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Modular Control Loader Driver

CL_SPU_USB and BLDRV3 CL Cards

New - Nov 2018

BFF  Brushless Force Feedback Controller

 BFF modular brushless motor driver for force feedback flight controls.

CL_SPU_USB + BLDRV3 Data Sheet

Customer Installations

Follow the above link for examples of the CL system installation in heavy jet and other sims...

CLICK HERE FOR CARD PURCHASE INFORMATION

 

These are our latest generation of flight sim control loader drive cards for both leisure and commercial system builders.

 

The cards provide brushless motor drives for up to 3 flight control axes - elevator, aileron and rudder.

 

Each control station installation requires one CL_SPU_USB card plus one BLDRV3 motor driver card for each axis.

 

The CL_SPU_USB handles communications with the PC software and shares data and instructions with the individual BLDRV3 driver cards.

 

Up to three (3) BLDRV3 driver cards are then connected directly to the CL_SPU_USB - one for each control axis.

 

The BLDRV3 drivers support a wider range of motors than the older BLDRV2 cards. Other improvements include direct USB comms, onboard temperature and current monitoring, additional power-up calibration options and various software improvements.

 

Info on the older BLDRV2-24 cards is here...

 

 

DETAILS:

The CL_SPU_USB + BLDRV3 cards are driven by the BFF Control Loader software which supports FS9/X/P3D and X-Plane. NOTE these cards DO NOT operate with conventional USB output for FFB joysticks.

Please note that the BFF CL System generates force levels much larger than those from conventional FFB joysticks and this gives a more realistic flight experience when flying with a yoke, stick or flight column. The system can also be used to build FFB rudder pedals. The level of force generated depends on the selected motors and the mechanical transmission ratios designed-into the flight controls.

The BFF CL system was primarily intended for leisure use by flight simulation enthusiasts. It has also been adopted by many sim builders providing systems for flight training.

 

I normally supply the CL_SPU_USB + BLDRV3 cards only; to complete a Control Loader project you will need to source for yourself all other components required for the system.

 

Pre-built enclosed systems are available - details on request.

 

A BFF CL Software non-commercial use licence is included with card orders. Please contact me for commercial use of the software.

 

For an essential review of the steps required to build and complete a flight control loader system please read CAREFULLY the project overview documentation provided for a self-build flight yoke project.

FEATURES:

Brushless Motor Driver

CL_SPU communications and control card

Brushless Motor Driver

BLDRV3 motor driver with 80ST-M02430 motor

  • For operation with BFF Control Loader software. Follow the link for more details of the software loading components and features.

  • For use with 60ST-M01330 and 80ST-M02430 3 phase servo motors (with 2500ppr encoders)

    OR

    Agenzia Pini SpeederMotion MB082GA210 BLDC motors which should be fitted with 360 ppr (5V DC, A + B) quadrature shaft encoders.
     

  • 24V DC operation.

  • Modular system - up to 3 x BLDRV3 driver cards can be plugged into one CL-SPU_USB control and communications card.

  • Automatic power-up calibration (APUC) movement features or manual movement calibration.

  • Simplified system wiring; driver cards plug directly into the CL_SPU_USB to provide inter-card shared communications. Pluggable screw connectors provided for external power and motor side wiring.

  • Full galvanic electrical isolation between the high current motor drives and the PC/USB system. PC connection is by included USB cable.

  • 3 phase continuous sinusoidal motor commutation to generate smooth torque output for more realistic flight control force feel.

  • Onboard force calculation at 500Hz (for flight control movement related load components) with circa. 50Hz insertion of simulator flight dynamics related force components - combines fast and stable control loop operation with low resource on-PC CL software.

  • +/- 9bit force output resolution for smooth force control, 10KHz PWM.

  • PID controlled position following mode for AP following (and control station electrical linking - future option).

  • CL_SPU_USB setup parameters held in EEPROM can now be programmed directly from PC.

For further technical details PLEASE READ the data sheet here.

Motors

DIY Force Feeback Flight Yoke - BLDC Motor

MB082 BLDC Motor

The default BLDRV3 card programming is for use with 60ST-M01330 3-phase servo motors (with 2500 ppr encoders).

These motors are directly available from a number of Ali-Express sellers.

The 60ST-M01330 delivers approx 2Nm of torque when driven by the BLDRV3's. The larger 80ST-M02430 delivers approx 4Nm torque if a larger drive is required.

The cards are capable of driving other motors in the 60ST and 80ST range with suitable EEPROM settings changes.

Motor Wiring Diagram - 60ST & 80ST Servo Motors

In addition they will also operate with our original recommended Agenzia Pini SpeederMotion MB082GA210 BLDC motors which should be fitted with 360 cpr (5V DC, A + B) quadrature shaft encoders.

When building the motors into flight controls the mechanical transmission speed reduction ratios should be designed to generate the control force levels you require. Please contact me for guidance.

System Build

The BLDRV3 drives MUST be used in a properly designed and constructed electrical/mechanical system.

DIY Force Feeback Flight Yoke

The mechanical transmission connecting your flight controls to the drive motors must be carefully designed and built - it must be strong and stiff enough to carry the considerable forces generated by the motors. It must also be completely free of any play or backlash, be smooth in operation, have low levels of friction and have a suitable overall gearing ratio which is constant over the full working travel of the controls. The CL software and electronic hardware can not compensate for poorly designed or built mechanical transmissions.....

System Wiring

Please also read the card datasheet for further technical details.

 

BFF Control Loader System

 

The above system diagram MUST be read in conjunction with these notes - BFF System Wiring Notes.

 

You should also ensure that you download and READ carefully the BLDRV3 data sheet BEFORE attempting the project.

Power Supply

The Mean Well NES-350-24 (or later equivalents) is suggested for 3 axis systems with 60ST-M01330 or 80ST-M02430 motors.

See - https://www.meanwell.com/webapp/product/search.aspx?prod=NES-350

The supply rated at 14.6 Amp which is sufficient for a 2 axis system such as the DIY flight yoke when used with MB082GA210 motors. The 60ST-M01330 motor draws less current and this PSU would be sufficient for a 3 axis system

But it may be too small for a 3 axis system (including rudder pedals) using MB082GA210 motors.

 

The Mean Well SE-450-24 (or equivalent) 18.8 Amp is suitable for most 3 axis systems with MB082GA210 motors. However if all three axes are to be used routinely at full output simultaneously then a larger PSU may be required.

 

In some highly geared systems it may also be necessary to provide some current sinking capacity in the power supply. This is to allow the supply to handle current generated by the drive motors under some circumstances. A Lead-Acid battery pair wired in series with the PSU can provide this.

BFF CL Software features

See the Control Loader software see here for details of the CL software and loading features.

 

 

 

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