Starting point.


The bead roller.

I have a hand cranked bead roller witch is not very practical from user point of view. It is difficult to use alone, and when you do the result is usually not good. I made a stand for it earlier, but other than that it is as it came out of the box when purchased. 





When searching the  net there are several improvement ideas for these kind of bead rollers. Most common improvements are about stiffening the structure and motorizing them. I might end up applying some of the other improvement ideas also during this project, but the main objective is to motorize the roller!

The motor.
I have looked at different alternatives everything from garage door openers to drilling machines. I also found a kit made for the purpose but it could only be purchased in the states so that was not an option. So I decided to buy the cheapest ATV winch I could find. 

Specification: 
-    Capacity 907 kg winch
-    12VDC power supply, 115A at 908kg
-     Reduction gear with a gear ratio of 153:1 
-     Permanent magnet DC motor 1,9hp (1,4kw)
-     Hand held controller




 
There are a couple of reasons why I selected this motor. To mention some. The gear ratio of 153.1 should give fairly high torque with low power output on the electrical motor and the RPM of the out put shaft is low, witch is also a good thing in this case. The permanent magnet motor is easy to RPM control if needed with a PWM control circuit.  

I have done some tests. The shaft RPM is about 30 RPM when not loaded. For bead roller application this is a bit to high. Bead rollers with RPM controllers seem to be adjustable between 0-20 RPM. As I want to keep this a straight shaft drive and not add any additional reduction gearing I will probably need to go for a PWM speed controller to be able to reduce shaft speed further. I have tried to use the winch with resistance and measure the amperes to try and get a feel of how much amperes the PWM speed controller needs to be able to take. When pulling in the winch wire while hauling in the wire I get figures around 15 amperes. This is a very basic test and honestly I don't know how close this value is to what the amperes will be when bead rolling but I think this is closer to the truth than the maximum amperes of 115A for the motor . There are fairly cheap PWM controllers up to 60A witch I think should be more than enough for this application. In  the future I would like to have a AC/DC converter to be able to plug the bead roller to a normal 230 VAC socket. But I need to measure the amperes on DC side while used for bead rolling before purchasing a converter to know what size I need, so I will probably run the bead roller from a car battery in the beginning. 

Disassembling the winch.   

This is what it looks like without the cable.       


ATV fastening bracket removed. I'm hoping to use the bracket.



This mechanism is for releasing the drum, enabling drum to rotate freely from motor when deactivated. Used when pulling cable out from winch. Unfortunately I broke the small shaft when trying to remove the operating handle (not shown on picture), not an issue for this project.


I'm planning to install the motor in line with the shaft where hand crank is connected now.  The hole is about 15mm of so that will require a mounting bracket with an offset.

Shaft outer diameter in mm.

Crank inner diameter in mm and upside down, but it would look even stranger if I turned the picture around...












Comments

Post a Comment

Popular posts from this blog

Ready! At least for now!

Image
The end product! Footswitch and battery setup. Other details: Electrical work ongoing. Wiring diagram: "Original plan" ended up using a bigger junction box with mounting plate witch made the installation easier. Future plans Mainly use it! Getting rid of the battery by adding an AC/DC converter is on the agenda.    
Read more

How to fasten the electrical motor to the bead roller.

Image
What is it I want to build?  I need to figure out how to fix the motor to the bead roller. I'm thinking I want to be able to convert the roller back to hand crank use if needed, for example the motor breaks or the construction I'm making does not work, so I will try to make a bolted bracket for the motor. I need to be able to adjust the motor position to get the shaft aligned as good as possible. As I will have to dismantle the bead roller and probably need to do some welding to the frame, it would make sense to stiffen up the construction while I'm at it. I think the easiest way to stiffen the bead roller would be to weld square tubing or a thick plate to the back side of the bead roller frame. As I need a way to get the motor more towards the back of the roller a suitable tick plate might solve two problems at once. The plan is now to strengthen the body of the bead roller at the same time as preparing fastening point for the motor assembly. Purchasing material. With some...
Read more

Speed and direction control

Image
 I purchased a PWM (pulse width modulation) speed controller from an online shop. There was very little information on the sight about the controller it only said max current 60A, so I thought that should be sufficient. When I got it it is clear by looking at it that it is not intended for use anywhere near nominal currents of 60A but maybe for really short periods it can withstand it.   Terminal marking on casing is in Chinese I think, but on the circuit board it is indicated in English. Hooking up the controller. I used the cables from the remote controller from the winch they had end terminals on with correct markings so it was straight forward. I did some tests with the controller. One was to remove the display unit and did not make any difference, works fine without it so that one I will leave out. I see no use for it. I tried to measure the amps when bead rolling also but my multimeter freaked out so I did not get any result. Need to try that again at some other time. Th...
Read more