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routercnc
10-05-2025, 09:05 PM
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
17-05-2025, 04:33 PM
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
18-05-2025, 03:08 PM
Maybe but I've not found it in the 'documentation'. Would simplify things if it did.
routercnc
18-05-2025, 03:09 PM
Episode 2, just making it better all round . . .

https://youtu.be/nSVjT4hpeaE
EddyCurrent
19-05-2025, 10:50 PM
These inverter parameters look interesting;
PD118, PD119, PD120, PD121, PD122, PD123, PD124, PD125
routercnc
20-05-2025, 02:57 PM
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
24-05-2025, 09:52 PM
I decided to look into the inverter parameters . . .

https://youtu.be/rUjTy3utnsc
routercnc
01-06-2025, 04:29 PM
Prototype PCB!

https://youtu.be/cuSpk5dGZ4c
routercnc
15-06-2025, 11:21 AM
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
22-06-2025, 08:16 PM
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
27-07-2025, 01:53 PM
I finally get the controller installed . . . after more tinkering!

https://youtu.be/hDzTCiMsE7Y
Lee Roberts
05-08-2025, 06:50 PM
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
25-08-2025, 11:35 AM
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
13-09-2025, 07:14 PM
I had another idea, seems so obvious now . . .


https://youtu.be/bcbtGN6m8Rs
routercnc
15-09-2025, 07:56 PM
Thanks for embedding the video links Lee!
routercnc
28-09-2025, 05:37 PM
Time to test this thing out for real !



https://youtu.be/3iZA39cHo2g
Muzzer
29-09-2025, 04:48 PM
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!