Projector Installation on 6dof Motion Platform

[sagrada737]

Hello Folks,

I have completed the trim of the projector screen assembly.  The finished result will yield a 210 degree wrap around display with the three (3) Optoma GT1080HD projectors.  The screen support matrix type structure is quite robust and does a good job of keeping the projector screen stable. 

The photo below shows me climbing around on the Nose Section/screen support structure to work on the wiring harness.  This made it easy to access various areas to secure the projector wiring harness.  I was able to finish routing the HDMI cables and the 120 AC power to the Projector Platform.

For the HDMI cable requirement, I chose to use an Fiber Optic Active HDMI cable 25 ft. in length.   The fiber optic HDMI cable eliminates any electrical noise getting into the display signals.

While I am waiting for my new Optoma ZH406ST Laser projectors, I decided to install my existing projectors in order to continue with the Sim Project toward completion.   Once I get the new projectors, it will be fairly easy to swap out projectors.   One reason for this, is that I made the Projector Mounting Board such that it can "slide" fore/aft.  The forward position is the active mode, and the aft position is for projector installation/removal and maintenance.  Below are photos that show the different positions.  The projector mounting board is also foam-dampened to help reduce shock and vibration to the projectors.  The new laser projectors will be largely immune to this.

After getting all the projectors installed and wired, I connected the P3D Sim Computer to test the projector display.  All projectors started correctly and the existing calibration was almost perfect, except for the Center Projector.  I will need to perform a new warp&blend calibration, which should be fairly easy using my auto-leveling laser level.   I'll take a shot at this tomorrow.   The main consideration was the Nose Section obscuring the display, but it turned out not to be a problem.

After I complete the new screen calibration, I will next retest the 6dof Motion Platform to insure that nothing changed in its operation.  After that I will work on final placement and securing of the MIP, TQ, Rudder, and Pedestal modules.  Once these are in place, I will finalize the primary wiring system, and hopefully at that point I will be able to fly the Sim for further active testing of the Motion Platform.   If all that goes well, I will focus on finishing up the Yokes/Control Columns and cleaning up the rest of the Sim to a point where it is basically completed.   I will still need to fabricate the Aft Section (all the stuff from the Circuit Breaker Panel back to the cockpit door, but that will be a follow-on project, which should be a lot of fun.

Mike

[FredK]

Really looking terrific!

Fred K

[Trevor Hale]

Hi Mike,

Looks really good,  Can't wait to see it operating.  The only comment I may make and it something that may or may not be a factor.  Your projectors are very close together.   The Heat Blowing out of one projector May blow into the intake of the other Projector.  You will notice after a couple hours of usage you may start getting Overheating alarms.  I know we had that issue with Sam's.

Trev

[sagrada737]

Very astute observation Trevor...

Indeed, with the Optoma GT1080HD projectors in the "direct projection layout", the Central and Right projectors need a Baffle between them in order to keep the hot exhaust air from the Right projector from being sucked into the Central projector input vent ports.

In my case, I am using a thin aluminum shield to accomplish this.

As you pointed out, this can be a problem, that usually results in the Central projector flickering.   Using a deflector shield totally eliminates this problem.

Mike

[Trevor Hale]

Good stuff bud. Just wanted to make sure you were aware of the possible issues. 

Trev

[blueskydriver]

Hey Mike,

All looks great!

Along with Trevor's observations, it might help to put a vent hole in the flat board/metal above the projectors, and add a small fan to help suck the heat away.

My projectors were in the same configurations, but no fan. Then, I had problems with the chips and pixels. After adding a fan, no more issues. 

John