- Completed seat support plate
- Mini Tachobox83 – compact interface for simulators
- Smart gearbox with 16 gears
- Steering wheel base and steering wheel assembly
- Next
After several weeks of intensive work, our SIM83-TS01 simulator is beginning to take shape as a comprehensive and professional device, ready for demanding simulations. This time, we focused on key components that directly affect the user experience – from the seat and steering wheel to advanced electronic solutions.
If you want to find out how the construction began, you can read part 1 of the simulator construction diary.
Completed seat support plate
We began by manufacturing and processing the seat support plate, which is one of the most important structural elements of the simulator. It is a thick steel plate that must bear the entire weight of the user and any forces generated during the simulation of movement, vibrations, and sudden changes in direction. For this reason, we opted for a durable material and precisely drawn plans that ensure optimal load-bearing capacity and compatibility with the seat guides and shock absorbers.
We first cut the plate roughly with a cutting plate, then manually processed the edges and corners to prevent damage during use or assembly. This was followed by drilling precise mounting holes for the seat, cable guides, and fasteners. The holes were positioned to allow for multiple configurations depending on the type of seat and rider position, which will be crucial when testing different ergonomic setups.
Finally, the entire plate was coated with a two-component industrial paint that offers high resistance to rust, wear, and mechanical damage. The paint was left to dry for several hours, resulting in an even and aesthetic finish without bubbles or irregularities. The result is a sturdy, aesthetically pleasing, and fully functional support unit, ready for seat installation.
Mini Tachobox83 – compact interface for simulators
We have also installed a completely new, improved version of our electronic interface – the mini Tachobox83, which was developed in response to the needs of simulators with tachographs already built into the dashboard. We developed this compact and modular interface specifically for cases where there is no longer a need for an external tachograph housing, but where reliable communication between the hardware and the simulation environment is crucial.
The Mini Tachobox83 takes up minimal space and can be screwed directly onto the simulator’s support structure. Its design includes an optimised PCB circuit, an integrated USB interface for plug-and-play connection, and electronic protections that enable safe use even in more demanding environments with high electromagnetic interference.
Functionally, it enables the simulation of basic digital tachograph functions such as device start-up, motion detection, working time switching, and simulated data recording. This makes the simulator useful for training and testing in transport companies, where knowledge of tachographs is essential for working with category C and E vehicles.
All connections are routed according to an internal diagram without exposed cables, which contributes to a clean and professional installation. The installation itself does not require additional programming – the interface is automatically detected within our software, which further facilitates its use.
The Mini Tachobox83 has thus become a key link between realistic physical simulation and the recreation of the administrative work that truck drivers perform daily in the real world.
Smart gearbox with 16 gears
One of the biggest and most challenging innovations this week was the redesign of the gear lever, which has evolved from a simple mechanical component into a complex electronic device with advanced operating logic. The goal was clear – to create a system that would mimic the operation of real truck gearboxes as closely as possible, including the characteristic ratio between high and low gears and intermediate gear modes.
To this end, we completely dismantled the existing lever, removed unnecessary mechanical parts, and installed a microcomputer with multiple inputs that enables the detection of movement in multiple directions and positions. We programmed the computer to detect every physical change in the gear shift pattern and interpret it accordingly – either as a high or low gear range or as an intermediate position, as we know it from ZF or Eaton Fuller gearboxes.
The system now allows for up to 16 realistically separate gears, which means we can simulate driving with a classic H-pattern, including shifting between gear ranges.
Steering wheel base and steering wheel assembly
In the final phase of this week, we assembled the steering wheel assembly, which includes the steering wheel base, the steering wheel rim, and the steering wheel itself. This assembly is one of the key elements for a realistic simulated driving experience, as it provides direct physical feedback to the driver and thus contributes significantly to the feeling of control over the vehicle.
We used a high-torque steering wheel base as a basis, which enables strong and precise force feedback – it can simulate everything from vibrations when driving on rough terrain to resistance when cornering sharply and the effects of load imbalance. The electronics inside the base are optimised for fast signal refresh, ensuring seamless synchronisation with what is happening on the screen and the movement of the cabin.
The rim and steering wheel are modular in design. This means that by simply changing the attachments, we will be able to install other types of steering wheels in the future – for example, American steering wheels with a larger diameter or sports steering wheels for other types of vehicles. This time, we have chosen a classic truck steering wheel with a robust grip and a quick-change mounting system that offers exceptional stability even during intensive use.
Next
In the coming days, we will connect all the electronic components and begin testing. Programming and final configuration will follow. Our simulator is rapidly approaching its final form!
