Spindle failure

[mechanicer]

I use a 24.000 rpm 1600 Watt commercial router as spindle. My 3axis CNC router must work 8 hours in a day, cutting hardwood. But spindle always fails. Sometimes the bearings, sometimes brushes. I plan to use a AC 3 phase squirrel-cage motor. It is 3000 rpm, 2 HP. I will increase the rpm using a timebelt.

Are there anybody having same trouble? Any other suggestion?

P.S. (I don't plan to use 5000/10000$ commercial high speed spindles)

[jdownie]

Wood routers, such as the Porter Cable units, etc., are simply not designed for the sort of duty cycles you are asking for. There is a reason that the Porter Cable is $300 and a Colombo is $5,000.

[ger21]

You can get one of these for $2000-$3000. Either the 1.34HP or the 2.68 should work much better for you. http://www.ekstromcarlson.com/router_packages.htm

[walter]

Design simple "quick change" mounting bracket and use 2 Porter Cable routers. Pause program every 2 hours and switch router.

[Lionclaw]

Walter's solution is a good idea. You could probably also buy one of the store warranty policies so you can quickly exchange the routers locally when they fail. They might not be too happy when you come in to exchange the product every other week... but hey *shrug*...

[sendkeys]

what about doing a upgrade to the spindle. Buy some high end bearings and brushes. then balance it Maybe add in some more cooling via water channels/pipes or more air or more metal ect

[walter]

Originally Posted by mechanicer .... But spindle always fails. Sometimes the bearings, sometimes brushes......

People who use Porter Cables 8 hrs/day or more replace brushes monthly, bearings every 2-3 months.

[mechanicer]

I will design and manufacture a belt spindle. It will be continous duty and has a ER20 collet.

[signIT]

I had the same problem with an El Cheapo router, the bearings and brushes just don't works as long as I expected, one idea is to slow down speed with a Variac, from in my case, 30000 rpm to just under 18000 rpm, it seems that this speed is the best for ordinary high speed ball bearings.
But... can I cut with this low speed I use various materials like MDF,Masonite, Plexi and aluminium, maybe I should run in short spell of work.

Leffe

[ger21]

Originally Posted by signIT one idea is to slow down speed with a Variac, from in my case, 30000 rpm to just under 18000 rpm, ............ But... can I cut with this low speed I use various materials like MDF,Masonite, Plexi and aluminium, maybe I should run in short spell of work. Leffe

It depends on the tool size, but on our commercial router, with 1/2" spiral tools, we cut at 400 ipm and 16000 rpm. With 1/4" tools, 18000rpm and 150-200ipm.