DC motor conversion
Posted: Mon Aug 23, 2021 4:11 pm
I'm am largely out of action again, this time because of a spinal stenosis. So I have time on my hands and I started looking into how DC motors from treadmills have been used on various machines, many lathes especially. I saw a Youtube about a guy who put some kind of DC motor in a Shopsmith, and it appeared to completely replace the original motor and mechanical speed controller. There weren't many details though.
Read on if this subject interests you. I'll provide a summary of my thoughts and if anyone is interested I'll flesh it out.
So, replacing the motor in a Shopsmith headstock with a treadmill motor. It would need an adapter/coupler to provide a 5/8" shaft for the fan sheave and spring. The motor would be a little smaller than Shopsmith motors, but probably wouldn't leave enough room for a variable DC power supply in the motor area, and that supply would produce a lot of excess heat. I think the power supply and motor controller should be in an external control panel box connected to the headstock where the power switch is. The control panel would have an on/off switch, forward/reverse switch, spindle RPM display, and a dial control for the motor speed, maybe a motor RPM display.
So what does that create? The DC motor has a top speed in excess of 6000RPM at full power. With the Shopsmith speed controller at the fasted setting the spindle speed could be over 9000RPM. However, when the motor is running at full speed the slowest speed could be higher than 1300RPM. To get slower the motor has to be slowed down, that's what the dial control for the motor speed is for. The motor can slow down a lot, to 60RPM or less. The catch is that the motor is slowed by reducing power to it. There are practical limits to how slow the spindle can get and still produce useful torgue.
These motors are typically rated at 2.5HP. Might as well throw that number out the window. When loaded it might produce half that, or 1.25HP which is still better than the Shopsmith 1 1/8. The motors usually have a large flywheel that improves their performance characteristics, and the Shopsmith speed changer improves torque at lower speeds. Reducing voltage reduces motor speed and power together. At half speed you might only have performance comparable to a 3/4HP motor. Half motor speed is something over 3000 RPM, very similar to the standard AC motors, and the power available in the oldest Shopsmiths. I use a Greenie for years and it's 3/4 HP motor was just fine in most cases. At half motor speed, Slow on the speed dial will be around the same as the standard Shopsmith. You can keep reducing motor speed and spindle speed down to the point where you have no effective power left.
Ok then, why?
1. A treadmill motor and controller is nearly free. Depending on some details, actually free.
B. Installed in a headstock as I suggest it will increase max spindle RPM to over 9000. Within some range of spindle speed and loading it would outperform a 1 1/8 HP motor.
III. It can also slow spindle speed down to less than 100 RPM, albeit with a corresponding loss of power.
𐤃. The direction of rotation can be reversed.
Read on if this subject interests you. I'll provide a summary of my thoughts and if anyone is interested I'll flesh it out.
So, replacing the motor in a Shopsmith headstock with a treadmill motor. It would need an adapter/coupler to provide a 5/8" shaft for the fan sheave and spring. The motor would be a little smaller than Shopsmith motors, but probably wouldn't leave enough room for a variable DC power supply in the motor area, and that supply would produce a lot of excess heat. I think the power supply and motor controller should be in an external control panel box connected to the headstock where the power switch is. The control panel would have an on/off switch, forward/reverse switch, spindle RPM display, and a dial control for the motor speed, maybe a motor RPM display.
So what does that create? The DC motor has a top speed in excess of 6000RPM at full power. With the Shopsmith speed controller at the fasted setting the spindle speed could be over 9000RPM. However, when the motor is running at full speed the slowest speed could be higher than 1300RPM. To get slower the motor has to be slowed down, that's what the dial control for the motor speed is for. The motor can slow down a lot, to 60RPM or less. The catch is that the motor is slowed by reducing power to it. There are practical limits to how slow the spindle can get and still produce useful torgue.
These motors are typically rated at 2.5HP. Might as well throw that number out the window. When loaded it might produce half that, or 1.25HP which is still better than the Shopsmith 1 1/8. The motors usually have a large flywheel that improves their performance characteristics, and the Shopsmith speed changer improves torque at lower speeds. Reducing voltage reduces motor speed and power together. At half speed you might only have performance comparable to a 3/4HP motor. Half motor speed is something over 3000 RPM, very similar to the standard AC motors, and the power available in the oldest Shopsmiths. I use a Greenie for years and it's 3/4 HP motor was just fine in most cases. At half motor speed, Slow on the speed dial will be around the same as the standard Shopsmith. You can keep reducing motor speed and spindle speed down to the point where you have no effective power left.
Ok then, why?
1. A treadmill motor and controller is nearly free. Depending on some details, actually free.
B. Installed in a headstock as I suggest it will increase max spindle RPM to over 9000. Within some range of spindle speed and loading it would outperform a 1 1/8 HP motor.
III. It can also slow spindle speed down to less than 100 RPM, albeit with a corresponding loss of power.
𐤃. The direction of rotation can be reversed.