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Thread: DC motor conversion
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6th Aug 2020, 10:58 AM #1New Member
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DC motor conversion
I have recently refurbished my Hercus 9 lathe and converted it to DC MicroV drive.
I have used a 3 HP dc Motor and a KB Penta Drive Controller.
This setup works great, I had to fit an idler roller on the headstock to get the MicroV belt to the motor and machine the mid range pulley for the MicroV Belt
I now have speed range between 0 and 1750 RPM with the controller giving me excellent torque throughout the range.
I have mounted the controller on the front of the machine for easy control
Without the carriage gears the lathe is very quiet
Low Cost Venture
Controller $150 With reverse Switch
Motor 3HP DC Leeson Free from abandoned treadmill
MicroV Belt 640mm $40IMG_0818.jpgIMG_0817.jpgIMG_0815.jpgIMG_0814.jpgIMG_0816.jpg
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6th Aug 2020, 03:08 PM #2Member: Blue and white apron brigade
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Looks Good.
One issue I'd like to raise is I think 3HP is bit much for such a small lathe like a Hercus 9" If something jams its liable to to do some serious damage before the motor stops. I'd be limiting the current to no more than about a 1HP draw and/or running the belt on the loose side.
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7th Aug 2020, 04:07 PM #3
Hi errolf2
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Welcome to our Forums
Grahame
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7th Aug 2020, 04:14 PM #4
Electrical Disclaimer
DISCLAIMER
No liability is accepted by U-Beaut or the Metalwork Forum's administrators
or moderators for advice offered by members posting replies
or asking questions regarding electrical work.
We strongly advise contacting a Licensed Tradeperson for all electrical work.WARNING
Information supplied within posts is not to be considered as detailed formal instructions to complete a task.
Members following such information do so at their own risk
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7th Aug 2020, 10:18 PM #5Golden Member
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I would like to know more about the controller, I have a couple 180v treadmill motors in the 2hp range I would like to make proper use of and there's no shortage of them around
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7th Aug 2020, 11:29 PM #6Most Valued Member
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I think you're getting a bit carried away with that disclaimer Grahame. The OP posted some pics of his lathe and listed the mods he had done to it. No detailed instructions on wiring were given. Are you going to put up that disclaimer every time someone makes a post that refers to electric motors?
Chris
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7th Aug 2020, 11:53 PM #7Golden Member
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I did this on my Hercus 9” too. Used a KB Electronics driver and a 3.5HP treadmill motor. But I had a hell of a time keeping the treadmill motor cool. Even went to the trouble of water cooling the motor but in the end I think they’re not great motors unless you get a really good one.
I got a free 1HP 3PH motor with a bandsaw and managed to pull out the star point and used a VFD. Night and day difference and no more issues.
I think DC motors can be made to work but you need a good motor to start with and cooling is a major issue.
Great install. Hopefully you don’t have the same issues I had.
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8th Aug 2020, 01:57 AM #8
Hi Guys,
Ever noticed the rather large fans on some treadmill motors, also the treadmill motor controller is usually a PWM one, which means that the motor doesn't get subjected to a continuous DC feed, but a pulsed one. Admittedly at a frequency above audible range. In addition it has to spin fast enough to provide a cooling air flow across the case, which for lathe work it may not do.Best Regards:
Baron J.
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8th Aug 2020, 10:02 AM #9New Member
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KB Penta Drive Torque
Hi Bobl thanks for for your input
The torque control on the Penta Drive Takes care of the overload factor, it is adjustable with pots in the controller.
I have been using this DC setup on my Qualos Junior 4 " for many years and it has been quite successful.
Thanks for your interest and comments
Regards
Errol
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8th Aug 2020, 02:39 PM #10New Member
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KB Penta Drive
[QUOTE=NedsHead;1972599]I would like to know more about the controller, I have a couple 180v treadmill motors in the 2hp range I would like to make proper use of and there's no shortage of them around[/QUOTE
Good Afternoon
The controller is a KB electronics KBPC -240D
Input 115/230VAC-50-60Hz
Output 90/180 VDC
If you keep your eye on ebay you can pick one up locally
Try to get one with a reverse switch as this an option
A word of warning the default configuration is 110VAC so you need to change the internal jumpers to 230VAC.
I have used this same setup on my Qualos Junior for a few years and have had no trouble with overheating.
Thanks for your interest
Errol
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8th Aug 2020, 10:19 PM #11Senior Member
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I love how neat and compact that setup is, really takes away all that bulk at the back of the machine.
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10th Aug 2020, 04:15 AM #12Most Valued Member
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10th Aug 2020, 09:49 AM #13Member: Blue and white apron brigade
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I don't think so given that DC is significantly more dangerous than AC .
The danger voltage depends on the size/health of the individual, the wattage available, and where the body contacts are made which in turn determines the resistance and hence the current. DC voltages from a substantial power supply as low as 50V directly across the chest (ie one side of a body to another) can result in death. The DC stops the heart and the diaphragm. How likely is this? Apparently its more likely than one might think and typically happens when someone tries to slide through an narrow gap with either their back or chest touching ground (ie a metal shed) and the corresponding side touching DC (ie a machine). The DC paralyses them so they cannot move and stay in that spot and die! If most people pick up something at 100V DC and have good enough contact with earth it is impossible for them to to let it go. With AC you have a chance in the first couple of seconds of contact of moving and letting it go.
In addition to severe paralysing muscles it also messes with blood chemistry producing bubbles and can result in a brain gas embolisms. At work we used up to 6kV DC on analytical machines and we were taught to use it with great respect. I could go into details of several of the zaps I received but maybe another time.
About 10 years ago the husband (a 40 something strapping engineer) of a researcher at work decided to install his own solar PV system on top of his skiilion roofed shed and one day his wife came home from work and found him dead on the ground with a broke his neck. The assumption was he just slipped of fetch roof, but the autopsy found small burn marks on his leg and hand. It appears he brushed a live ~600V contact with his leg while touching the roof with his hand - the zap appeared to have contracted all his muscles between his leg and arm and thrown him off the roof.
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10th Aug 2020, 09:41 PM #14Most Valued Member
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Red herring. Did you miss the bit where I said no detailed wiring instructions were given? The OPs post didn't invite anyone to do the same conversion on their lathe. Had anyone asked for detailed instructions on how to go about this mod a disclaimer might be valid. However, when the disclaimer was posted nobody had. Hence I believe it was overkill.
I am a regular contributor on a few forums and lurk on many others. This is the only forum I peruse where the mod regularly posts disclaimers when people ask for advice that is electrical in nature (and sometimes even when they don't). The mods certainly don't do it on HMEM and I can't recall having seen one on Practical Machinist or HSM. That's the USA and the UK covered. Are people in those countries more competent than Aussies? Less litigious?
It embarrasses me that people from OS read this forum and regularly see this bright blue and red disclaimer. Are we such pussies in Oz that we need to protect grown adults from themselves?
And TBH Bob, your post just looked like an excuse to show everyone how much you know. You were taught to treat a 6kV machine with respect? No kidding. And the relevance of that to this thread is what exactly?Chris
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10th Aug 2020, 10:28 PM #15Member: Blue and white apron brigade
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I don't think it matters that much there were no instructions given.
I'm more than happy for these disclaimers to be inserted into electrically related threads I start, even when no working instructions are provided, occasionally I even insert my own disclaimers.
The facts are that electrocution still remains the number one cause of death from DIY activities in Oz and as Higher V DC is more dangerous than AC it deserved a special mention.
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