Ultimate X2 Speed Controller

[Adamj12b]

Hi Guys,

I have been working on a project to build a drop in replacement motor controller for the X2. This will be setup to be wired directly to mach's step and direction outputs for speed control. All the inputs will be opto-isolated and the whole controller is micro-processor controller.

I hope to build these and sell them for a very reasonable price.

They will be about 2 times the power capability as the stock controller, with the option to switch between 110 and 220VAC source. I plan to incorporate some form of tach feedback to be able to lock onto a speed.

OK, Now the thing is I need you guys' help. I want to make this something that everybody wants.

1.) Would it be better for it to make the spindle into a servo? It would require adding a full encoder to the spindle. It would also increase the price of the controller because it would have 4 times as many transistors to do servo positioning. Would also dynamic braking. It could also be programed to stop the key in the spindle in the same spot every time. ie. 0 degrees at the front.

2.) Forward or reverse switched through a relay, with a tach pulse used to modify frequency to change the speed of the motor. It would use the load to slow the motor and would not have any dynamic braking.

3.) Forward or reverse with no modifying of the speed. Whatever the pulses tell it to run, Thats what it dose. The computer would then be in-charge of modifying the pulses to compensate for load.

I also need to know, if there is an interest in having it power by 220V as well. If there is no need I will not do it.

If you have any other ideas, Please let me know.

-Adam

[The Blight]

Thumbs up for the 220v

[kawazuki]

Hi Guys,

I have been working on a project to build a drop in replacement motor controller for the X2. This will be setup to be wired directly to mach's step and direction outputs for speed control. All the inputs will be opto-isolated and the whole controller is micro-processor controller.

I hope to build these and sell them for a very reasonable price.

They will be about 2 times the power capability as the stock controller, with the option to switch between 110 and 220VAC source. I plan to incorporate some form of tach feedback to be able to lock onto a speed.

OK, Now the thing is I need you guys' help. I want to make this something that everybody wants.

1.) Would it be better for it to make the servo into a spindle? It would require adding a full encoder to the spindle. It would also increase the price of the controller because it would have 4 times as many transistors to do servo positioning. Would also dynamic braking. It could also be programed to stop the key in the spindle in the same spot every time. ie. 0 degrees at the front.

A. Are you planning to junk the stock motor then? If so I wouldn't be interested! Also a direct drive 1:1 servo spindle is good but what about all the belt drive conversions - won't they all be cock-eyed in comparison to motor (known) rpm?

2.) Forward or reverse switched through a relay, with a tach pulse used to modify frequency to change the speed of the motor. It would use the load to slow the motor and would not have any dynamic braking.

A. Sounds good although i've never seen the point of reversible motor on a milling machine unless it was a servo and then only for tapping? Shouldn't the load increase the rpm to maintain cut speed / chip load

3.) Forward or reverse with no modifying of the speed. Whatever the pulses tell it to run, Thats what it dose.
A. Can see an over loaded motor losing steps or stalling with this senario?

I also need to know, if there is an interest in having it power by 220V as well. If there is no need I will not do it.

A. Pretty much most of the world outside the US uses 220-240v so by not having it, it could reduce your market? If it is a stock motor controller and not a servo replacement, i'd be interested especially if it used the motor function from my Gecko540!

If you have any other ideas, Please let me know.

-Adam

.

[Adamj12b]

A. Are you planning to junk the stock motor then? If so I wouldn't be interested! Also a direct drive 1:1 servo spindle is good but what about all the belt drive conversions - won't they all be cock-eyed in comparison to motor (known) rpm?

A. Sounds good although i've never seen the point of reversible motor on a milling machine unless it was a servo and then only for tapping? Shouldn't the load increase the rpm to maintain cut speed / chip load

A. Can see an over loaded motor losing steps or stalling with this senario?

A. Pretty much most of the world outside the US uses 220-240v so by not having it, it could reduce your market? If it is a stock motor controller and not a servo replacement, i'd be interested especially if it used the motor function from my Gecko540!

Ok, There was a typo in #1. It would use the stock motor with an encoder mounted to it for servo control. It would have have an index pulse for mach that would give mach the motor speed. I believe that you can configure mach to calibrate the spindle so that a certain output equals a certain speed. I have to look into this more. I have not successfully got a spindle to be speed controlled by mach. Last time I tried I blew up the c6 and the X2 controller. That was 2 years ago.



I would like to be able to do tapping, But I really dont know if that will happen. As for the load thing... What I meant was that the load would decrease the speed of the motor from an overshoot of what it needed to me.

As for #3. This is my least favorite option. Yes, it could stall and start breaking tools. I would like to do #2 at the least with a estop wired into the circuit for killing mach if the motor is too far under speed or overloaded or stalled.

I also would not like to limit the controller to just the US. I think I will make it selectable with a switch for 120/240.

I also looked into multiple signals for control, 0-10V and step/Dir. I think it will have both, as it is very easy. Just a small switch will be needed to switch between them.

-Adam

[Tallen]

Not much input, but I am already interested. Projected cost?

[SCzEngrgGroup]

Mach allows you to define up to 16 pulley ratios, and each can be either normal or reversed direction. For each pulley you can define the min and max RPM for that pulley. Mach will use that information and the commanded RPM to calculate the required step rate or PWM ratio required to achieve the commanded speed, and to warn if the commanded speed is too high or too low for the current pulley. There is already a DRO in the standard screenset that allows the user to set the pulley currently in use.

Not sure I understand why you would *need* the spindle to always stop at a particular location with R8, or especially MT, tooling, and I doubt anyone is going to fit a CAT30 spindle to an X2. It'd be a lot simpler to simply remove the (completely useless) alignment pin from your spindle, and you can insert your tools in any orientation. That pin is of *zero* value.

If you want a good spindle I/F, buy a DC-03 from Homann Designs - they work great, and accurate enough no feedback is necessary. I run my knee mill with a VFD controlled by one, and it's never off by more than 0.5Hz. Mach seems happier with a PWM spindle than Step/Dir.

Regards,
Ray L.

[Waldermac]

Another interested user here. Have the 540 as well. Projected cost??

[Trewella]

Yes another 220-240v interested party!

[Adamj12b]

Hello Everyone,

Ok, You have spoken, and the controller will have a 110-240V input range.

Now I need to know what is wanted to control input. I am thinking of including 0-10V for the G540 users, Pulse and Dir for others, and Im looking into a PWM option as well.

For the reversing I was thinking of including the relay that would be needed. I would lay it out so that the Normally Closed contacts are used for forward operation. That why if you dont want reverse, you dont even need to hook the Dir pin up.

Now, What is wanted for feedback? I like the idea of encoder servo feedback, but the circuitry needed would drive the price up real fast. So, I think that a tach pulse is the best feedback for the controller to lock on the speed. It then could fed the tach pulse or a modified pulse back to the computer.

I still hope to include the spindle load meter. It will probably just be a simple readout based of current, but could still be useful.

As for price, I hope to keep it affordable. I not going to say right now how much, but I can say it will be cheeper then the replacement regular control boards on LMS.

I also want to mention that I believe this will be capable of powering the motor on a stock X3 as well. Im not sure as I dont have one. But I think that can be arranged to work as well.

-Adam

[Trewella]

Is it possible to add a couple of 12v fan headers?

[Adamj12b]

Yes, That is very easy. Is more then 1 needed? Would this be to replace the small 12V supply board for the stock case fan?

-Adam

[Trewella]

Yes, That is very easy. Is more then 1 needed? Would this be to replace the small 12V supply board for the stock case fan?

-Adam

I was thinking of two, one for the controller case & another for an additional fan on the spindle motor.