Advice needed - replacing variator on lathe

Advice needed - replacing variator on lathe

Post by Paul Sti » Sun, 06 Feb 2005 03:30:22



I have an Harrison Model AA-10 lathe with a 2HP motor with a dodgy
Kopp  varitor.

I  need to replace the variator.

I am uneducated in these devices, but it has been suggested that a VFD
setup would do the trick. (I need to be able to reverse, if that is a
factor that need extra consideration.)

I have three phase power available at the lathe and a budget of about
$1000 with some wiggle room.

Any advice would be appreciated.

Paul Stine
Texas A&M University
Geochemical and Environmental Research Group
College Station, TX

 
 
 

Advice needed - replacing variator on lathe

Post by Jon Elso » Sun, 06 Feb 2005 08:42:45


Quote:

>I have an Harrison Model AA-10 lathe with a 2HP motor with a dodgy
>Kopp  varitor.

>I  need to replace the variator.

>I am uneducated in these devices, but it has been suggested that a VFD
>setup would do the trick. (I need to be able to reverse, if that is a
>factor that need extra consideration.)

>I have three phase power available at the lathe and a budget of about
>$1000 with some wiggle room.

I assume this "variator" is some form of variable speed drive.
Depending on what the output speed of the variator is, you may be able to
use a standard 3-phase motor directly, or you may need a separate reduction
gearbox between the motor and the rest of the lathe.

But, the variable speed part is straightforward.  Without forced-air
cooling,
you can get about 30 - 150% speed from a standard motor.  With heavy
external cooling applied, you can get from 5% up to wherever your danger
threshold is.  I don't feel too comfortable spinning large motors much more
than 50% above rated speed.

With a VFD, you get rated torque from 0 - 100% of the motor's rated speed.
Above 100% speed, you get constant HP, so up there is works just like a
variable speed drive.  But, below rated speed, the power drops off linearly,
UNLIKE the VSD.  If the variator accomplishes a great deal of speed
reduction,
then just bypassing it may lead to a loss of low speed torque.  If you
get your
low speed ranges from other gear reductions, like in the headstock, then it
shouldn't be a problem.

All VFDs can handle reverse.  Pretty much all of them can also brake the
motor, which is a nice feature.

I have a Sheldon R15-6, which was made with 8 fixed speeds.  (4 speed
gearbox on the motor, and backgear in the headstock.)  It is wonderful with
a VFD.  I get smooth starts, braking, plus a jog function for certain
gears that don't
want to click right in.

If you have a dual voltage (230/460 V) motor, and you set it up for the
lower
voltage and run it with a 230 V VFD, you get an extra level of insulation
protection.  VFDs can be *** motors, but by using a motor with 460 V
insulation with a 230 V VFD, you should have no problems with insulation
breakdown.

Jon

 
 
 

Advice needed - replacing variator on lathe

Post by geoff » Sun, 06 Feb 2005 17:44:04


I assume this variator is the same one as used in the Colchester
Chipmaster. Parts (as you have discovered) are unobtainable - I got
the last spider bit in existence 10 years ago.
 A VFD works well on them - I know of a couple of Chipmasters using
electronic drives. Mine is making a horrible noise today, so I suspect
the end is nigh, and a VFD and new motor will be a late Xmas pressie
soon. You get the advantage of exact speed control, RPM readout, ramp
up and down for speed, etc
Geoff
 
 
 

Advice needed - replacing variator on lathe

Post by Scott Blac » Sun, 06 Feb 2005 22:53:49


http://www.dealerselectric.com/acafdrive.cfm

These guys were at the Cabin Fever expo and had some very nice VFDs that
were reasonably priced. They could run in both directions, you could program
start and stop acceleration, brake, rpm or freq. Very nice. It would be for
a 3phase motor of course. The 2hp ones were running around $150-$200 and up.
If I have to replace the motor on my lathe this is definitely the way I will
go. 3 phase motors are cheap and this way you have infinitely variable rpm
with an LED readout which can also be controlled by a CNC controller if you
choose.

Quote:

> I am uneducated in these devices, but it has been suggested that a VFD
> setup would do the trick. (I need to be able to reverse, if that is a
> factor that need extra consideration.)

> I have three phase power available at the lathe and a budget of about
> $1000 with some wiggle room.

 
 
 

Advice needed - replacing variator on lathe

Post by Robert Swinne » Mon, 07 Feb 2005 05:00:47


Hey!  With all the "smarts" at Texas A&M why don't you check with the
Electrical Engineering Dept?

Bob Swinney

PS:  Be careful about asking anyone at A&M how to stack wood, though!


Quote:
>I have an Harrison Model AA-10 lathe with a 2HP motor with a dodgy
> Kopp  varitor.

> I  need to replace the variator.

> I am uneducated in these devices, but it has been suggested that a VFD
> setup would do the trick. (I need to be able to reverse, if that is a
> factor that need extra consideration.)

> I have three phase power available at the lathe and a budget of about
> $1000 with some wiggle room.

> Any advice would be appreciated.

> Paul Stine
> Texas A&M University
> Geochemical and Environmental Research Group
> College Station, TX

 
 
 

Advice needed - replacing variator on lathe

Post by John Normi » Mon, 07 Feb 2005 09:46:32


I too am an owner of a 10AA with the Koop variator.   When I got this
machine the variator was making a lot of noise, and I thought the unit
was going bad.   What I found was that there is an adjustment on the
output side of the unit, that was loose.   I took out the play in this
bearing (?) adjustment and it quieted right down.   No more banging on
start up.  

Also the use of the wrong lube will cause the banging noise and soon
destroy the unit.   This per one of the "old timers" at Harrison
service.

I also found that the input pulley was loose on the shaft, and this
also contributed to the noise.   Take out the tool storage compartment
to check this.

Hope this helps

John Normile



Quote:
>I have an Harrison Model AA-10 lathe with a 2HP motor with a dodgy
>Kopp  varitor.

>I  need to replace the variator.

>I am uneducated in these devices, but it has been suggested that a VFD
>setup would do the trick. (I need to be able to reverse, if that is a
>factor that need extra consideration.)

>I have three phase power available at the lathe and a budget of about
>$1000 with some wiggle room.

>Any advice would be appreciated.

>Paul Stine
>Texas A&M University
>Geochemical and Environmental Research Group
>College Station, TX