Tos FN22 milling machine (Deckel clone)

[RichardM]

A longer stud and put a nut on it. The longer stud to make sure there was the correct length of thread in the other casting.

 

[Ton-up]

Can you put this or a longer bolt in from below and put a nut on the top to save cutting the bolt, then if you ever have the gearbox out again(!) you could change it.

 

[Pete.]

I can probably do all of those. I'm sure that a stud will go past the gearbox or indeed screw in from below, just that at the time it was a forehead slapping moment

 

[paradipiro]

I can probably do all of those. I'm sure that a stud will go past the gearbox or indeed screw in from below, just that at the time it was a forehead slapping moment

Maybe, if you loosen up the gearbox screws in the front, and take out the two conical pins, the whole gearbox can be swinged to the side enough to drop the screw.

 

[Pete.]

Maybe, if you loosen up the gearbox screws in the front, and take out the two conical pins, the whole gearbox can be swinged to the side enough to drop the screw.

Can't do that without removing the feeds rod, which requires the feed gearbox removed, which requires the selector removed, ad the feed screw too, plus the z screw housing.

 

[Pete.]

Got the motor in this evening. It's a heavy lump at 32KG. I fitted it onto the swivel plate and tried to get the whole thing in but there just wasn't the clearance to slide it in so I had to mount the plate first, slide the motor in on a bit of timber then fiddle about getting the four M16 bolts in. Here it is with the belts and tensioner fitted. There's no writing to read on those belts though.



There's a third belt that runs down to the feeds gearbox from the large pulley which does have the size printed on it but it was too long for the tensioner pulley to remain inside the (not yet made) cover so I cut it with a mini-grinder and wrapped it round the pulleys to overlap the ends and marked it, then measured the length with a tape measure. Interestingly, even though it was cut with a 1mm disc, the measured original length was 10mm shorter than the length printed on it.

Anyway, by using this useless belt as a gauge I've got the lengths to replace the two short belts in the pic and the longer one for the feeds gearbox. The orignals were all A-section but I've ordered AX belts which are the same size but will cause less parasitic loss because they bend more readily.

 

[paradipiro]

Can't do that without removing the feeds rod, which requires the feed gearbox removed, which requires the selector removed, ad the feed screw too, plus the z screw housing.

The Y axis feedrod is around 500mm long, it will not be a problem, if the gearbox is tilted with around the needed 10-15 mm. Z nut is installed separatedly. The movement is driven with gearset, what can be separated slightly i think.

 

[Smouser]

Got the motor in this evening. It's a heavy lump at 32KG. I fitted it onto the swivel plate and tried to get the whole thing in but there just wasn't the clearance to slide it in so I had to mount the plate first, slide the motor in on a bit of timber then fiddle about getting the four M16 bolts in. Here it is with the belts and tensioner fitted. There's no writing to read on those belts though.

View attachment 419895

There's a third belt that runs down to the feeds gearbox from the large pulley which does have the size printed on it but it was too long for the tensioner pulley to remain inside the (not yet made) cover so I cut it with a mini-grinder and wrapped it round the pulleys to overlap the ends and marked it, then measured the length with a tape measure. Interestingly, even though it was cut with a 1mm disc, the measured original length was 10mm shorter than the length printed on it.

Anyway, by using this useless belt as a gauge I've got the lengths to replace the two short belts in the pic and the longer one for the feeds gearbox. The orignals were all A-section but I've ordered AX belts which are the same size but will cause less parasitic loss because they bend more readily.

You forgot to paint the motor and brackets!

 

[Brad93]

Got the motor in this evening. It's a heavy lump at 32KG. I fitted it onto the swivel plate and tried to get the whole thing in but there just wasn't the clearance to slide it in so I had to mount the plate first, slide the motor in on a bit of timber then fiddle about getting the four M16 bolts in. Here it is with the belts and tensioner fitted. There's no writing to read on those belts though.

View attachment 419895

There's a third belt that runs down to the feeds gearbox from the large pulley which does have the size printed on it but it was too long for the tensioner pulley to remain inside the (not yet made) cover so I cut it with a mini-grinder and wrapped it round the pulleys to overlap the ends and marked it, then measured the length with a tape measure. Interestingly, even though it was cut with a 1mm disc, the measured original length was 10mm shorter than the length printed on it.

Anyway, by using this useless belt as a gauge I've got the lengths to replace the two short belts in the pic and the longer one for the feeds gearbox. The orignals were all A-section but I've ordered AX belts which are the same size but will cause less parasitic loss because they bend more readily.

what size belts you need pete i can check stock

 

[Pete.]

what size belts you need pete i can check stock

Two ax50 and one ax81 but I've already got them coming mate cheers

 

[Pete.]

You forgot to paint the motor and brackets!

I didn't. The motor has been reconfigured from a 415v dahlander 2 speed connection to a 240v straight delta. I'm not sure that it won't go up in smoke the first time I use it.

 

[Onoff]

No, but I've been thinking I could cut the head off this one, thread it into the hole and use a nut.

Could you just mill one face off the bolt?

 

[Moose McAlpine]

Could you just mill one face off the bolt?

Or use a socket head maybe?

 

[Pete.]

Few small jobs this evening, The feeds gearbox belt tensioner idle pulley was very worn and had rotten bearings. I have no idea what the original shape was so I just machined a flat groove in it with angled sides to run on the flat back of the belt. Then I fitted two new bearings and fitted it to the tensioner arm. I don't have the new belt yet so I cut and spliced the over-length one that was fitted just to see how it all went together. Seemed to all work out alright.



I filled the spindle gearbox with oil to half way up the sight glass I made. Haven't found any leaks yet but I'm holding judgement until I get the thing spinning.



I found some 4-core SY cable to use for the motor power lead. Ran the earth wire out to the screw provided.



Then I dug out the Lenze 2.2kw VFD I bought for powering to motor. I've wired the motor to it and a temporary power lead whilst I figure out what control system I'm going to use. I'll leave it on the bench for now with enough lead to reach into the casing to the motor. All being well I will get the motor under power tomorrow and see how it all runs. Long way to go yet but this will be a nice milestone.

 

[paradipiro]

Few small jobs this evening, The feeds gearbox belt tensioner idle pulley was very worn and had rotten bearings. I have no idea what the original shape was so I just machined a flat groove in it with angled sides to run on the flat back of the belt. Then I fitted two new bearings and fitted it to the tensioner arm. I don't have the new belt yet so I cut and spliced the over-length one that was fitted just to see how it all went together. Seemed to all work out alright.

View attachment 419967

I filled the spindle gearbox with oil to half way up the sight glass I made. Haven't found any leaks yet but I'm holding judgement until I get the thing spinning.

View attachment 419966

I found some 4-core SY cable to use for the motor power lead. Ran the earth wire out to the screw provided.

View attachment 419965

Then I dug out the Lenze 2.2kw VFD I bought for powering to motor. I've wired the motor to it and a temporary power lead whilst I figure out what control system I'm going to use. I'll leave it on the bench for now with enough lead to reach into the casing to the motor. All being well I will get the motor under power tomorrow and see how it all runs. Long way to go yet but this will be a nice milestone.

View attachment 419964

The idler's original shape is just a radius.

 

[Pete.]

The idler's original shape is just a radius.

Ah, well in that case it wasn't worn out just had rotten bearings.

 

[Pete.]

Well, I got the motor fired up in the machine but it's very clear that the Lenze vfd does not like it. I had re-connected the 2-speed windings to act as a single speed 4 pole delta would motor but it had not been a success as it pulls a lot of current (I half expected it to go bang right away) to the extent that it causes the vfd to go into over-current after a few minutes.
I can't really diagnose it any further since the vfd does not display any monitoring data except for output frequency.

So I have put an advert in the sale section looking for a modern 2.2kw replacement.

 

[Brad93]

Well, I got the motor fired up in the machine but it's very clear that the Lenze vfd does not like it. I had re-connected the 2-speed windings to act as a single speed 4 pole delta would motor but it had not been a success as it pulls a lot of current (I half expected it to go bang right away) to the extent that it causes the vfd to go into over-current after a few minutes.
I can't really diagnose it any further since the vfd does not display any monitoring data except for output frequency.

So I have put an advert in the sale section looking for a modern 2.2kw replacement.

I'll have something

 

[Brad93]

Sick with covid at the minute but may venture to workshop tomorrow if i feel up to it. I'm sure there is a 2.2kw 4 pole in the shed

 

[Smouser]

Well, I got the motor fired up in the machine but it's very clear that the Lenze vfd does not like it. I had re-connected the 2-speed windings to act as a single speed 4 pole delta would motor but it had not been a success as it pulls a lot of current (I half expected it to go bang right away) to the extent that it causes the vfd to go into over-current after a few minutes.
I can't really diagnose it any further since the vfd does not display any monitoring data except for output frequency.

So I have put an advert in the sale section looking for a modern 2.2kw replacement.

That is a shame.

I was rooting for your rewired 2 speed motor.