Good day everyone,
I have successfully designed and manufactured my own steering wheel simulator prototype. I completed the entire design and production process in just 39 days on a limited budget. Following this, I had the opportunity to exhibit my prototype and have guests test it at the Teknofest Bilişim Vadisi booth and the Formula Student Turkey event at the Körfez Racing Circuit. During this time, I received highly positive feedback from real racing pilots.
Regarding the technical specifications of the project:
The steering system primarily consists of the motor base and the steering wheel units. Thanks to its dual-motor, dual-fan, and belt-driven design, it can provide force feedback with approximately 6 Nm of torque.
The steering wheel was designed with driver ergonomics in mind, featuring a shape and button layout that ensures comfort for the hands and wrists. The buttons are fully customizable, and the paddle shifters feature adjustable length and reach settings. To keep the wheel lightweight, its construction utilizes an aluminum plate combined with 3D-printed ABS plastic. This lightweight design reduces the moment of inertia, ensuring that the force feedback from the motor is transmitted to the driver much more clearly.
The motor unit was engineered based on the principles of durability and detailed feedback. Bent steel plates were used in its construction to eliminate any flexing. To ensure that the steering forces from the simulator are transmitted crisply and to prevent the belt from skipping teeth, there is a tensioner system on the plate where the motors are mounted. The secondary plate holding this bent plate also functions as a slider, allowing the belt tension to be adjusted from underneath via a bolt. This mechanism minimizes any loss of motor feedback caused by belt stretching. Furthermore, the belt is positioned at a safe distance so it remains unaffected by the heat generated by the motors. Finally, a mechanical stop is integrated into the mechanism to prevent the internal cables from snapping.
