I decided to build a full scale rudder pedal what would match the control stick I am working on.

-The dimensions and travel will be identic to the Bf109G6`s.
-Independent toe brakes
-Gas springs for the realistic force effects.
-Hall sensor for the yaw /high quality pots for the brakes
-Adjustable pedal angle

I have a pair of pedal castings to be used in this project.



Some early design shots:


rudder 1 by csaba.moharos


rudder 2 by csaba.moharos

Nice! You had those castings made for you, or is there someone who had a large run made for him and is selling them by the pair?

Hi,

it was made for me, but maybe he can make more. I will send you his contact in pm.

Thanks for the offer, but it wouldn't be my thing. You might have peeked the interest of others though.

VO101MMaister would you know if its possible to get hold of a KG13 cast?

What did you use to model that? It is BEE YOU TEE FULL

Autodesk Inventor

I use the same method as on the control stick. The only difference is that in this case I am using a gas spring to have a realistic force + damping sensation.

Here is a very early schematic:

You can also incorporate end stops in the cam, but make sure you dimension the bearing arm to be able to take the load. also, how do you account for asymmetry in the cam profile?

http://avia-sim.ru/forum/files/pedals26_193.jpg



Sokol1

Hi Brandano,

thanks for your comment. The end stops will be incorporated into the cam, but I would like to have some kind of an adjustable travel, will see.

The asymmetry is a very good point, thx for the head up! I will have to design the CAM profile to have the same lift of the CAM arm in both direction!

Sokol1,

I know Baur`s work it is very inspiring, but we both use a well known technical solution used in hydraulic steered aircrafts. It is called "the feel and centering unit" what can be seen here:
feel and centering unit

I am currently thinking how to convert my pedals to this sort of mechanism ,pretty simple if you look at what is currently used for centering:

And I want also to try and make something similar to replace the gimbals on my Hotas Cougar. With the difference that I am going to make it all using just hand tools, pencil and paper. Probably I will fail, but at least I'll have fun trying

Brandamo, sample of gimbal made with hand tools - with similar mechanism.

http://avia-sim.ru/forum/files/_01_212.jpg
http://avia-sim.ru/forum/files/_02_897.jpg
http://avia-sim.ru/forum/files/_03_185.jpg

Used in this "stick": http://www.youtube.com/watch?v=ylH5RU07vX0&feature=player_embedded

Sokol1

Very nice design, that double cam is a brilliant idea. My approach is probably not going to be so robust, but perhaps slightly more compact. Most designs place one of the sensors on the inner portion of the gymbal, what I want to do is to have one of the axes on a sliding contact so that both pivots for the sensors can be solidal to the base. This would allow me to add some force feedback mechanics later on, but requires some care to avoid backlash.

Some progress. The pedal I would say is 90% finished. I managed to make a CAM profile which produce a totally linear gas spring compression both ways.


rudder 3 by [/url], on Flickr


[url=http://www.flickr.com/photos/22174211@N02/6822869525/]
rudder 4 by [url=http://www.flickr.com/people/22174211@N02/][/url], on Flickr


I have to think about the sensoring method. Pots or Hall sensoring. On the main axis it will be hall sensore for sure. On the brakes some good quality pots could do the job as well.

Is there any affordable compact "pot style" hall sensor on the market? I remember some sensors what were offered as an upgrade for TM cougars. They were nice, compact ones. I know it is possible to make some homemade sensors, but I would prefer a ready made one.

They look great! The Cougar upgrade sensors are provided by Cubpilot - Cubpilot's Hangar
I used them in my homebuilt stick and pedals - they seem to be reliable and are very easy to mount. Affordable? depends on your budget, they are certainly more expensive than the DIY. You can email Cubby for details.

9T

Very nice center system!

I think that is more easy use HALL sensor for brakes than pots - these require gear do match movements.
DIY HALL assembly have a small ~30/40 degrees of pratical course, so you easy fit then in brake axis.
You find HALL sensor assembled like pots, like Clarostat HRS100 - not expensive like Cub's ones.

http://www.newark.com/honeywell-s-c-clarostat/hrs100-s-s-a-b-090/hall-effect-sensor/dp/32M7190
http://parts.digikey.com/1/parts/1599703-sensor-hall-effect-rotary-hrs100ssab090.html

Sokol1

Woww these are pricey. I think I will stick to the DIY version.

BTW - The above another option of assembled HALL cost over 3 digit...

Another option, assembled MaRS sensor (theoretically better than the HALL), sold by GVL224 from Ukraine - 10 Euros(15 Euros plus magnets).
http://tinyurl.com/7yfnjsf
http://tinyurl.com/7yfnjsf

Sokol1

Thx Sokol they look very interesting indeed. I get in touch with this guy. I hope he speaks english:)

Only a small update. Everything is coming together. In the last month I have finalized the design and made many modifications. I found and ordered standard parts required for the build, including sensors, dampers, springs, bearings ect...
I am also finished now with all the drawings, and got the workshop who will make the parts.

The main change on the pedal design was that I skip the gas spring as main tensioning element. It has too flat spring characteristic + they are not designed for a high frequency usage. Therefore I put a standard extension spring in, and an additional hidraulic damper cylinder.

I also decided to use a simple steel plate base. It is cheap and it will be very easy to mount into the floor of a cockpit stucture. Later I can attach any mounting fitting to it if necessary. So it is very flexible.

The machining and cutting of the parts will start in June. Hopefully I can assemble everything in July:)

Some pictures. Hopefully the very last rendered ones:)


pedal1



pedal2

The pedal castings require some polishing and filing. So I started it as well. On the left is the orginal, on the right is the "almost" finished:)


DSC_0182[1]