Poorly N sick Fadal 15 VMC Will live again!

[JAZZCNC]

Dean - you mention running this off single-phase. What kind of spindle motor would that be? It looks like a big, heavy machine so 4KW or so spindle motor? Just curious - no way would it fit my workshop! Interesting to watch the design/component choice/build proces - thanks for letting us watch the thought processes!

It's 7.5Kw/10HP Neale. It will just about run off a single phase but obviously not a 13A supply...Lol
The trick will be finding a VFD that plays nice with this motor and does closed loop.!! . . . I may just have to stick with sensorless Vector drive and feed the encoder back to the controller for ridged tapping and stick with the Wye/Delta to control speed/torque.

Edit: Also under consideration is a Servo Spindle motor.!!

The footprint isn't massive really for this size machine, or it won't be when I've finished. W=1900 D=1700 The height I think will just fit under an 8ft ceiling.
To be honest, If I wanted to get really crazy about it the whole enclosure comes apart and I could make the machine narrower by about 500mm with maybe a slightly less wide door opening but I won't be going to those extremes . .

[Uguessedit]

Just saw your last post. You may want to check with automation direct they have sensored vector drives but I don’t know if the size you need will operate on single phase. If it does you would likely need to go with a larger vector drive to fit your needs. Also you could compare it to buying a servo motor and drive package from a AliExpress vendor I’m certain I’ve seen them in the 7.5 to 10hp range with 15,000rpm Complete package for around $2,000usd. I suspect any good parts you’ve taken off should fetch enough to offset the cost of your build.

[JAZZCNC]

Just saw your last post. You may want to check with automation direct they have sensored vector drives but I don’t know if the size you need will operate on single phase. If it does you would likely need to go with a larger vector drive to fit your needs. Also you could compare it to buying a servo motor and drive package from a AliExpress vendor I’m certain I’ve seen them in the 7.5 to 10hp range with 15,000rpm Complete package for around $2,000usd. I suspect any good parts you’ve taken off should fetch enough to offset the cost of your build.

Hi,
Yes, I've seen and considered those Servo motor packages. To be honest, there's nothing wrong with the AMC Drive or Baldor Spindle it's just the 3 phase I'm trying to get away from, but that might not be so easy to do and keep all the power it currently has.

The plan is to remove the DC motors and drives which all work, only the Z-axis card is faulty. I think some of the control cards have gone down which is why I've pulled it apart, it's just not worth replacing Axis and Control cards without knowing 100% if that's all that's wrong.

When I've fully decided which route I'm taking then I'll make a list of what I'm selling. Currently, it's looking like Delta AC servos with either a Centroid OAK controller or a Chinese GSK controller. So I'll have pretty much everything that's inside a Fadal and the Monitor, keyboard, etc in the control panel, Plus the Fadal VH65 4th axis with full wiring harness and drive plus axis card. So like you say it should go a long way to offset some of the costs, provided I can find buyers.!

I'm still sat on the fence regards the spindle.!!

[JAZZCNC]

Ok another small update, Spindle motor off ready for clean up or replacement with Servo Spindle motor.?

I needed to measure shaft length, diameter plus find bolt spacing because I'm considering fitting a 10,000rpm 11Kw Servo Spindle so needed this info, which I could probably have found from Fadal spec sheets if honest but I wanted to get in there and give it a good clean up and check belt condition, etc. Which is like brand new.

With the belt off, I can now feel and check the spindle bearings and balance, both of which are perfect I'm pleased to say.

As you can see nothing on this machine is lightweight so it's a bloody good job I've got a fork truck because I wouldn't fancy humping that big lump down from up there.!!

[JAZZCNC]

Another update. So it's been decided as to what's going into and onto this machine now and just tonight I've hit the Go button.

So it's a full conversion using Controller and Motors Etc from Shenzhen Guanhong Automation CO.,LTD (SZGH) in China, including swapping out the Spindle motor for a Custom built Servo Spindle and Drive.

I must say the people at SZGH have been amazing with replys and answering all my many questions. They have bent over backwards to help and are custom building the spindle motor to suit this conversion. All the manuals they have provided are very good with minimal Chinglish.
Both the Engineers and the admin girl I've been dealing with have replied with perfect english and answered every question very quickly. The Engineers clearly know what they are doing and have been very helpful answering technical questions and giving good suggestions going above and beyond to help with the conversion. Any fears I had on the technical backup with it being a Chinese controller have been laid to rest these last few days.

So the finalised spec is this.
4 Axis 1000MDc high performance(ATC & PLC support) Absolute Controller with Type C control panel.
https://www.szghauto.com/product/64.html

7.5Kw (48Nm) 12,000rpm Servo Spindle and Drive. Based on this but higher RPM with custom machined shaft to Fit Fadal Pulley.
https://www.szghauto.com/product/114.html
https://www.szghauto.com/product/125.html

1.5Kw 130mm AC servos with Japanese Tamagawa-Seike 23bit Absolute encoders. With Matching AC drives.
https://www.szghauto.com/product/156.html
https://www.szghauto.com/product/141.html

Along with all cables I/O and Relays boards, brake resistor for spindle etc and they even through in a nice MPG pendant FOC.

The price was amazing coming in just over £4k delivered to my door. This is plus VAT but I can claim that back.
That's a lot of serious stuff for that price so lets see what happens when it lands.?

[Uguessedit]

You’d have to ask about voltage needs but this is one of those I was talking about. Pretty certain again that I talked to these folks or another party and they could make changes for voltage by request. They 15kw were the $2,000 models. With a bt or cat 40 if you can fit it that would be ideal torque given the rpm suits your needs.

US $1,148.00 | high performance 380V 48Nm 7.5kw spindle servo motor with drive SZGH-S4T5P5
https://a.aliexpress.com/_d6zXpk1