STM32 Platform with EtherCAT Option

The new Motion4Sim Controller is more than an update – it’s a complete platform transition.
New hardware, new firmware, and a modern STM32 architecture deliver significantly higher performance, improved availability, and open the door to new capabilities such as Step/Dir servo control, EtherCAT, dual wind systems, and web-based control.

Designed for demanding motion simulators – from proven Step/Dir setups to modern EtherCAT servo systems.

Read more in our documentation.

One Platform – Three Versions

All versions are based on the same high-quality hardware platform.
The feature set is defined by firmware and configuration.

➡️ Basic – proven & focused
➡️ Pro – expanded & future-ready
➡️ Pro-Plus – maximum connectivity

Features of the Board:

1. STM32 powered
2. External power input (12 V), efficient design
3. External power with USB short-circuit protection
4. USB Type-C connector
5. Ethernet LAN port (100 Mbps full duplex)
6. Second LAN interface in EtherCAT mode (Pro-Plus version)
7. RGB LCD support for handhelds via DB25 (available on request)
8. Support for smart handhelds (EM / Online button) RJ45 Connector
9. Secondary servo control MCU for failover and safety monitoring of Step/Dir servos
10. External security with unique ID chip and EEPROMs to ensure tamper resistance and configuration integrity
11. Dual PWM channels for fans – connect fans directly to the board
12. 0–10 V analog output for torque signal support
13. anLogic for Servo Brakes and Output Gpio
14. Pinheader for optional FTDI breakout Board
15. CanBus prepared for Development Projects (IC not populated,on demand)
16. Pinheader for external Homing Switches

Why Choose Motion4Sim?

If you’re building a motion simulation platform, the Motion4Sim Servo Motion Controller is your ideal solution.
Designed for cost-effective AASD servo motors, this controller maximizes their performance for motion simulation applications.
It also supports other motor drivers operating in Step/Dir mode, including NEMA 17, 23, and 34 stepper motors with digital drivers, as well as servo systems such as YMPC AASD, Delta B2, and Lichuan LCDA4.

Note:
When choosing the EtherCAT version, the higher controller cost can often be offset by using high-performance yet cost-efficient
StepperOnline EtherCAT motors, which typically offer a price advantage compared to traditional AASD servo systems.
These motors have been tested and confirmed to work reliably.

The M4S-AASD15A controller ensures fast and seamless transmission of motion data from PC simulation software to servo motors.
Data is exchanged via interface software such as SimTools, FlyPT Mover, Motion4Sim Dashboard, SimHub and DRSM,
ensuring precise and smooth operation.

How It Works

Interface software calculates motion vectors and transmits values via USB or Ethernet to the Motion4Sim controller.
The controller drives the servo motors and performs real-time calculations for smoothing and refining motion cues.
Servo motor amplifiers connect via DB25 cables (AASD pinout compatible), or via simple Ethernet patch cables when using EtherCAT.

Controller Features and Technical Specifications:

• EtherCAT master mode
  • currently limited to A6 EtherCAT servos from  StepperOnline;
  • additional drive support planned
  • Tested with up to 6 servos; 10–12 or more planned
• Step/Dir mode
  • Control of up to 7 servo motors
  • Pulse frequency up to 550 kHz
  • Torque signal feedback for homing and error detection
• Fully configurable actuators, including:
  • Inline and foldback directions
  • Lead screw pitch
  • Gearbox resolution
  • Unlimited stroke length
  • Encoder resolution
  • Freely adjustable parking position for horizontal or vertical parking in 6DOF rigs
• Support for linear, rotational, and 360° continuous actuators
• Automatic homing (limit switch or torque-controlled)
• 16×2 LCD display with full configuration menu
• Status LEDs
• Emergency stop and force-offline inputs
• Rotary encoder with push button for local control
• Logic output for servo motor brakes
• USB communication with CRC data checks
• 32-bit processor for real-time motion calculations
• Internal motion processing at 1000 Hz
• Real-time inverse kinematics for 2–6 DOF rigs
• Internal memory for configuration storage
• Position limit monitoring
• Platform health monitoring
• Park function to prevent rig drop when powered off
• Support for DIY belt tensioner systems
• Soft start algorithm to prevent jerks and spikes
• Internal pulse filtering
• Intelligent spike protection
• Service and diagnostic modes
• USB powered (5 V)
• External 12 V power input (also powers PWM fans)
• Native Ethernet for LAN or EtherCAT operation
• Optional secondary W5500 Ethernet interface (Pro-Plus)
• Dual PWM fan channels for wind simulation

🔹 Basic Version

Proven. Reliable. Now with wind support.

The Basic Version is the solid foundation for classic motion simulator builds.

Highlights:

• USB connection to PC
• Step/Dir control for servos and steppers
• Servo brake support
• Full Motion4Sim motion feature set

New:

Single-channel wind system

1× PWM-controlled fan powered from the 12 V system

Direct onboard connection

➡️ Ideal for classic DIY rigs with a focus on reliability.

🔹 Pro Version *

More performance. More I/O. Ethernet/LAN ready.

The Pro Version is aimed at advanced simulator builders.

In addition to the Basic Version:

• Ethernet support for better connectivity
• Dual wind system
  • 2 independent PWM channels, 12 V powered
  • Fully integrated in firmware
• Torque Signal Analog 0–10 V servo output (Servo 7, torque)

➡️ For powerful simulators

🔹 Pro+ Version *

More performance. More I/O. EtherCAT ready.

The Pro+ Version is aimed at advanced simulator builders and high-end setups.

In addition to the Basic and Pro Version:

• Native EtherCAT support
• Dual Ethernet setup (factory installed)
  • Onboard Ethernet dedicated to EtherCAT
  • Second Ethernet port via integrated W5500 SPI Ethernet module
• Enables:
  • Separation of EtherCAT and telemetry traffic
  • Parallel network operation
  • Advanced communication topologies

EtherCAT – Current Status

• Officially supported:
  • StepperOnline A6 EtherCAT series
• Other EtherCAT drives are technically possible, but:
  • Not officially supported at this time
  • May require adaptations
• Tested with up to 7 EtherCAT servos
• Realistic target: 12–20 axes

➡️ For powerful simulators and modern drive concepts.

Supported Motors and Applications

• AASD servo motors
• NEMA 17, 23, and 34 stepper motors with digital drivers
• Servo systems such as YMPC AASD, Delta B2, and Lichuan LCDA4
• EtherCAT servo models from StepperOnline
• Lichuan EtherCAT and SVN660 derivative models may work, but are not officially supported

Comprehensive Support

The Motion4Sim controller is highly versatile and designed to support a wide range of simulation projects.
If you’re unsure whether your setup is supported, feel free to contact us.

Join our community on Discord.

* needs an short Internet connection for license checking every 20 day

*  3m Dbsub25 cable is recommended and off. supported, 5m is reported also to work

Enhance the control and safety of your Motion4Sim system with this Smart Button Box. Designed for intuitive operation, it allows you to seamlessly switch between online and offline modes and instantly engage the Emergency Mode for maximum security.

A high-quality locking button provides clear visual feedback, signaling different system states with green, red, and yellow indicators. This ensures that the current operational status of your motion controller is always visible at a glance.

The button box connects effortlessly via an RJ45 (patch) cable, ensuring a stable and reliable connection. (Cable not included in this offer.)

For easy mounting, the housing is equipped with two M8 screw holes. These are positioned 95 mm apart, making the box ideal for installation on Nut 8 aluminum profiles or other compatible surfaces.

Ideal for professional and enthusiast motion simulator setups, this compact and efficient control unit enhances both convenience and safety.