Two Degree of Freedom Motion Simulator Design, Fabrication, and Analysis

Abstract

For my Senior Thesis project, I designed, fabricated, and analyzed a 2 degree-of-freedom motion simulator seat system that could be ridden for gaming and roller coaster simulation. With the aid of technology, I modeled, built, and programmed its dynamic structure and controls system. The fabrication process involved the careful selection of materials for both their structural properties and ease of machining. Designs for all major components were created using Creo Parametric CAD software and assembled into a dynamic model to visualize and adjust the motion of the motion simulator system being built. The entire fabrication process was documented in detail, along with notes for future improvements and engineering drawings of parts so that others could replicate the design. Proportional-Integral-Derivative (PID) control was utilized in conjunction with rotary potentiometers to precisely control the position of the motors and their corresponding lever arms. A custom MATLAB script was developed to interface directly with the motor controllers to aid in benchmark testing and tuning of the PID coefficients. The process of designing a sufficiently robust system both structurally and electronically, along with the challenges of sourcing materials and learning the necessary manufacturing techniques, such as welding, has helped me develop my skills as an engineer entering the theme park ride/show control industry upon graduation from Princeton University.