Greaves 3D Engineering builds collapsible simulator with 45 igus components such as maintenance-free drylin linear and drive technology

The British company Greaves 3D Engineering has developed a professional racing car simulator called “The Ultimate Drivers Rig”, which can be quickly folded up and stored in a road case. This makes transport to racetracks, trade shows and company events much easier. To reduce maintenance work when travelling, engineers rely on robust and lubrication-free linear and drive technology in addition to energy chains and plain bearings from igus.

When owners open the road case of the Ultimate Drivers Rig, they can move the chassis of the racing car simulator over a ramp to the ground by means of rollers. Then a fascinating unfolding process begins, reminiscent of a science fiction film like “Transformers”. The driver unfolds three 32-inch gaming monitors that offer an ultra-wide field of vision. After that, the driver’s seat and pedal box are positioned, whereby both horizontal and vertical adjustments are possible. When tilted all the way back and downwards, the driver can assume the position of an F1 racing driver, while an upright posture and a pedal box pulled closer simulate that of a rally car. As soon as the driver has taken hold of the steering wheel and thus the instruments and screens, the journey can begin. Greaves 3D Engineering promises a realistic driving experience through life-like feedback mechanisms in the steering wheel, pedals and seat, which provide haptic feedback and convey an authentic feel for the car and the track.

Ecological and economical: engineers rely on lubrication-free linear and drive technology from igus

The simulator is designed in such a way that it can be used in a variety of ways – be it in racing teams, at trade shows or at home. The engineers paid attention to saving installation space and weight and keeping maintenance requirements as low as possible. This was a challenge as the electromechanical framework for the numerous adjustment functions is complex and consists of hundreds of components. To meet these requirements, the experts opted for lightweight, compact and lubrication-free linear technology from igus. For example, they use linear rails from the drylin W series to adjust the centre console and driver’s seat. The compact carriages that are connected to the seat move on aluminium rails and use bushings made of high-performance plastic.

During operation, these bushings release solid lubricants that enable low-friction dry operation without relubrication. “The components retain their mechanical specifications without maintenance or cleaning. No grease is used, which could mix with dust and dirt and form blocking deposits,” explains Michael Hornung, Product Manager drylin Linear and Drive Technology at igus. The iglidur G polymer bearings, which are installed in the frame for seat angle adjustment, also use this self-lubricating effect. “At the same time, dispensing with lubricants, which are usually made from fossil resources, improves the simulator’s environmental footprint.” Greaves 3D estimates that up to two litres of lubricant can be saved every year.

e-chains protect cables of the driving simulator from breaks

Lubrication-free and compact linear modules of the drylin SHT series with lead screw drive are used for the automatic adjustment of seat and monitors. igus supplies these ready for connection with stepper motor and motor control system, which saves installation space and reduces the design effort. Finally, the energy and data cables are housed in energy chains made of high-performance plastic from igus, which protect them against uncontrolled movements and cable breaks. The components installed include twistable and telescoping e-chains from the triflex series, which consist of round chain links that can move in 3D. “The Ultimate Drivers Rig contains a total of 45 components from igus,” says Hornung. “They all contribute to improving the reliability, cost-effectiveness and environmental balance of the driving simulator.”