I posted this up yesterday, but this morning after several attempts to log in to HM only to have an error messages and finally after successfully logging in, I noticed everything I posted including PM's where nowhere to be found. Weird....anybody else lose posts/messages?
Yesterday, I turned the first project on the lathe. It's an aluminum collar that secures to the balance ring. The balance ring has 12 threaded holes evenly spaced. Only two holes (next to each other) have set screws. These holes where confusing the mag pick up sensor. I verified the ring was not magnetized so that only left the holes to blame for the unreliable RPM reading.
The Collar started out as 1" wide x 5" diameter disc. The piece was secured in the 3 jaw by the OD first to face, core, bore and chamfer. The piece was then rotated and rechucked by the ID. The second side was faced to final width and turned to final OD. During the boring operation, I plugged in the numbers in the DRO and took .060" per pass and one final pass twice using the reversing feed knob. The cut difference on second final pass was crazy low like .00004" The new collar first almost too tight but will slide if pulled evenly. I normally would have snuck up on the final ID/OD with the 1440, but those days are over.
The fist side faced. The surface finish was impeccable using old inserts.
Use the largest annular cutter I had to save a little time.
Bored bt the numbers including final pass.
Test fit was almost too tight.
Flipped ring and scored it by the ID. Faced to dimension and turned Diameter then Chamfered.
OD.
Almost done.
Set up the mill to create two magnet pockets 180º apart. The depth was .125" for a flush finish. Also rotated the ring 90º and drilled/tapped for a single SS set screw. The set screw will secure over the only blind hole on the ring.
Red loc-tite was tabled into the 5/16" pockets and the magnets where set with north pole up. Two center punch strikes stake in the magnet while the red loc-tite cures. Using two magnets will provide a lower PRM reading.
The SS set screw.
The tach now works in all ranges, although the last digit still hunts +/- 2. We have a better quality sensor on order.
Here's a short video of the two stage motor brake in action. The E-stop will always brake in 1.2 seconds regardless of switch position.
Position 1 = brakes in 1.2 seconds
Position 2 = brakes in 2-5 seconds
Thanks for looking.
Paco