Moves up when pedal is depressed

[cciRRus]

Hi there!

I am very grateful for this project, thank you so much! I've done the "Replacement Design" with the super cheap 49E hall effect sensor. It works fine on G29, while I play Gran Turismo 7 on PS4.

There is a slight issue. When my throttle pedal is fully depressed, the entire device lifts up. I don't have a photo of the actual issue because I forgot to take a photo before assembling the pedal. But the issue looks something like this:

I made sure the whole replacement is as tightly secured as possible, especially the Clip. Yet this happens.

While the thing works for now, I'm not sure if it will last. Repetitive up/down movements over time may wear out the 3D printed device. Is this behavior expected?

[neilser]

Sounds like you may have a misalignment - the black gearwheel in the picture may not be engaging in the right place with the gearwheel connected to the pedal. Or do you mean that it moves when the pedal is fully released? That would be pretty normal, if the leg on the gearwheel pictured is resting on the metal when the pedal is released. (It has never been 100% clear to me if that's the correct location when released or if it should be one tooth further along, but my best guess is that "resting on the metal" is the correct location.)

[GeekyDeaks]

Hi! Sorry, I completely missed the notification for this. I agree with @neilser - if it's happening when you full depress the pedal, then that doesn't sound right and something is amiss. If it's when you release the pedal, this is something I noticed happened on the original pedals before I started this mod and as @neilser mentioned, appears to be when the leg on the gearwheel contacts the base. I simply rotated the gear around one tooth when using the mod to prevent it from happening on my prints.

[cciRRus]

Thanks @neilser and @GeekyDeaks for your replies. Please refer to the videos below.

1. This is how the original setup looks like: https://github.com/GeekyDeaks/g29-hall-sensor-mod/assets/84564999/6ae5fff8-0e72-4be0-a5fd-3e9819e8b55b

2. This is because the original potentiometer has a tight fit: https://github.com/GeekyDeaks/g29-hall-sensor-mod/assets/84564999/0b52dc9c-db9a-46f6-8c30-0584abe72edd

3. This is how my 3D printed Replacement Design looks like: https://github.com/GeekyDeaks/g29-hall-sensor-mod/assets/84564999/cea5fd19-4f5d-4c0a-9e97-e935a02f8652

4. This is because there is quite a bit of play between the Replacement Design shaft and the holder: https://github.com/GeekyDeaks/g29-hall-sensor-mod/assets/84564999/05840033-f53b-4296-96dc-76f8b9a30c07

[cciRRus]

FYI, I tried aligning the gear meshing at +1 or -1 tooth, but it does not help.

[GeekyDeaks]

oh, this is with the 3D pot! Sorry, I totally misunderstood and thought it was the mod that attaches to the original pot. I'll need dig out an old model to check, but I don't remember anywhere near that amount of play. I'll be honest, I only really did that for a bit of fun and for others to experiment with and I never used it myself. I suspect I made the model with the tolerances for my Ender 3, so if your printer is more accurate you might need to just make the inner diameter of the piece the shaft goes through a tiny bit smaller or the shaft diameter a tiny bit larger. I'll check which variables in the SCAD file adjusts this later tonight.

One other thing to note - I seem to remember that things were much better with that model when it was packed with grease, all the way to where the shaft exits the model.

[neilser]

I had (like @GeekyDeaks) failed to spot the mention of "Replacement Design" in the original post above. The videos make it very clear that the lifting up happens when the pedal is fully released - which is normal. However the amount of play is higher than I saw with the replacement design and may indicate that your printer doesn't behave quite the same way as the one @GeekyDeaks used when printing the one I tested. Nonetheless, I would have expected that you should be able to eliminate the up/down movement by rotating the arm 1 notch clockwise (as seen in the third video) because then the arm will never touch the metal base and reverse the loading. Also, while I'd like to see the amount of play in the motion reduced (i.e. tighter fit) I doubt that wear would be a big deal even as-is, because the movement isn't caused by the pedal forces per se, but rather by the not-very-strong spring on the pot which keeps it engaged with the teeth in the pedal (until the arm hits the metal base). Sorry for the essay - hope some of that makes sense ;)