This build is inspired by a similar build by Wendelspanswick who was a member on here. There are some pictures of his build in his albums. There's also a few posts of his describing his work but I'm not sure there's a dedicated thread as such. Mine's a little different but his build helped with mine.
This is my motor. (Mug for scale) 24v, 8 rpm. It has a big reduction gearbox and 62 Nm of torque. I think they are used in chair lifts and bath/bed lifts. Lots of strong slow deliberate power.
This is my gear to fit to the motor. It needs a keyway cutting into it. The gear is 2.5 modulus. Bought not made. The motor has a 15mm shaft and a 5mm key. I bought the keyway broach cutter but I made the broach bushing myself. It is the third broach bush that I've made. There was a slight error in machining as the slot for the broach is a little too deep. To remedy this, I made another shim to pad it out. The bush needs remaking properly but it got the keyway cut in the gear without too much fuss.
The gear was also shortened from its original length, as it was deeper than the maximum length that the broach could cut. The pic below shows the gear after shortening. The plain round part on the right used to be longer and housed a grubscrew but that's all gone now.
Gear broached on the press.
Gear mounted (Wrong way round) on the motor.
In the words of shoddy welders and machinists the world over, "That aint going anywhere...."
This is the standard Chinese bead roller. I reinforced the other side years ago with box section to stiffen it up. Used a Clarke 150amp mig at the time. Not the best choice for welding to 15mm plate, but it was all I had then. I've now added a mounting plate for the motor. It is 3mm plate doubled up to create a 6mm piece.
Wendelspanwick welded his plate to the roller frame. Instead, I've utilised the two boltholes that hold the bearing blocks in place. I replaced the original bolts with longer ones to accommodate the 6mm of steel plate. I like to make my mods reversible, just in case I don't like how they turn out.
Bolt holes drilled. The motor has slots to give a bit of adjustment up and down if needed. I thought about welding the two plates together, but I have six bolts connecting the two, so I think I can get away without it.
All fitted and bolted up. I've used five 6mm washers and one 8mm washer in a stack as spacers for each of the four motor mounting bolts.
Gearmesh.
Gear mesh on the other side. I'm going to make a sheet metal cover or something similar for those gears. They will crush most things small enough to get trapped in there. I'm reminded of Kyle Reese's speech from The Terminator. "It can't be reasoned with. It doesn't feel pity, or remorse, or fear. And it absolutely will not stop... ever, until you are dead!"
OK, maybe not the last bit but, "It will give you a nasty suck" as my Dad used to say.
This is it running. Got the electronic controls still to sort.
https://youtu.be/jHBr9nEGwmQ
This is my motor. (Mug for scale) 24v, 8 rpm. It has a big reduction gearbox and 62 Nm of torque. I think they are used in chair lifts and bath/bed lifts. Lots of strong slow deliberate power.
This is my gear to fit to the motor. It needs a keyway cutting into it. The gear is 2.5 modulus. Bought not made. The motor has a 15mm shaft and a 5mm key. I bought the keyway broach cutter but I made the broach bushing myself. It is the third broach bush that I've made. There was a slight error in machining as the slot for the broach is a little too deep. To remedy this, I made another shim to pad it out. The bush needs remaking properly but it got the keyway cut in the gear without too much fuss.
The gear was also shortened from its original length, as it was deeper than the maximum length that the broach could cut. The pic below shows the gear after shortening. The plain round part on the right used to be longer and housed a grubscrew but that's all gone now.
Gear broached on the press.
Gear mounted (Wrong way round) on the motor.
In the words of shoddy welders and machinists the world over, "That aint going anywhere...."
This is the standard Chinese bead roller. I reinforced the other side years ago with box section to stiffen it up. Used a Clarke 150amp mig at the time. Not the best choice for welding to 15mm plate, but it was all I had then. I've now added a mounting plate for the motor. It is 3mm plate doubled up to create a 6mm piece.
Wendelspanwick welded his plate to the roller frame. Instead, I've utilised the two boltholes that hold the bearing blocks in place. I replaced the original bolts with longer ones to accommodate the 6mm of steel plate. I like to make my mods reversible, just in case I don't like how they turn out.
Bolt holes drilled. The motor has slots to give a bit of adjustment up and down if needed. I thought about welding the two plates together, but I have six bolts connecting the two, so I think I can get away without it.
All fitted and bolted up. I've used five 6mm washers and one 8mm washer in a stack as spacers for each of the four motor mounting bolts.
Gearmesh.
Gear mesh on the other side. I'm going to make a sheet metal cover or something similar for those gears. They will crush most things small enough to get trapped in there. I'm reminded of Kyle Reese's speech from The Terminator. "It can't be reasoned with. It doesn't feel pity, or remorse, or fear. And it absolutely will not stop... ever, until you are dead!"
OK, maybe not the last bit but, "It will give you a nasty suck" as my Dad used to say.
This is it running. Got the electronic controls still to sort.
https://youtu.be/jHBr9nEGwmQ