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on Thanos Controllers


Thanos controller info
Thanos Controller: Description and Features
The Thanos Controller devices are much more than they appear; they are neither a simple USB-to-DB25 adapter nor an Arduino device. These controllers are uniquely designed to work with any servomotor in the AASD-15A family. As the name suggests, the Thanos Controller is a controller that not only translates signals from motion software but also operates using multiple state machines from which four main modules interface to the outside world and work simultaneously, processing information at a rate of 2000 cycles per second.
The Thanos controller uses real-time communication with the motion software, elevating the simulation experience. The shared information enables the integration of additional features in the motion software or even overrides certain settings within the Thanos Controller or the motion software itself.
Objective of the Thanos Controller
The primary objective of this controller is to convert "raw motion position data" into precise timing "control signals" the servo drives need to perform the motion requested. In short, it determines the number of rotations and the speed for each servomotor, while considering a wide array of parameters and information detailed below.
Main Modules
To better understand its operation, it is essential to consider how all modules work together, processing information 2000 times per second to deliver a smoother and safer experience compared to other products on the market.
- Virtual Model of the Actuators:
This module stores all relevant information about the actuators, providing the controller with the data it needs to understand the actuators construction and specifications, including:
- Actuator Stroke
- Actuator type (rotary or linear)
- Leadscrew size.
- Movement limits (maximum distance)
- Park position
- Park speed
- Timeout settings (speed and time)
- Current position and real time position
- Filter Model:
This module is responsible for maintaining control over all parameters; it processes information based on each actuator's parameters to allow movement within defined boundaries. If the motion software sends incorrect information or movement beyond the defined limits, this module takes control and sends the corrected information to the servomotors. This module also manages the Spike filter, Speed limits, and Pulse filter boundaries.
- Automation:
The Automation module works in the background, managing essential functions whenever required. It calibrates the system at startup, moves the rig to park position as needed, handles the Standby position, and ensures smooth transitions between different states of the rig, such as from Park to Online mode or from Standby to Park. Automatically takes control when the communication with the PC or motion software ends for any reason.
- Safety Module:
This module is triggered by the Filter Model whenever parameters are out of range. It defines the actions to maintain rig behavior within acceptable limits.
Together, these modules enable a smoother and safer experience compared to many other market options.
Additional Key Features:
- Pause Motion: Pauses motion without stopping the simulator software on the computer
- Custom Park Position: Defines a specific park position for the rig, useful for ease of access
- Define Stroke Length: Allows setting the actuator limits (not recommended to exceed actual actuator capacity)
- Bidirectional Communication: Enables the motion software to access data from the controller for added functionality
- Manual Control: Allows rig movement testing without a PC connection
- Define Park Position Speed: Sets the desired speed for moving to park position
- Standby Position: Defines the pre-motion position, or lets the motion software control it
- Separate Park Positions defined by function: For example, a vertical position for certain actuators and a different position for horizontal actuators
- Define Leadscrew pitch: Specifies the pitch of each actuator
- Define Movement Direction: Indicates the primary movement direction for the motor, whether inline or foldback (Extend or Retract, CW or CCW)
- Manage Reduction Ratios: Allows adjustment for foldback actuators that use belt with some ratio
- Pulse Filter: Ensures smooth, consistent movement of the motors reducing noise in some cases
- Emergency Stop (E-Stop) Operation: Configures actions upon E-stop activation, such as holding position powered or cutting power to the motors (actuators may drop from gravity in some cases)
- Force Offline (FSW): Ignores motion data from the PC and parks the rig when set
- Power Save Mode: Manages LCD backlighting and power for servomotors after defined inactivity, potentially reducing noise
- Spike Filter: Filters out large spikes in data in motion by setting minimum movement ranges
- Backtrack: Controls how far the servomotor retracts from the leadscrew hard stop, reducing torque loading of the motor
The Thanos Controller is designed to handle data errors and prevent unwanted movements, but it depends on proper rig configuration, accurate actuator information, and correct simulation software usage. It cannot guarantee accident prevention, so always remain aware of potential rig movements or be sure to be out of harms way if you are not sure.
Disclaimer
Thanos Motion disclaims all liability for any damages, injuries, or accidents resulting from the use of this device. By using the Thanos Controller, you acknowledge and accept that Thanos Motion is not responsible for any incidents caused by improper use, incorrect setup, or malfunctions within systems utilizing this device. Operate this device with caution and remain aware of potential rig movements.
Questions and Answers
- What actuator systems or motors are compatible with the Thanos Controller?
It is compatible with any servomotor from the AASD-15A Servo Drives family; any size actually, AASD-20, AASD-30A and all motor flange sizes, 60ST, 80ST, 90ST, 110ST, 130ST. Additionally, it is an integral part of the actuator kits sold by eRacing-Lab and is also compatible with prebuilt surge/ traction loss system (Low Slider from RaceAtHome), among many others. It is also compatible with DIY SFX100 actuators and often used on other DIY builds like actuators for hexapods using Departed Reality plans etc.
- Is the Thanos Controller an Arduino?
No, the Thanos Controller is not an Arduino device. While some simulation controllers use Arduino-based hardware that requires the user to write code and compile it to load it on the Arduino device, the Thanos Controller comes with preloaded ready to use firmware, on custom secure bootloader that allows free firmware updates via AVRUBD utility. The Thanos controller is exploiting the microcontroller silicon entirely differently, as it’s programmed at machine language level (Assembly). It is a specialized controller that integrates multiple advanced modules to precisely and safely manage the actuators in a simulator, processing data at a rate of 2000 cycles per second, capable of producing 200Khz pulse train signal for real time control of the servomotors. This sets it apart from Arduino, as it is optimized for high-precision simulations and is not a generic programmable device.
- What is the difference between the AMC and the 4U?
The key differences between the AMC-AASD15A and the Thanos4U are:
-
- Actuator Capacity:
The AMC-AASD15A can control up to 7 actuators in a single device, whereas the Thanos4U supports up to 4 actuators. However, in SimHub, you can combine any number of Thanos controllers either AMC-AASD15A or Thanos4U to get as many axis you need. For example one Thanos4U for the four vertical actuators and a second Thanos4U for the horizontal actuators (Surge + double TL + Belt tensioner). - User Interface:
The AMC-AASD15A includes an LCD screen and a control knob, allowing users to configure and adjust the device parameters directly from the hardware. In contrast, the Thanos4U lacks an LCD and requires configuration through a downloadable software. - Ease of Use and Configuration:
The AMC offers a more intuitive experience for local configurations due to its physical interface. Conversely, the Thanos4U depends on software, which may be preferable for users who prefer managing settings from a PC.
- Actuator Capacity:
In summary, the AMC-AASD15A is ideal for users requiring more actuators in a single device and value direct hardware configuration. The Thanos4U, though limited to 4 actuators per unit, offers flexibility for advanced configurations in SimHub by combining two devices and is a simpler option for software-based setups.
- What motion software is compatible with the Thanos Controller?
SimTools, SRS (Sim Racing Studio), SimHub, DR-SIM (Departed Reality) and FlyPT Mover, which enhances its integration capabilities with various simulation platforms.
- How is the Thanos Controller connected and what does it require?
The Thanos Controller connects to the computer via a USB cable.
Recommendations for USB:
-
- On the computer side, a USB-A connector is used.
- On the controller side, a USB-B connector is used for the AMC and USB-C for the Thanos4U.
- The USB cable is recommended to be shielded not longer than 6ft if possible.
- It is recommended to use a USB hub 3.0 with its own power supply for a more stable connection and to alleviate failures from incorrect PC power management settings.
- Ferrite cores are also advised to minimize issues with ground loops and EMI noise.
Connection to the servo controller:
-
- Between the Thanos Controller and the Servo Drive, DB25 straight cable with female connectors on both ends are used.
- It is recommended that the cable be shielded to ensure signal quality and avoid external interference and preferably have all 25 wires 1:1 connected.
- How does the Thanos Controller connect to the motion software?
The Thanos Controller uses a fast 250kbs data communication protocol with very low latency, that uses hardware interrupts to process the motion data. This enables seamless data processing between the motion software and servo drives, ensuring real-time synchronization at a processing speed of 2000 cycles per second.
- What makes the Thanos Controller different from similar devices?
The Thanos Controller is not a simple USB adapter or an Arduino device. Its unique design includes advanced modules (virtual actuator model, filter model, automation and safety module), positioning it as a robust and secure controller for high-precision simulators. The high stability of the Thanos controllers allows for uninterrupted use with up to 100% duty cycle. Additionally USB communications are established via use of official FTDI interface that uses certified and signed drivers already included in windows operating systems.
- How does the Thanos Controller manage motion limits?
The virtual actuator model that the Thanos controllers use ensures that actuators operate within predefined limits. It’s impossible for the motion software to send out-of-range commands and if invalid data were to be received, the controller corrects or rejects and adjusts these to prevent damage to the system.
- What is the Spike Filter function?
The Spike Filter smoothens movements by switching to a slower artificial movement method with slower speeds while keeping track of the real time motion cues, helping to avoid abrupt changes that could cause damage or discomfort during the simulation, providing users with greater versatility in adjusting their simulator.
- Can the Thanos Controller handle both rotary and linear actuators?
Yes, the controller supports both rotary and linear actuators, as long they are using servos that belong to the AASD-15A family. Additionally, specific parameters such as spindle size, stroke limits and parking speeds can be defined.
- What happens if the connection between the motion software and the controller is interrupted?
There is a connection detection process that will detect loss of communication and will switch the controller to offline automation mode. The system will smoothly return the actuators to the “Park” position, waiting for next time that connection will be established.
- How can I define custom positions for actuators?
Individual "Park" positions can be set for a subset of actuator group. For instance, a specific "Park" or "Standby" position can be defined for vertical actuators and another for horizontal actuators. Additionally, the range of movement and limits for each actuator can be configured.
- What advanced configurations are available?
The controller allows:
-
- Adjusting reduction ratios for belt-driven actuator systems.
- Setting specific speeds that the actuators can move to Standby or Park positions.
- Configuring actions for emergency activations (E-Stop).
- Adjusting power-saving parameters, such as LCD backlight and servo motor power.
- Can it be used without a PC connection?
Yes, the controller includes a manual control function that allows testing rig movements without a PC connection. This is useful for testing actuators during rig construction or verifying actuator movement once assembled. On the AMC Thanos controller there are 4 direction buttons that can manually move the actuators while pressed. Furthermore, there is a manual loop test that moves the actuators slowly allowing the observation of the range of motion of the rig before using the motion software.
- How are the actuators calibrated?
The automation module calibrates the system at startup in under a second for most actuators. This ensures that all actuators are in their correct initial positions and reduces operational errors during simulation. Some horizontal placed actuators that are defined for use as Surge or Traction Loss, park at 50% and might take a few extra seconds to fully retract when you switch their Power On, before calibrating and move back to their 50% park position.
- What safety measures does the Thanos Controller include?
The safety module responds to any anomalies, such as out-of-range data or motor errors and takes corrective measures to prevent damage to the simulator and ensure safe operation. The Thanos controllers have detection of Servo Drive errors (alarms) that usually lead to disabled power to one of the actuators and automatically park the rest of the actuators until the error is resolved (usually just a power cycle of the power of the servo drives).
- Does the controller support firmware updates?
Yes, firmware updates can be downloaded from the official repository. This allows for continuous improvements and new functionalities as they become available.
- What is the difference between the Thanos Controller and a CAN Bus system and what types of motors do they use?
The Thanos Controller is specifically designed to control AASD-15A family AC servomotors in motion simulators using real time pulse positioning protocol. These AC servomotors are high-precision motors with feedback systems to control position, speed and acceleration, enabling precise and highly accurate repeatable movements with nominal voltage operation 220v AC (can work on 110v AC) and single phase Making it very efficient to use as these mostly consume power mostly when the load needs to be moved around. Their standby wattage is usually 10watt (each servomotor) while during normal gaming they average 50w to 75w. Of course, if demanded to execute a fast movement of the load, the motor can continuously draw up to 750w, or peak up to 1000W for several seconds. --- The CAN Bus, in contrast, is a just communication protocol widely used in automotive industry since the 80s, interconnecting multiple electronic devices in a distributed network sending packets of data over half duplex serial data line. Servo systems managed by CAN Bus are often lower voltage DC or BLDC motors 24V or 48V, which may lack the precision and feedback power of the AC servomotors. Furthermore, BLDC motors are known to have lower loaded holding ability because of the type of coils used, as they are more suited for continuous rotation operation (like scooter constant speed applications).
- What is the estimated lifespan of the Thanos Controller under heavy use?
The Thanos Controller has no moving parts and does not generate intense heat that could degrade its soldering or internal components. Its durability is comparable to that of any low-power electronic device operating at near-ambient temperatures. With proper use and under normal conditions, it can have a long lifespan.
- What additional servomotors, apart from the AASD-15A, have proven compatibility?
While servomotors from the AASD-15A family have proven plug and play compatibility with the Thanos Controller, it is possible to connect other servo drives or servomotor systems via custom cabling. Some of the tested Servo systems that are verified to work with the Thanos controller include the Teknic Clearpath SD family servomotors, Dorna M1 drives and with limited compatibility Syntron HS drives. No tests have been conducted, nor is compatibility guaranteed, with other types or families of servomotors, as they may differ in functions available.
- How does incorrect spindle configuration affect simulator precision?
Incorrect spindle configuration can cause several issues:
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- Incorrect speed: The actuator will move at an incorrect speed, affecting overall simulator synchronization.
- Imprecise distance calculation: The controller will miscalculate distances, resulting in desynchronized movements.
- AL-09 Alarm: The servo controller may trigger the AL-09 alarm when torque limits are exceeded.
- Actuator damage: Significant configuration errors may cause the actuator to reach its end of travel with excessive speed and inertia, potentially leading to mechanical damage, which is usual primarily for DIY actuators with 3D printed ends.
- Proper spindle configuration is essential for safe and precise simulator operation.
- What is the E-STOP compatibility and what functions supported?
Both AMC and Thanos4U controllers have and RJ45 connector next to the USB connector that provides input and output signals needed for a proper e-stop button box. The signal lines include two inputs, one for emergency stop button and another for a Force Offline button switch. The emergency stop switch is used to stop the motors in their current position (holding with power), while the Force Offline button switch is used to ignore any motion data from the PC and the motion software without breaking the connection. With Force Offline the platform will park itself providing a safe way to interrupt the game motion and to ensure the user can get in or out of the platform without fear of the platform moving potentially causing injuries because of moving parts. The RJ45 connectors also include three outputs that are used to indicate Some of the states of the controller. LEDs are usually used to represent these states, with RED LED to indicate the Emergency stop engaged, Yelllow LED to represent the system on Park or standby (blinking) and finally the GREEN LED to represent the system being online with motion enabled. The Thanos F-STOP button box has only the Green LED as part of the force offline button switch as indication, for simplicity of use.