Another Treadmill Motor Speed Controller conversion thread

[RJSakowski]

Reading this, I solidly stand in my defense of trying to find a finished (cheap) one.

Don't get me wrong, this is awesome, very useful and thoroughly impressed and we definitely need more of this in the world but for me to learn how to do that would be equivalent to learning how to speak Swahili. As I get older, I'm getting better on learning to pick my battles.

Also sounds like your taking the same design cues and signal control of a high end audiophile amp. Looking forward to seeing it complete.

You will have to define finished and cheap. Handling 2+ hp isn't trivial and finding a low cost plug and play solution isn't trivial either. I had difficulty finding a controller too which is why I am taking the route that I am on.

 

[Inferno]

If I knew how to step up PWM effectively, I could write a code for arduino. Rheostat controlled or pulse to increase/decrease is something I could code.

 

[silverchips]

You will have to define finished and cheap. Handling 2+ hp isn't trivial and finding a low cost plug and play solution isn't trivial either. I had difficulty finding a controller too which is why I am taking the route that I am on.

Defining what finished and cheap is, is subjective depending on who you ask but for me if I would consider a plug and play DC speed controller for approx. 12-18a@100v for $50 as being cheap and good value.

I do see some used DC controller boards online around the same price that fit the specs but then you would have to add a heat sink, controls, misc items and enclosure plus the time needed to assemble it and thats if the the used part you buy works properly. Mind you, I'm not one with electrical components like heat sinks, enclosures or an ample amount of controls laying around laying around and will need to buy them. I don't mind fabricating enclosures.

When you add the items needed to finish one, you're not too far from what I can buy a used finished KB DC controller in its own enclosure like the one above sells for but I would like to find a cheaper solution that doesn't require a huge amount of my time that takes me away form restoring machines and making mechanical devices.

What do you think, it that doable?

 

[NortonDommi]

So, I removed the centrifugal pulley. It was pretty easy, really. All these motors have a left hand thread. You just spin the pulley off.

The shaft seems to be an odd size. A little over 17mm (17.05mm) and a little under 11/16.
Any ideas on what's going on there?

Measure the pitch that should tell you if it is Imperial or metric. Keep in mind that a thread O.D. is normally under the designated size.
Here is a chart of Metric threads:

 

[Inferno]

Measure the pitch that should tell you if it is Imperial or metric. Keep in mind that a thread O.D. is normally under the designated size.
Here is a chart of Metric threads:

Hey! That's a great idea. Why didn't I think of that?!

Thanks.

 

[RJSakowski]

Defining what finished and cheap is, is subjective depending on who you ask but for me if I would consider a plug and play DC speed controller for approx. 12-18a@100v for $50 as being cheap and good value.

I do see some used DC controller boards online around the same price that fit the specs but then you would have to add a heat sink, controls, misc items and enclosure plus the time needed to assemble it and thats if the the used part you buy works properly. Mind you, I'm not one with electrical components like heat sinks, enclosures or an ample amount of controls laying around laying around and will need to buy them. I don't mind fabricating enclosures.

When you add the items needed to finish one, you're not too far from what I can buy a used finished KB DC controller in its own enclosure like the one above sells for but I would like to find a cheaper solution that doesn't require a huge amount of my time that takes me away form restoring machines and making mechanical devices.

What do you think, it that doable?

Those are some pretty tough requirements, especially if you want to do multiple motor controls. If I had not started down the path that I am on, I would probably go with a cheap low power PWM controller and add the proper MOSFET and power supply for driving a high power motor.
Here is an example:

Low Voltage DC 1.8V 3V 5V 6V 12V 2A Motor Speed Controller PWM 1803B

Only US$2.59, buy best low voltage dc 1.8v 3v 5v 6v 12v 2a motor speed controller pwm 1803b sale online store at wholesale price.

www.banggood.com

http://edge.rit.edu/edge/P17054/public/Final%20Documents/PWM%20Data%20Sheet.pdf

This does pretty much what my controller would do for little more than the cost of the pot. Instead of driving the motor directly, I would drive an external MOSFET .

Add a 200v 20 amp bridge, a filter capacitor, and a power MOSFET and you're almost home. Yes it does require some work to maker a complete package but if you are making a bunch of them, you would have the advantage of having the same controller design for all your motors instead of a hodge podge of different controllers.

Heck, I might just order a couple for myself just to play with them.

My idea of a (near) perfect PWM controller would have some feedback from an encoder to provide rock solid speed control regardless of load, over current (stall) protection, and variable acceleration/deceleration. This in addition to return to preset speed and reversing, all with low EMI.

That is a future project though. My immediate goal is to have a basic functional VSD for my d.c. lather motor.

 

[markba633csi]

If you watch Ebay, the KB controllers come up for sale in the 50$ range. KBIC-125 is one I use, good for 16 amp, probably a bit more with forced air.
I got one for around 15$ because it was dusty, in a different box and the seller didn't know if it worked. Blew off the dust and it fired right up. Yes, the motor will hum a bit, but they are very reliable and easy to repair- no exotic parts
-Mark

 

[Inferno]

So, reading through all this, I see circuit board numbers and stuff that are like alien code to me.
I still have the motor control board from the treadmill and was lucky enough to get a second, brand new, one when I picked up the TM.

Maybe that's the way to go since the motor does have an encoder.

 

[silverchips]

I found this and wonder what

Those are some pretty tough requirements, especially if you want to do multiple motor controls. If I had not started down the path that I am on, I would probably go with a cheap low power PWM controller and add the proper MOSFET and power supply for driving a high power motor.
Here is an example:

Low Voltage DC 1.8V 3V 5V 6V 12V 2A Motor Speed Controller PWM 1803B

Only US$2.59, buy best low voltage dc 1.8v 3v 5v 6v 12v 2a motor speed controller pwm 1803b sale online store at wholesale price.

www.banggood.com

http://edge.rit.edu/edge/P17054/public/Final%20Documents/PWM%20Data%20Sheet.pdf

This does pretty much what my controller would do for little more than the cost of the pot. Instead of driving the motor directly, I would drive an external MOSFET .

Add a 200v 20 amp bridge, a filter capacitor, and a power MOSFET and you're almost home. Yes it does require some work to maker a complete package but if you are making a bunch of them, you would have the advantage of having the same controller design for all your motors instead of a hodge podge of different controllers.

Heck, I might just order a couple for myself just to play with them.

My idea of a (near) perfect PWM controller would have some feedback from an encoder to provide rock solid speed control regardless of load, over current (stall) protection, and variable acceleration/deceleration. This in addition to return to preset speed and reversing, all with low EMI.

That is a future project though. My immediate goal is to have a basic functional VSD for my d.c. lather motor.

I found this one, how does this look? Not sure if this would work and if I read it right but looks like it works up to 2000 watts @ 90v with 110v AC input for $65 to your door.

https://www.ebay.com/itm/AC20-110V-input-DC-Motor-Speed-Controller-Board-PWM-Spindle-2000w-w-PLC-MACH3/114019185482?_trkparms=aid=555021&algo=PL.SIMRVI&ao=1&asc=20190711100440&meid=e7b187fcccdf4e10b6267352668b29d9&pid=100752&rk=17&rkt=18&mehot=co&sd=192669869665&itm=114019185482&pmt=1&noa=0&pg=2047675&algv=SimplRVIAMLv5WebWithPLRVIOnTopCombiner&_trksid=p2047675.c100752.m1982&autorefresh=true



EDIT: I also found the same one on Aliexpress for $44 to front door, via slow boat from Asia.

https://www.aliexpress.com/item/329...earchweb0_0,searchweb201602_,searchweb201603_

 

[Inferno]

I found this and wonder what



I found this one, how does this look? Not sure if this would work and if I read it right but looks like it works up to 2000 watts @ 90v with 110v AC input for $65 to your door.



https://www.ebay.com/itm/AC20-110V-input-DC-Motor-Speed-Controller-Board-PWM-Spindle-2000w-w-PLC-MACH3/114019185482?_trkparms=aid=555021&algo=PL.SIMRVI&ao=1&asc=20190711100440&meid=e7b187fcccdf4e10b6267352668b29d9&pid=100752&rk=17&rkt=18&mehot=co&sd=192669869665&itm=114019185482&pmt=1&noa=0&pg=2047675&algv=SimplRVIAMLv5WebWithPLRVIOnTopCombiner&_trksid=p2047675.c100752.m1982&autorefresh=true

Am I reading it right that you'd have to use the speed control instead of an on-off switch?