Spindle Encoder (milling machine or anything with a pulley stack)
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I have been pondering how to attach a spindle encoder to my milling machine for rigid tapping. Older vertical mills…
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I have been pondering how to attach a spindle encoder to my milling machine for rigid tapping. Older vertical mills with pulleys and quills with drawbars pose a problem as there isn't much space or a good place to add an encoder. My preference would be to add a toothed wheel and optical encoders (A/B/Index). But I could not figure out a good way to implement this. I saw a lathe spindle encoder video by Kent VanderVelden, https://www.youtube.com/watch?v=0nCH2G9oAmU and decided this approach could work with my mill.
You will need to adjust the openscad script modifications to fit your pulley profile. See comments and added code starting at line 128 and line 204. Use the original OpenScad script for a pulley to fit your encoder shaft.
I designed an encoder mount which replaces the left spindle housing belt cover.
How I Designed This
Step 2. Print out encoder pulley.
Once I knew the number of teeth on the spindle it was easy to use the OpenScad script to generate a matching encoder pulley. (You want a multiple of the number of teeth.)
Step 3. Electronics
I used an ebay $22 Omron E6B2-CWZ1X encoder with a Mesa Electronics 7i85s card that supports differential A/B/I signals. Electrical connection is a cookbook spindle encoder.
To get ready for rigid tapping, I also connected a USB to serial port to communicate with the GS2 VFD.
Step 4. Software
I use LinuxCNC which supports the Mesa encoder and GS2 serial communications. Relatively simple to connect everything up.
Step 5. Results
Spindle Speed and Position
With the encoder mounted, wired up, and programmed LinuxCNC can display the spindle speed and position.
Rigid Tapping
Using the VFD control and the appropriate G codes and the mill can now rigid tap.
Next Step
The design is working, but the pulleys are a larger than required. I am trying to redesign down to 120T which would allow substitution of an off the shelf 120T aluminum gear for the encoder.
Category: Machine Tools