or 6-axis system, allowing it to be expanded as needed. This not only creates an adaptable test platform but also provides a solid foundation for exploring different motion concepts.

A key technical aspect is the reduction of moving mass. In dynamic systems, the lower the mass that needs to be accelerated, the better the achievable performance. For this reason, the drive system is designed so that as many components as possible remain stationary, while only the necessary structure is in motion. At the same time, the kinematics are defined to create a clear relationship between rotational and linear movement — in the current concept, one full rotation of the drive corresponds exactly to 100 mm of travel. This makes the system not only easier to understand, but also significantly easier to test and control.

The choice of Hall sensors for position feedback follows the same principle. They provide a simple, robust, and directly usable method of position detection, which can be transferred to the later full-scale version without significant additional complexity.

In summary, this is not a traditional model, but rather a scalable development tool that allows behavior, control systems, and overall architecture to be thoroughly tested before moving on to the full-scale build.

With this step, a structured component system is introduced.

The goal is to organize recurring elements into clearly defined, reusable modules.
Instead of redesigning individual parts for each project, standardized components can be used and combined as needed.

This approach improves consistency across different builds and reduces development time. At the same time, it makes it easier to modify or expand existing systems, since individual components can be replaced or adapted without affecting the overall structure.

The component system is designed with a focus on modularity, compatibility, and long-term reuse.

After publishing the NanoMotionRig, I am now starting the construction of the next project: the MidiMotionRig.

Like its predecessor, this is again a desk-sized driving simulator. Compared to the NanoMotionRig, however, it already uses slightly more advanced hardware. In this version, Hall effect sensors are used for position feedback, along with a Sabertooth 2×32 motor driver as the motor controller.
For the actuators themselves, the components remain intentionally modest for now — 12-V geared motors are used.

So why not build a full-scale, human-carrying simulator right away?

A system of this size makes it possible to test many concepts without requiring much space. At the same time, the overall setup can be explored and refined without immediately having to work with large and correspondingly expensive components.

Another advantage of this approach is that the hardware grows together with the development stages. Components such as the Hall sensors or the Sabertooth motor controller are deliberately chosen so that they can later be reused in larger versions of the simulator. The Arduino used in the NanoMotionRig can also be used again here. In other words, the hardware is not replaced but carried forward from one development stage to the next and expanded step by step.

This time, the design is intentionally developed from the inside out. For this purpose, the simulator is divided into several functional modules:

1.) Surge

2.) Pitch and Roll (2DOF Seat Mover)

3.) Heave

4.) Sway and Yaw

This approach makes it possible to think through and design the individual motion axes separately at first. At the same time, the entire system is structured so that individual modules can also be built independently. For example, anyone who initially wants to build only a seat mover can start with this module and later expand the simulator step by step with additional motion axes.

Here is a first look at the current state of the design:

The design is, of course, still at an early stage. Anyone interested can follow the further design and construction process here on the blog.

With the 6-DOF Desktop Motion Rig, an important milestone has been reached — the design phase is complete. The manufacturing phase is now starting, and the first 3D-printed parts are gradually coming off the print bed.

The next steps will include assembly, commissioning, and initial motion tests. The goal remains a compact, modular entry point into motion systems, while also serving as a test environment for the larger platform.