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Open FFBoard

A modular and open source force feedback interface and motor driver for DIY wheels and controllers

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The goal of this project is to develop a simple and highly customizable force feedback interface for stepper motors and servos or other motors for hobbyists as an alternative to expensive commercial options or for custom setups.

This will allow for example to build DIY direct drive wheel with high accuracy and responsive force feedback yourself or any crazy simulation interface you can dream of.

While there are several commercial toy grade FFB steering wheels and some higher end simulator grade producs these are very expensive and and are often not moddable or come with their own expensive ecosystem.

It makes sense to focus this project on a simple open source force feedback interface as this is the part where the community lacks a good and open solution.

Therefore the main goal will be to develop a universal FFB controller (Open FFBoard).

It will provide a modular architecture and interfaces with multiple motor drivers (think about vesc and odrive compatibility) and a reference motor driver board based on the TMC4671.

The FFBoard is just an interface for USB HID, encoders, buttons and pedals. It can interface with almost any sensor or motor.
The software is modifiable for different motor drivers and control outputs (USB HID for most users. Could also be a PPM output).

  • 1 × Motor driver For example TMC4671 FFBoard driver
  • 1 × Servo or Stepper motor
  • 1 × 36V or 48V Power supply

  • New TMC drivers!

    Yannick (Gigawipf)10/18/2020 at 20:16 1 comment

    Finally after a long wait the new TMC4671 boards are here!
    This time almost fully assembled from the factory. Not going to make any more completely by hand...
    The picture shows the old one compared to the new one.


    Changes include:
    • 2 motor caps
    • Onboard 5V regulator
    • Differential SinCos encoder inputs (Insane resolution)
    • Common voltage reference for shunt amps
    • Mosfets not blowing up on 48V (lowside gate pulldowns, safery zeners + 5v regulator for quick startup)
    • LM74700 instead of LM5050 for much stronger and faster active diode switching.
    • Better terminal layout for connecting motors due to rotated power stage.
    • NTC temperature sensor

    Update video hopefully coming soon with some details about the changes and sincos features.

  • SinCos encoders and a tiny wheel

    Yannick (Gigawipf)06/25/2020 at 19:25 1 comment

    While working on the next pcb version one task was to improve the support for analog sine/cosine encoders.

    With sincos encoders we have the option to use high resolution absolute encoders and in the next version hopefully even with differential inputs for less noise.

    For testing i made a few AS5115 based magnetic encoders and mounted a magnet to the shaft of a drone motor as a test setup.
    That gave me the idea to make a tiny ffb wheel :)

  • Added 3 phase servo support

    Yannick (Gigawipf)05/23/2020 at 20:54 0 comments

    As most high end direct drive wheels use servos instead of steppers servo support is important.

    The 130ST-M10010 and 130ST-M15015 are the most common servos for this application with over 20Nm of torque.

    In the last weeks i was able to compare the Nema34 stepper and a Mige 80ST-M02430 and a 130ST-M15015. Two very different servos.

    The 80ST is with under 5Nm a bit weak but has very low resistance and good reaction speed while the 130ST has dangerous amounts of torque and a bit more mass and resistance.

    For a wheel the 130ST is probably the best option here.


    The next TMC motor driver will also have the new chip with a few fixes, an onboard step down for better reliability and will probably keep the external braking resistor as the large servo does generate quite a lot of voltage when being turned manually.

    Update summary from the last video:



    Reasonable motors are for example:

    3 Phase servos:
    130ST-M15015
    130ST-M10010
    80ST-M04025
    80ST-M02430

    Nema34 Steppers with Encoder:

    34HE59-6004D-E1000
    34HS59-5004D +Encoder (E6B2CWZ6C or AMT132)

    Those are all usable motors :)

  • Developing a GUI

    Yannick (Gigawipf)03/27/2020 at 11:15 1 comment

    The setup procedure via command line can be confusing and error prone.
    Therefore a graphical interface should help with the setup and tuning of parameters.

    I chose python with Qt as this allows rapid development of a nice interface for changing main classes or setting up the motor driver.

    This is a very early version and later the most common setups might be done via a simplified wizard to reduce problems.
    The DFU mode allows to flash new firmwares without a debugger. Remember to do a full erase if problems occur as sometimes the ST programming tool does not erase the correct sectors...
    Later the DFU programmer will hopefully be integrated as well.


    The GUI can be found on Github (Ultrawipf/OpenFFBoard-configurator).

  • Announcement video

    Yannick (Gigawipf)03/13/2020 at 15:03 3 comments

    After working on this project for a year now i feel its finally time to make an official announcement video detailing some of the ideas and the current state of this project.

    Due to some requests in the end are also some longer racing demos of the OpenFFBoard in a wheel configuration.


    In this video i am showing project cars 1 and assetto corsa.
    Project cars 2 feels also great with that. Pretty much any racing sim should work nicely with this without drivers.

  • Finally FFB again!

    Yannick (Gigawipf)02/15/2020 at 13:56 4 comments

    The last days i spent preparing the firmware for a modular architecture, porting the old FFB code and improving it to a usable point.


    Constants for the driver and some settings are stored in flash and loaded at boot so you only have to set parameters like motor type, main class, encoder parameters and button sources once.

    Thrustmaster wheels with buttons are supported now as well as 8 local digital pins as button sources.

    Most of the effects are implemented and set to reasonable values.
    Its HID Physical Interface compatible so it works without drivers for any supported platform and game.

    Here is a short race with the new boards on low/medium power for checking some parameters:

    No comments on my driving or the mess of a table please^^

    The motor used is a Nema34 with a 10k ppr encoder on the back with a supply of 19V (Notebook psu).

    The large cap on the left is connected to the internal motor power rails to buffer the power without enabling the braking resistor too often. You don't need a cap this large but having more capacity is always a good idea here.

    I am now waiting for a new version of pcbs to arrive with better hall/encoder filtering as with some very noisy motors the pwm can cause some issues. Apart from that i am pleased with how good it works and feels and with some tuning it should get even better.

  • Improving noise with filters and better amps

    Yannick (Gigawipf)02/04/2020 at 17:23 1 comment

    In the first version of the TMC board i tried INA282 current shunt amplifiers.

    It turns out despite having very good specs on paper they are extremely susceptible to fast rising common mode voltages.

    And we have these a lot as the TMC needs to measure currents on the floating motor outputs.

    This meant extremely bad noise on the current measurements.
    As an alternative there are the AD8417 which are much better suited for this application for the same price.

    See for yourself what a difference this makes:

    3 Phase openloop current
    Open loop current of slow 3 phase motor

    Looks pretty good considering that this is on a low scale and we can go MUCH higher and maybe even improve the noise with filter tuning.

    INA282
    INA282 at more than double the current

    Looks very bad right?
    This is because the INAs output spikes >1V up or down for up to 15µs after almost every pwm cycle (25-50khz).

    This is the output of the INA282 with no motor current. Only pwm active. yup. pretty bad.

    Obviously we are now using the AD8467. For even better noise the AD8468 with low gain could be used but this would decrease the maximum current even more. I am aiming for >25A fullrange for this version for now.

    By using different shunts or the lower gain AD8468 we can decrease or increase the limit depending on the application.

    We will also add low pass filters to the encoder and hall inputs as with some motors significant pwm noise gets back through these lines and causes glitches. This means even more components to solder :/

    Next step is to order new pcbs to fix the previous errors and write the firmware.
    The firmware is currently in a stage where most base features are working and i am implementing an example for FFB soon

    Also as the board is quite small there is not much room to add capacitors causing high ripple on the motor voltage rail when backdriven as there is currently only space for one larger cap.
    When used with large motors it is recommended to add external caps between GND and PB+.

  • Boards. More Boards. Finally TMC4671!

    Yannick (Gigawipf)01/29/2020 at 22:25 0 comments

    After a long time planning the pcb and waiting for parts the first motor driver board is finally assembled.


    This is a fully featured motor driver with dedicated power stage for high currents, support for a braking resistor and active backfeed protection for high efficiency.

    Braking resistor can be activated either automatically via the TMC at a hard voltage level or forced externally at lower levels as well (if internal voltage higher than external for example)

    Encoder and Hall effect inputs are buffered and protect the TMC. All pins of the TMC are broken out to accessible headers.

    This board is not just for the FFBoard. It can be used for other projects as well.


    Its made to connect to the STM board via a ribbon cable or stack directly under the STM board for a compact setup.

    STM Boards for USB interfaces
    USB Interfaces

    Yes! First open loop rotations! (Connected to a Trinamic Landungsbrücke via SPI)

    Motor Driver
    TMC4671 powered first rotation

    Of course there are still issues as this is the first hardware prototype of this version and changes might be made:

    1. INA232 shunt amplifiers are extremely common mode step sensitive despite very high claimed CMMR. The slopes are too steep while switching. This causes high noise in the measurements.
      1. Change amps to AD8417 which might behave better but with higher gain maximum current is slightly lower
      2. Smooth spikes out with more aggressive low pass filtering
      3. AD8478 and higher value shunts for even better noise but lower efficiency
    2. Embarrasing error: The Oscillator is permanently disabled due to gnd at tristate pin... Fix: Scraped pad off... Easy fix in next pcb revision.
    3. Despite analog inputs on the tmc being 0-5V the single ended VM input only measures half range and a maximum of 1.25V. Very strange decision from tmc...
      1.  I did not catch this before so we will need a new pcb for this. Not a big deal for now because its only relevant for the forced brake resistor failsafe enable by the tmc which should not even be needed as the STM will do this normally

    Apart from these issues that can be easily fixed in the next revision the important parts seem to work correctly and the board can be used to start developing the software interface and initialisation routines.

    Also those industrial terminals are pretty expensive and might be changed to open screw terminal style which are also better for some permanent installations.

  • Testing the TMC4671

    Yannick (Gigawipf)11/23/2019 at 11:56 0 comments

    As mentioned before the reference motor driver could be powered by a Trinamic TMC4671.
    This motor controller promises everything a universal torque mode motor driver should do while being compatible with 2 phase steppers, 3 phase servos and DC motors with the same power stage. Nice.

    Big thanks to Trinamic MC for sending me a TMC4671 Devkit. This way i can begin testing the features before the fixed chip is sold again and the final pcb is manufactured.


    I tested the chip with the TMC IDE Trinamic provides for this kit. This software nicely explains with wizards in the form of a tutorial how to setup the core parameters of the TMC4671.
    It also helps debugging with graphs and register browsers.
    I have made a setup with a 2 phase stepper, an 8192ppr encoder and torque mode to see how it responds and it pretty much does everything the old OHSC with the powerstep01 did but much better and in hardware. Nice.

    A modular design would also allow support for multiple TMC Motor Drivers on one SPI bus for 2 or 3 axis systems.

    Video of the TMC4671 running

    And if you perfectly align the encoder speeds impossible for normals stepper drivers can be achieved.

    The next step is to finish a pcb and wait until the TMC4671 is sold again. This might be the best solution fo a reference motor driver for this project.

    *Update*
    Trinamic said to me that the TMC4671 in the fixed version is planned to be released in march 2020.
    Until then the current version is sold that has a few hardware problems.
    This means that the next prototype will still have the old version of the chip.
    For SPI control and FFB the bugs should not be an issue apart from having to slow down the spi clock a bit for now to avoid a data corruption issue.

    The step/dir interface does not work and the adc and spi MSB might have sporadic glitches which fortunately did not affect the motor control in the tests.
    All known issues are listed in the errata of the datasheet.

  • Change of project direction. More FFB, more compatibility

    Yannick (Gigawipf)11/04/2019 at 11:29 0 comments

    The goal of this project was originally to create an open source motor driver focussed on racing simulation controls.

    There are many different motor drivers but not many of them were really suited for the task AND hobby budget friendly.

    It makes sense to focus this project on a simple open source force feedback interface as this is the part where the community lacks a good and open solution.

    Therefore the main goal will be to develop a universal FFB controller (Open FFBoard).

    While the first prototype (OHSC) did kind of accomplish this goal it was clear that for reliable use and high accuracy the powerstep01 was not suited. They sometimes locked up or died as they were not used as intended and only provided 7 bits of resolution. I realized there is no way to reach the goal of reliable and high fidelity torque control with this device and there is a reason servo drivers are expensive.


    I was pointed to the Trinamic TMC4671 motion controller which would do everything needed directly in hardware and can be configured for steppers, 3 phase servos and DC motors simply via spi with the same hardware. The TMC4671 had as few issues in the first revision but will be fixed soon Trinamic promised me. Therefore i am confident that it should make things more robust and simpler on the software side if the task of controlling the motors is completely done by a separate chip.

    Building an external 4 half bridge power stage is more complex and expensive but will allow for much better cooling and higher currents.
    The goal remains to create a budget friendly kit but it is clear that the motor driver will get more expensive. (Think ~30$ parts OHSC -> ~50$ BOM cost TMC board + more work. We need 10 mosfets and drivers... etc.). From my calculations it should still be possible to make a kit like this below 100$ :)

    The current idea for the project will split into two main parts:
    1.
    An open source Force Feedback interface board with an STM32F411 for usb communication and control.
    This will support different motor drivers and will be modular. You can use your own motor driver or control schemes by writing c++ classes for this controller. The main software parts will be the motor control part for encoder input or force output and the control interface which will be USB HID for most users but could also be changed into a class that outputs PPM values depending on the steering wheel position and receives force values back to pass to the motor interface.
    For example a VESC or a commercial servo driver could be made compatible.

    2.
    A reference motor driver based on the TMC4671. This will be the intended motor driver for a direct drive wheel but can also be used as a standalone motor driver or development board for arduinos and different purposes. The STM board will be optimized for this motor driver.

    The next step is to test if the TMC4671 fits this goal and which motor drivers are a good alternative.

    This will be interesting and i will keep you updated. The new boards are almost finished and i am waiting for Trinamic to release the chip soon.

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jaygrovr wrote 11/09/2020 at 20:29 point

If I get some boards made, is this project far enough along it will run my servomotor with the software you provided?  Great job btw.  Is there a place i can donate for the hard work?

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mayataotaotao wrote 07/22/2020 at 04:49 point

Hi Yannick,
Can you send me a complete keil project?

I download your source code from gethub, but many libraries are missing and there are many errors in compiling. Now I have a complete set of hardware and software of motor driver, and I want to write a program similar to MMOs separately. However, after reading your source code and the open source simucube source code on gethub, there are still a lot of problems, which I don't understand. Do you have open source materials for MMOs firmware?

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Yannick (Gigawipf) wrote 11/13/2020 at 09:41 point

its a stm32cube project and should compile directly. if not check some include paths.

mmos firmware is not open source and the creator afaik abandoned it years ago.

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Peter Fröhlich wrote 06/07/2020 at 09:26 point

Hi Yannick, thanks for sharing the great project! I'm a professor teaching elektrical machine to mechanical engineering and mechatronics students (only basics, I'm no drives expert). Out of interest for a DIY FFB wheel and for the topic I found your project. I would like to create a prototype for testing myself. I cannot promise that I can make any useful contributions but who knows. Found everything on Github - thanks for sharing!


For force feed back we need only to control the torque, correct? Is that the main variable that's being passed on from the PC FFB driver to the wheel controller?

Thank you!

Peter

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fernando wrote 05/26/2020 at 17:05 point

I recently bought this hydro servo, to try to use it with another project, servo driver + arduino, but I didn't want to make it work, I would like to know more about the project.
I have this kit at the moment
https://en.aliexpress.com/item/33041958959.html?spm=a2g0s.9042311.0.0.2742b90amEFHwV

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Datch O`Neil wrote 04/20/2020 at 11:41 point

Hi! It is great project! Wanna try to use it, so I've ordered nema 34 stepper motor with driver and STM32F411RE developer board. Hope that I can run it with you software in a week!

Because of it got some questions:

Is it any PC software available? I just want to set up turning angle from PC, but I didn't saw it in your video.

What model of encoder are you using and how is it connected?

Is it any wiring diagram available?

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paytufo wrote 04/01/2020 at 23:37 point

Wow!!! I'm realy shocking!!! Congrats!!!

Will this work to use with a bike as a turbo trainer with programs as zwift?? The idea is very similar but simulating inclination and some other fisic parameters.

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Sean McVeigh wrote 02/28/2020 at 19:02 point

I'm working on a similar project to yours (even considering using TMC4671 early in the design stage, but I expanded my project to a custom FOC design). Its not for FFB, but does implement closed-loop torque control.

"INA232 shunt amplifiers are extremely common mode step sensitive despite very high claimed CMMR. The slopes are too steep while switching. This causes high noise in the measurements."

TI has an APP notes (sboa170b and sboa174a) and on currents sense amplifiers that describes this. There are three types of current sensing for an H-bridge: high side, low side, and inline. The TMC4671 expects you to use inline (at least the eval design uses it). One of the primary disadvantages of inline is the dV/dt. 

"We will also add low pass filters to the encoder and hall inputs as with some motors significant pwm noise gets back through these lines and causes glitches. This means even more components to solder :/"

Check out note sboa170b:

"For applications that require measuring current in a high dv/dt common mode transients like motor control and solenoid control, the INA253 is specifically design to reject PWM signals with a settling time of <10μs."

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Crousti wrote 12/17/2019 at 14:37 point

Hi, i kind of stumbled on your project as i am currently making one myself.

I am using a stm32f4 discovery board,  a Xnucleo powerstep01 for control, a hybrid 2 phase stepper that consumes a maximum of 6A per phase, with a 1000PPR encoder.

I am trying to adapt the software  from simucube instead of MMOS, as it is supposed to work better, but it seems i still have a very long way to go.

I am also building a 8 speeds H shifter that will be connected to the board.

For now i'd really like to see the thing moving. I will surely follow your example and use the TMC driver when it is released, but for now i'd like to get the first step, with the powerstep.

It does not matter If it fries, or is not good enough. It will motivate me to continue ...
Since you abandoned the powerstep solution, would it be possible to get a look at your code ?

Thanks :)

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Yannick (Gigawipf) wrote 12/20/2019 at 11:00 point

The main part will now be a stm32f4 based usb interface with a modular software architecture. This would be kind of an open source alternative to mmos if you are interested.
You could use it to also control a powerstep based motor driver. I can send you some ressources, but while it worked, it was also far from finished.
Therefore the new modular software approach.
The first boards for that should arrive soon. Think of it like the top half of the old board with a bunch of headers for extension and your own motor drivers.

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mayataotaotao wrote 07/22/2020 at 04:40 point

Hello, man, do you have the source code of MMOs? I'm also doing the same thing as you, but I don't have all the source code of simucube. I still think it's better to have the source code of MMOs.

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julien.greffeuille wrote 12/04/2019 at 18:18 point

Hi Yannick, i'm looking to make a diy nema 34 based steering for over 2 years, i'm now in first year of electronic school (hopefully i would be able to created circuits like you one day :) ). I'm looking at your project for several months now and i would be glade to be one on the first to try this circuit when it will be finish.

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Yannick (Gigawipf) wrote 12/05/2019 at 12:49 point

The next motor driver board will probably be made soon once the pcb design is final.
Its pretty much almost finished. I will post a log once it runs and if you have any requests you can message me via PM or the group chat.

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Benjamin wrote 11/22/2019 at 21:27 point

It would be wonderful if you could add 2 axis/joystick force feedback to this project. An open source solution is much in demand.

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Yannick (Gigawipf) wrote 11/23/2019 at 18:24 point

Currently not the main goal as i am trying to get a reference motor driver finished and the boards done, but certainly possible to implement later.

----
The design will be modular with the ability to have up to 3 motor drivers on one bus. It should be possible to implement that in software.

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Dmitriy wrote 07/08/2019 at 10:30 point

Great project! Any chance you can show piece of code for maintaining constant torque while changing position? I'm just curious of powerstep01 capabilities

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Yannick (Gigawipf) wrote 11/23/2019 at 18:21 point

I have used a foc like control scheme by sending bursts of step pulses to align the measured encoder angle to the current phase of the powerstep. Crude but worked. The the motor current was changed to set the torque together with a 90° phase offset of these step bursts. The next version will feature a real FOC motor driver and should run much better.

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Daren Schwenke wrote 05/11/2019 at 19:35 point

I have always dreamed of a controller board which could handle both steppers and BLDC motors.  FOC applies to both in the realm of what you have done here.  The H-bridges required don't care if they are all bound to a single motor, so the same board could effectively handle both 3 stepper motors (6 H-bridges required), or 2 BLDC (3 phase delta wired) motors (6 H-bridges required) and use FOC control.  Just a thought...  :)

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