Build Thread- Super-PID speed controller installation to Fixed speed Router

[Khalid]

Hi,
For the past 6-years i have been using Fixed speed chinese Router (25000RPM) for doing various wood related projects... I got this Router 4-year back for the amount of 35US dollar... This Router worked very well so far with following issues:

1- Frequent change of Bearings
2- High Noise
3- Can't machine plastic/acrylic/Aluminum at low RPM

To replace the above fixed speed router i have purchased another variable speed router (min speed: 10000RPM, Maximum Speed: 25000RPM), but due to heavy weight and slight modifications in Z-axis plate i never tried to install it...

Recently i have seen a thread on Super-PID speed controller here at CNCZone and received one from RomanLini to test out on my DIY CNC machine...
Here is How it works:
"The Super-PID has an accurate LCD tacho with 48 bar power bargraph on the lower half of the LCD. This feature shows the percentage of power applied to the router at all times. The Super-PID can operate a fixed speed router within 5000~30000 RPM range.If it starts cutting, the power bargraph will rise to maybe 20-30% depending on the depth of cut and this is shown on the bargraph even though the speed stays at 5000 RPM or very close. The speed is controlled through Potentiometer"
The quality of the PCB and all accessories i got with it was awesome... Now, to install on my machine i started this thread so that if anybody interested for this low-cost speed controller can get help to see lot of pictures i will present here in future...

For now, i have one limitation of mounting the IR sensor as the Router Collete is not extended well to mount it as you can see the router picture...

However, I have a nice idea how to install the sensor in such a way that it will always be dustproof and foolproof..

Since 8-month i never touched my CNC machine and yesterday i have to clean all the leadscrews and ran the machine and i was astonished to get all the axes working without any smoke

I also installed XBOX 360 controller and now i can control miscellaneous functions of the machine standing near it...

[CarveOne]

Hi Khalid,

I think you will find a lot more uses for your CNC machine once you can slow the router motor down. Have fun with this evaluation project. I have so far.

CarveOne

[Khalid]

Originally Posted by CarveOne Hi Khalid, I think you will find a lot more uses for your CNC machine once you can slow the router motor down. Have fun with this evaluation project. I have so far. CarveOne

Hi welcome.. You are my mentor on this Super-PID controller... I am strictly following your thread and you really impressed me

As stated earlier, I have High noise high-RPM problem... I am now happy to feel that i can cut acrylic and other material... As you know, I involve in Funfair-Charity event in my community and i have to make lot of stuff... I have only two months and i am planning to make Sundials this time

These sundials will be carved on wood , acrylic and may be on marble.. Let us see how this all comes out

[CarveOne]

Originally Posted by Khalid Hi welcome.. You are my mentor on this Super-PID controller... I am strictly following your thread and you really impressed me As stated earlier, I have High noise high-RPM problem... I am now happy to feel that i can cut acrylic and other material... As you know, I involve in Funfair-Charity event in my community and i have to make lot of stuff... I have only two months and i am planning to make Sundials this time These sundials will be carved on wood , acrylic and may be on marble.. Let us see how this all comes out

Knowing the quality of work you do, the sundials will be a very popular item. Please show them here on CNC Zone.

CarveOne

[harryn]

Hi, interesting progress. Are you using the xbox controller as a unix controller with emc ?

ps- I also would enjoy seeing the sun dial pictures when you get that far.
Take care,

Harry

[Khalid]

Hi Harry,
I am using Xbox 360 with Mach3 ..
I am using shadows Pro full working "Limited time Trial license" especially developed by François Blateyron for me... His contribution for this great cause really impressed me Following is his website and you can see how accurate and detailed sundial can be made with few clicks of mouse...

Shadows Pro Official Web Site

I will definitely share the CNC carved sundials with you

[harryn]

Thank you for sharing - that is a really neat project and software. I can imagine these made also from that special wood you have there. Makes me want to import some of that wood and get my router built and working.

Perhaps this winter it will be possible to finish the router, depending on funding.

I might need your guidance to help with the gcode aspect, as this is still a steep learning curve.

Take care,

Harry

[RomanLini]

Hi Khalid! Nice to see you get your machine commissioned and running again!

Those sundials sound like a cool project.

[Khalid]

Some progresss on Super-PID..I have just purchased two small Fans about 2inch diameter to add to the Enclosure as a Force draft.. These Fans are unfortunately 12VDC but i will run them on 5 VDc, Roman just told me that a connection of +5VDC is available on Super-PID (I mis-interpreted, actually he told me to provide external +5VDC to super-PID)...I am running my CNC Router under 1.5Ton window air-conditioner in a small room so i think the addition of fans may rather more for fancy purpose...

I normally run my Router 8-hours straight so i think the fans at Super-PID enclosure will help dissipating minor heat and enhance the electronics life time...

Here is the picture in progress of the enclosure.. By tomorrow i will be able to complete the setup and trial run...

[CarveOne]

You will need to run 5vdc and return wires to the Super-PID board. I just used speaker wire for my testing and took the 5vdc and ground from my breakout board. (Shielded wire will be better.) Then you can also use it to power the fans in the box.


CarveOne

[Khalid]

Hi CarveOne.. I suggested RomanLini to give a 5V and 12VDC points at Super-PID PCB in the next upgraded design (if possible)..This will eliminate the external power supply and reduce the wiring....

Carve One, should we supply +5Vdc externally to the Super-PID to run its logic???

[Al_The_Man]

You could run a 3 wire shielded cable from PC P.S. using one of the 4pin connectors to the PID unit for the PID 5v and 12v for the fans.
This supply will be at ground potential already, as per the PDF.
Alternatively you could use a 120v fan fed from the incoming AC.
Al.