DIY spindle stall monitor

[routercnc]

I've been wanting to do this project for a while. I wondered if it would be possible to build a spindle monitor to check if it has stalled out and then e-stop. Hopefully this would stop it breaking end mills. Sounds easy in principle . . .

https://youtu.be/QuVHUmiW8xo

[EddyCurrent]

I would exxpect the VFD to have a motor stall function in it's parameters, the ABB one I use certainly has although I have not tested it in practice.

[routercnc]

Maybe but I've not found it in the 'documentation'. Would simplify things if it did.

[routercnc]

Episode 2, just making it better all round . . .

https://youtu.be/nSVjT4hpeaE

[EddyCurrent]

These inverter parameters look interesting;
PD118, PD119, PD120, PD121, PD122, PD123, PD124, PD125

[routercnc]

These inverter parameters look interesting;
PD118, PD119, PD120, PD121, PD122, PD123, PD124, PD125

Reading them now. Looks interesting! Worth experimenting with to see if it really can detect a stall through current monitoring and then trip the onboard relay (although I think that is omitted on my model, although I might be mixing it up with the inverter inspection I did for the drill press project)
External current monitoring did not seem to show much but maybe internally it is reading a different part of the circuit.

Might turn out to be the biggest waste of time project (except for the fun and learning)

[routercnc]

I decided to look into the inverter parameters . . .

https://youtu.be/rUjTy3utnsc

[routercnc]

Prototype PCB!

https://youtu.be/cuSpk5dGZ4c

[routercnc]

More developments, some hardware but mostly software including storing user values in non-volatile memory. Also a look ahead to the next PCB revision . . .


https://youtu.be/O_N773pcSwo

[routercnc]

New PCB boards to split the LCD display and the processor. Went smoothly apart from the bits that didn't.


https://youtu.be/uu9BClLFsGY

[routercnc]

I finally get the controller installed . . . after more tinkering!

https://youtu.be/hDzTCiMsE7Y

[Lee Roberts]

Thanks for sharing this @routercnc, love seeing this kind of stuff come through on the forum, special hats off to you for always going the distance.

[routercnc]

Time for episode 8 - Hall effect sensors. Should be fairly straightforward . . .


Can't seem to paste video direct, forum buttons have disappeared!

Youtube link below:

https://youtu.be/gKwJzVpfJPk

[routercnc]

I had another idea, seems so obvious now . . .


https://youtu.be/bcbtGN6m8Rs

[routercnc]

Thanks for embedding the video links Lee!

[routercnc]

Time to test this thing out for real !



https://youtu.be/3iZA39cHo2g

[Muzzer]

Without going back over your design decisions, was there a reason not to use a "spindle at speed" or "spindle stalled" signal from the inverter, rather than have to create your own detection system? Sorry if I misunderstood the process.

On my large milling machine, nothing's going to stall the spindle unless I'm running a large face mill, in which case the axis drives would stall before the cutter broke. Smaller cutters go ping if they get gummed up.

That's an impressive machine you've built there, with great attention to detail!

[routercnc]

Without going back over your design decisions, was there a reason not to use a "spindle at speed" or "spindle stalled" signal from the inverter, rather than have to create your own detection system? Sorry if I misunderstood the process.

On my large milling machine, nothing's going to stall the spindle unless I'm running a large face mill, in which case the axis drives would stall before the cutter broke. Smaller cutters go ping if they get gummed up.

That's an impressive machine you've built there, with great attention to detail!

I looked into the inverter controls in one of the earlier videos and it doesn’t seem to support any of those features. But if I’ve missed something let me know. Inverter is the usual Huanyang 1.5kW models. Thanks

[Muzzer]

Yes, those are the sort of features that get missed off some of the clone VFDs. You can get a fully featured 2.2kW Yaskawa GA500 with in-built EMC filtering and a plethora of features such as spindle at speed for a little over £200, which would have saved a lot of messing about, albeit without the challenge and fulfilment of developing something like this yourself.