How do I want to set up the motor control?

 How do I want to set up the motor control?

Most ready products available seem to have a speed  knob and direction selection and then just a foot controlled on/off switch, this would be the easiest to build. But, I would like the speed control to work in the same way as a sewing machine pedal so one can accelerate on the straight parts and slow down in corners or when you come close to the end of the pattern you are making, and when you let go of the pedal the motor stops. I'm thinking a similar floor pedal as I've seen on  tig welders.

Direction selection I would like to have on the bead roller body close to the adjust screws for the upper roll. Emergency shutdown button in same location might be a good idea.

Biggest challenge is the accelerator pedal. Might be possible to buy something but I don't know the values for the potentiometer and it has five conductors connected to it while potentiometers usually only have three so what the two "extra" wires are for I don't know. 

Lid opened to access the internals of the controller. The potentiometer and button for direction are connected with a small connector to the circuit board. maybe I could connect new potentiometer and put a longer cable to the button...





  Pros(+) and cons(-)
Alternative 1) Add a foot switch.
                               + Easy to make 
                               + Get the motorization of the bead roller done
                               - Usability

Alternative 2) Build an accelerator pedal so speed can be adjusted with foot while using the roller.
                             + Usability
                             - More complicated to build
                             - Requires some more investigation to determine potentiometer values

I'm leaning towards alternative 1. I get this project done for now and no work is in vain if I want to try and convert to alternative two later on.
                               . 

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