POWER SAVING SYSTEM FOR LATHE
POWER SAVING SYSTEM FOR LATHEABSTRACT In this modern world, the
power saving system is help to us many purposes. Here we are using
an electronic A.C motor speed regulator. This regulator is used to
maintain the set speed of the motor constant.
The speed variation due to over load, line voltage fluctuations,
over voltage, surge problems etc. Can be controlled and the speed
is maintained constant by using this POWER SAVING SYSTEM IN LATHE.
This unit can be used upto 1 H.P. A.C. motor.INTRODUCTION
In most of the applications of A.C. motor constant speed is most
suitable for many applications. Speed varied due to overload, line
voltage fluctuations in the input supply, over voltage, changes in
the frequency. Surge problems etc., Hence to overcome the above
electronics control unit are suggested. These problems may cause
poor speed regulation of the motor and also lesser efficiency. To
avoid these problems electronic this unit is used to maintain a
constant speed of the motor.
Electronic Digital Speed control of A.C. Motor can be
economically constructed ensuring the automatic speed regulation
irrespective of load conditions however being essentially we can
set the required constant speed with constant power. The motor
speed can be from zero to maximum rated speed. This unit can be
used upto 1HP A.C. Motor. For speed setting there is a regulating
potentiometer with points for Indicating the setting we can select
the required speed of the particular motor depends upon its
purpose.
LATHEThe lathe is a machine tool used principally for shaping
articles of metal (and sometimes wood or other materials) by
causing the work piece to be held and rotated by the lathe while a
tool bit is advanced into the work causing the cutting action. The
basic lathe that was designed to cut cylindrical metal stock has
been developed further to produce screw threads. tapered work.
drilled holes. knurled surfaces, and crankshafts. The typical lathe
provides a variety of rotating speeds and a means to manually and
automatically move the cutting tool into the workpiece. Machinists
and maintenance shop personnel must be thoroughly familiar with the
lathe and its operations to accomplish the repair and fabrication
of needed parts.
Lathes can be divided into three types for easy identification:
engine lathes, turret lathes, and special purpose lathes. Small
lathes can be bench mounted, are lightweight, and can be
transported in wheeled vehicles easily. The larger lathes are floor
mounted and may require special transportation if they must be
moved. Field and maintenance shops generally use a lathe that can
be adapted to many operations and that is not too large to be moved
from one work site to another. The engine lathe (Figure 7-1 ) is
ideally suited for this purpose. A trained operator can accomplish
more machining jobs with the engine lathe than with any other
machine tool. Turret lathes and special purpose lathes are usually
used in production or job shops for mass production or specialized
parts. while basic engine lathes are usually used for any type of
lathe work. Further reference to lathes in this chapter will be
about the various engine lathes.
SizesThe size of an engine lathe is determined by the largest
piece of stock that can be machined. Before machining a workpiece,
the following measurements must be considered: the diameter of the
work that will swing over the bed and the length between lathe
centers.
CategoriesSlight differences in the various engine lathes make
it easy to group them into three categories: lightweight bench
engine lathes, precision tool room lathes, and gap lathes, which
are also known as extension- type lathes. These lathe categories
are shown in Figure 7-2 Different manufacturers may use different
lathe categories.
LightweightLightweight bench engine lathes are generally small
lathes with a swing of 10 inches or less, mounted to a bench or
table top. These lathes can accomplish most machining jobs, but may
be limited due to the size of the material that can be turned.
PrecisionPrecision tool room lathes are also known as standard
manufacturing lathes and are used for all lathe operations, such as
turning, boring, drilling, reaming, producing screw threads, taper
turning, knurling, and radius forming, and can be adapted for
special milling operations with the appropriate fixture. This type
of lathe can handle workplaces up to 25 inches in diameter and up
to 200 inches long. However, the general size is about a 15-inch
swing with 36 to 48 inches between centers. Many tool room lathes
are used for special tool and die production due to the high
accuracy of the machine.
GAP OR EXTENSION-TYPE LATHESGap or extension-type lathes are
similar to toolroom lathes except that gap lathes can be adjusted
to machine larger diameter and longer workplaces The operator can
increase the swing by moving the bed a distance from the headstock,
which is usually one or two feet. By sliding the bed away from the
headstock, the gap lathe can be used to turn very long workplaces
between centers.
LATHE COMPONENTSEngine lathes all have the same general
functional parts, even though the specific location or shape of a
certain part may differ from one manufacturer The bed is the
foundation of the working parts of the lathe to another (Figure
7-3).
The main feature of its construction are the ways which are
formed on its upper surface and run the full length of the bed Ways
provide the means for holding the tailstock and carriage, which
slide along the ways, in alignment with the permanently attached
headstock
The headstock is located on the operators left end of the lathe
bed. It contains the main spindle and oil reservoir and the gearing
mechanism for obtaining various spindle speeds and for transmitting
power to the feeding and threading mechanism. The headstock
mechanism is driven by an electric motor connected either to a belt
or pulley system or to a geared system. The main spindle is mounted
on bearings in the headstock and is hardened and specially ground
to fit different lathe holding devices. The spindle has a hole
through its entire length to accommodate long workplaces. The hole
in the nose of the spindle usually has a standard Morse taper which
varies with the size of the lathe. Centers, collets, drill chucks,
tapered shank drills and reamers may be inserted into the spindle.
Chucks, drive plates, and faceplates may be screwed onto the
spindle or clamped onto the spindle nose.
The tailstock is located on the opposite end of the lathe from
the headstock. It supports one end of the work when machining
between centers, supports long pieces held in the chuck, and holds
various forms of cutting tools, such as drills, reamers, and taps.
The tailstock is mounted on the ways and is designed to be clamped
at any point along the ways. It has a sliding spindle that is
operated by a hand wheel and clamped in position by means of a
spindle clamp. The tailstock may be adjusted laterally (toward or
away from the operator) by adjusting screws. It should be unclamped
from the ways before any lateral adjustments are made, as this will
allow the tailstock to be moved freely and prevent damage to the
lateral adjustment screws.
The carriage includes the apron, saddle, compound rest, cross
slide, tool post, and the cutting tool. It sits across the lathe
ways and in front of the lathe bed. The function of the carriage is
to carry and move the cutting tool. It can be moved by hand or by
power and can be clamped into position with a locking nut. The
saddle carries the cross slide and the compound rest. The cross
slide is mounted on the dovetail ways on the top of the saddle and
is moved back and forth at 90 to the axis of the lathe by the cross
slide lead screw. The lead screw can be hand or power activated. A
feed reversing lever, located on the carriage or headstock, can be
used to cause the carriage and the cross slide to reverse the
direction of travel. The compound rest is mounted on the cross
slide and can be swiveled and clamped at any angle in a horizontal
plane. The compound rest is used extensively in cutting steep
tapers and angles for lathe centers. The cutting tool and tool
holder are secured in the tool post which is mounted directly to
the compound rest. The apron contains the gears and feed clutches
which transmit motion from the feed rod or lead screw to the
carriage and cross slide.
GENERAL LATHE OPERATIONS
LATHE SPEEDS, FEEDS, AND DEPTH OF CUTS
General operations on the lathe include straight and shoulder
turning, facing, grooving, parting, turning tapers, and cutting
various screw threads. Before these operations can be done, a
thorough knowledge of the variable factors of lathe speeds, feeds,
and depth of cut must be understood. These factors differ for each
lathe operation, and failure to use these factors properly will
result in machine failure or work damage. The kind of material
being worked, the type of tool bit, the diameter and length of the
workpiece, the type of cut desired (roughing or finishing), and the
working condition of the lathe will determine which speed, feed, or
depth of cut is best for any particular operation. The guidelines
which follow for selecting speed, feed, and depth of cut are
general in nature and may need to be changed as conditions
dictate.
Cutting Speeds.The cutting speed of a tool bit is defined as the
number of feet of workpiece surface, measured at the circumference,
that passes the tool bit in one minute. The cutting speed,
expressed in FPM, must not be confused with the spindle speed of
the lathe which is expressed in RPM. To obtain uniform cutting
speed, the lathe spindle must be revolved faster for workplaces of
small diameter and slower for workplaces of large diameter. The
proper cutting speed for a given job depends upon the hardness of
the material being machined, the material of the tool bit, and how
much feed and depth of cut is required. Cutting speeds for metal
are usually expressed in surface feet per minute, measured on the
circumference of the work. Spindle revolutions per minute (RPM) are
determined by using the formula:
12 X SFM = RPM3.1416 X DWhich is simplified to:
4 X SFM = RPM
DWhere SFM is the rated surface feet per minute, also expressed
as cutting speed.
RPM is the spindle speed in revolutions per minute
D is the diameter of the work in inches.
in order to use the formula simply insert the cutting speed of
the metal and the diameter of the workpiece into the formula and
you will have the RPM.
Turning a one-half inch piece of aluminum. cutting speed of 200
SFM. would result in the following:
4 x 200= 1600 RPM1/2Table 7-2 in Appendix A lists specific
ranges of cutting speeds for turning and threading various
materials under normal lathe conditions, using normal feeds and
depth of cuts. Note that in Table 7-2 the measurement calculations
are in inch and metric measures. The diameter measurements used in
these calculations are the actual working diameters that are being
machined. and not necessarily the largest diameter of the material.
The cutting speeds have a wide range so that the lower end of the
cutting speed range can be used for rough cutting and the higher
end for finish cutting. If no cutting speed tables are available,
remember that, generally. hard materials require a slower cutting
speed than soft or ductile materials. Materials that are machined
dry. without coolant. require a slower cutting speed than
operations using coolant. Lathes that are worn and in poor
condition will require slower speeds than machines that are in good
shape. If carbide-tipped tool bits are being used, speeds can be
increased two to three times the speed used for high-speed tool
bits.
FeedFeed is the term applied to the distance the tool bit
advances along the work for each revolution of the lathe spindle.
Feed is measured in inches or millimeters per revolution, depending
on the lathe used and the operators system of measurement. Table
7-3 in Appendix A is a guide that can be used to select feed for
general roughing and finishing operations. A light feed must be
used on slender and small workplaces to avoid damage. If an
irregular finish or chatter marks develop while turning. reduce the
feed and check the tool bit for alignment and sharpness. Regardless
of how the work is held in the lathe, the tool should feed toward
the headstock. This results in most of the pressure of the cut
being put on the work holding device. If the cut must be fed toward
the tailstock. use light feeds and light cuts to avoid pulling the
workpiece loose.
MICROMETER COLLARGraduated micrometer collars can be used to
accurately measure this tool bit movement to and away from the
lathe center axis. Thus. the depth of cut can be accurately
measured when moving the tool bit on the cross slide by using the
cross slide micrometer collar. The compound rest is also equipped
with a micrometer collar. These collars can measure in inches or in
millimeters, or they can be equipped with a dual readout collar
that has both. Some collars measure the exact tool bit movement.
while others are designed to measure the amount of material removed
from the workpiece (twice the tool bit movement). Consult the
operators instruction manual for specific information on graduated
collar use.
FACINGFacing is machining the ends and shoulders of a piece of
stock smooth. flat, and perpendicular to the lathe axis. Facing is
used to cut work to the desired length and to produce a surface
from which accurate measurements may be taken.
H O W C A N I T S A V E E N E R G Y ?1) Smart ControlThis
computerized control delivers high energy efficiency through
precise control of the spindle.
\The spindle reports to the computer where it is and the
computer compares this information with where the spindle is
suppose to be. After the analysis, the computer will instantly
adjust power drawn. This is all done instantaneously, you wouldnt
be aware of this adjustment occurring. For example, at 2000rpm, the
computerised DVR motor controller is calculating spindle position
at 400 x a second, and minutely adjusting just as fast!
The DVR motor only draws as much power as it needs for each
particular turning project and provides more or less power as
needed to maintain the spindle in the correct speed. At low speed,
almost no losses in the rotor are generated.
2) Less Heat GeneratedOrdinary DC and AC motors generate lots of
heat in low speed or when under heavy load. This heat not only can
burn out the wires but also wastes lots of energy needlessly.
DVR motor works by pure magnetic attraction. The motor can
safely and efficiently work in very low speed and have high torque
at the same time. This results in low heat generated and high
component reliability.
3) Direct Drive SystemMany other lathes also achieve variable
speed by using an electronic or mechanism device. However, you may
not know that these conventionally driven lathes are losing up to
20% of energy through the lathe belt or gear system.
This means a 2 HP motor can only deliver 1.6HP energy to the
lathe spindle. Sadly, you still need to pay your power bill for the
0.4HP energy lost in your variable speed device.
Because the DVR motor is a direct drive system, it can work
efficiently in low speed and with heavy loads. There is no power
loss through the belting system and this system also eliminates the
vibration caused by the belt and pulleys.
Major Problems in Lathe
Metal working latheis an extremely useful piece of equipment
that you can use in your workshop. For those who do extensive metal
work, owning a metal working lathe is very important. However,
having said that, it is also important to note that this piece of
equipment is as dangerous as it is useful. It may increase the
range of jobs that you can do, but it can also cause accidents.
There are many different lathe problems that can occur while you
are using this tool. Fortunately, most of these problems can be
avoided.
1. Metal is not Cutting ProperlyThis usually happens when the
cutting tool has not been set properly. Before you begin working,
always check the cutting tool installed on the metal working lathe
and make sure that it is placed right in the center. The proper
positioning of the cutting tool is important to ensure that the
cuts are made accurately. As you cut the metal, the tip of the
cutting tool may become heated due to friction. Give the equipment
frequent breaks so that the tools cool off and the chuck does not
rotate at a speed that cannot be controlled.2. Metal Working Lathe
Is Not Working Properly
The tailstock of the metal working lathe may not be fixed
properly. Although the tailstock does not have any specific
purpose, it has to be locked down properly before the chuck can be
fed into the metal. If the tailstock remains loose, the metal may
not be cut properly. To tighten the tailstock, inspect the screws
closely, and if they are loose, tighten them properly.3. Carriage
Is Not Moving
It is important to know how to move the carriage of the
equipment. The carriage moves along its tracks. Moving the carriage
is something that needs to be mastered in order for the machine to
work efficiently. Along with the carriage, the power feed handles
also have to be worked properly.
4. Threads Are Not Being Cut Properly
In a metal working lathe, the cutting of the threads is
controlled by a dial. It is always easier to control the dial when
you are working at a lower rpm. To be able to control the dial
efficiently, test the dial at different speeds by using different
kind of feeds. With each feed and speed, examine the ease of
handling that you experience. This way, you can get a feel of
working and controlling the dials before you actually begin using
the machine on the metal.
5. Accidents
Metal working safety cannot be stressed enough. Safety is
crucial whenever you are working any kind of machinery. Safety
Goggles are a must if you want to protect your eyes. If you are
wearing long sleeves while working, make sure that they are either
buttoned or folded so that they dot no get caught in the equipment.
The carriage needs to be cleaned regularly so that metal dust does
not settle on it. Keep a brush at a handy distance so that you can
brush off stray metal particles. These metal particles have a way
of settling on your skin while working and may cause bruises and
scratches.
Troubleshooting the Mini Lathe Variable Speed DriveThere are
several common types of failure that occur on the mini lathe's
variable speed drive. Find the symptoms your lathe exhibits, and
follow the steps to diagnose the problem.
This document covers the following mini lathes: Grizzly
Industrial model G8688
Harbor Freight (Central Machinery) model 33684 Micro-Mark
MicroLux models 82500 and 82710
Homier Speedway model 03911 (current production, not the early
Speedway with the SCR controller)
How It Should WorkFirst, lets start by describing the proper
operation of the mini lathe.
1. Turn on the power. Either open the big red emergency switch
or press the illuminated rocker switch so it is lit.
2. Turn the speed control knob to zero. On machines with an
emergency switch, there is an interlock that prevents the motor
from starting unless the knob has been turned to zero after the
power is on. On all machines it is a good idea to always start from
zero speed.
3. Put the direction switch in forward or reverse.
4. Turn the speed control knob clockwise to start the motor
turning.
Motor Will Not Run at AllIf the motor will not run at all, make
the following checks:
1. Check that there is power to the receptacle from which the
lathe is powered.
2. Check the fuse on the control panel. The required fuse is a
5-amp, fast-acting 5 mm x 20 mm fuse. See Testing the fuse and fuse
holder.
3. Check the fuse holder. They are prone to breaking.
4. Check the motor brushes to ensure that they are making good
contact with the commutator. In general, this means checking that
the caps that secure the brushes are tight.
5. Check all wire terminations inside the electrical box,
especially the slip-on connectors.
6. Check the switches and potentiometer for signs of physical
failure. Test them as described below. See Component Tests.
7. Check the MOSFETs on the speed control board. See Testing a
MOSFET in circuit.
8. Check the leads on the large power resistor near the center
of the speed control board to ensure that a lead has not broken. If
you find a broken lead, repair it with solder. Brace the resistor
by placing a small blob of RTV silicone under it.
Motor Runs Only at Full SpeedIf the motor runs at full speed no
matter the position of the speed control knob, one or both MOSFETs
on the speed control board have failed in a shorted condition. See
Testing a MOSFET in circuit.
Replace both MOSFETs. They are in parallel and must be matched
(that is, the same part number from the same manufacturer) or one
will take the entire load and fail prematurely.
Motor Runs IrregularlyIf the motor runs irregularly or makes
arcing or popping noises, it might be a failure of a brush
connection.
Remove the caps that retain the motor brushes and inspect the
brushes to ensure that the braided copper wire connects the carbon
brush to the brass contact cap. Repair or replace failed
brushes.
Fuse Blows When Power Is Turned On1. Check all wire terminations
inside the electrical box, especially the slip-on connectors.
2. Check the switches and potentiometer for signs of physical
failure. See Component Tests.
3. Check the MOSFETs on the speed control board. See Testing a
MOSFET in circuit.
Component TestsFollowing are specific tests for some components
of the variable speed drive system. These procedures assume that
you have and know how to use a volt/ohm/milliampmeter.
Testing the fuse and fuse holder Testing the emergency stop
switch Testing the illuminated on-off switchTesting the speed
control potentiometer Testing the forward/off/reverse switch
Testing a MOSFET in circuitTo test the components you have to
unscrew the four Philips head screws that retain the control box.
Do not disconnect any of the wires, unless you need to for a
particular test. With the control box loose, you can work inside it
to test the components.
Testing the fuse and fuse holder
1. Unplug the power cord.
2. Remove the fuse from the fuse holder.
3. Check continuity between the two metal ends of the fuse.
There should be continuity.
4. Inspect the fuse holder for cracks or breakage.
5. Replace the fuse in the fuse holder.
6. Check continuity between the two terminals on the fuse
holder. There should be continuity.
Testing the emergency stop switch
1. Unplug the power cord.
2. Orient the switch so that the hinge is horizontal at the top
and the cover swings up and down.
3. Raise the cover.
4. Check continuity between the two top terminals. There should
be continuity between these terminals.
5. Check continuity between the two bottom terminals. There
should be continuity between these terminals.
6. Close and latch the cover.
7. Check continuity between the two top terminals. There should
be no continuity between these terminals.
8. Check continuity between the two bottom terminals. There
should be no continuity between these terminals.
These tests are summarized in the table below:
TerminalsCover OpenCover Closed
Top terminalsConnectionNo connection
Bottom terminalsConnectionNo connection
Testing the illuminated on-off switch
1. Unplug the power cord.
2. Place the switch in the off position, as shown above.
3. Check continuity between the terminal on the 0 end and the
other two terminals. There should be no continuity between any of
the terminals.
4. Check continuity between the terminal on the 1 end and the
other two terminals. There should be no continuity between any of
the terminals.
5. Place the switch in the on position, with the 1 end
depressed.
6. Check continuity between the terminal on the 0 end and the
center terminal. There should be continuity.
7. Check continuity between the terminal on the 0 end and the
far terminal. There should be no continuity.
8. Check continuity between the terminal on the 1 end and the
other two terminals. There should be no continuity between any of
the terminals.
These tests are summarized in the table below:
TerminalsSwitch OffSwitch On
0 to CenterNo connectionConnection
0 to 1No connectionNo connection
1 to CenterNo connectionNo connection
Testing the speed control potentiometer
There are two versions of the speed control potentiometer. Some
have a switch on the back (and have five terminals), and some dont
(and have three terminals).
1. Unplug the power cord.
2. If there are five terminals, turn the potentiometer shaft all
the way counterclockwise.
3. If there are five terminals, check continuity between the two
terminals on the back of the potentiometer. There should be
continuity.
4. If there are five terminals, turn the potentiometer shaft
clockwise about 10 or 15 degrees. You should hear a click as the
switch changes position. Check continuitybetween the two terminals
on the back of the potentiometer.
There should be no continuity.5. Measure the resistance between
the two outside terminals on the side of the potentiometer. The
resistance should be between 3000 and 5000 ohms.
6. Measure the resistance between the center terminal and one of
the outside terminals on the side of the potentiometer. The
resistance should change smoothly from near the value you measured
in step 5 to near zero ohms as you turn the potentiometer shaft
from one stop to the other.
7. Measure the resistance between the center terminal and the
other outside terminal on the side of the potentiometer. The
resistance should change smoothly (but in the opposite direction
from step 6) from near zero ohms to near the value you measured in
step 5 as you turn the potentiometer shaft from one stop to the
other.
These tests are summarized in the table below:
TerminalsCounterclockwiseRotatingClockwise
Limitlimit
SwitchConnectionNo connectionNo
connection
Outer potentiometer3-5K ohms3-5K ohms3-5K ohms
terminals
Left to Center0 ohmsVaries from 0 to3-5K ohms
potentiometer terminals3-5K ohms
Right to Center3-5K ohmsVaries from 3-5K0 ohms
potentiometer terminalsto 0 ohms
Testing the forward/off/reverse switch
There are several versions of the forward/off/reverse switch.
Some have six terminals, some have nine and some have twelve
terminals. The testing procedure is the same for all of them.
1. Unplug the power cord.
2. Looking at the terminal side of the switch, rotate it so that
the handle moves up and down. There are vertical columns of three
terminals.
3. Place the switch in the off (center) position.
4. In each column of terminals, check continuity between the
center terminal and the other two terminals. There should be no
continuity between any of the terminals.
5. In each column of terminals, check continuity between the top
terminal and the bottom terminal. There should be no continuity
between these terminals.
6. Move the handle so it is in the up position.
7. In each column of terminals, check continuity between the
center terminal and the bottom terminal. In all the columns there
should be continuity between the center and the bottom
terminal.
8. In each column of terminals, check continuity between the
center terminal and the top terminal. In all the columns there
should be no continuity between the center and the top
terminal.
9. In each column of terminals, check continuity between the top
terminal and the bottom terminal. There should be no continuity
between these terminals.
10. Move the handle so it is in the down position.
11. In each column of terminals, check continuity between the
center terminal and the top terminal. In all the columns there
should be continuity between the center and the top terminal.
12. In each column of terminals, check continuity between the
center terminal and the bottom terminal. In all the columns there
should be no continuity between the center and the bottom
terminal.
13. In each column of terminals, check continuity between the
top terminal and the bottom terminal. There should be no continuity
between these terminals.
These tests are summarized for each column of terminals in the
table below:
TerminalsSwitch OffSwitch UpSwitch Down
Center to TopNo connectionNo connectionConnection
Center to BottomNo connectionConnectionNo connection
Top to BottomNo connectionNo connectionNo connection
Testing a MOSFET in circuitMOSFETs are very sensitive to static
electricity. Here are the procedures the U. S. Navy recommends when
testing them (out of circuit).
You must be extremely careful when working with MOSFETs because
of their high degree of sensitivity to static voltages. As
previously mentioned in this chapter, the soldering iron should be
grounded. A metal plate should be placed on the workbench and
grounded to the ship's hull through a 250-kilohm to 1 -megohm
resistor. You should also wear a bracelet with an attached ground
strap and ground yourself to the ship's hull through a 250-kilohm
to 1-megohm resistor. You should not allow a MOSFET to come into
contact with your clothing, plastics, or cellophane-type materials.
A vacuum plunger (solder sucker) must not be used because of the
high electrostatic charges it can generate. Solder removal by
wicking is recommended. It is also good practice to wrap MOSFETs in
metal foil when they are out of a circuit. To ensure MOSFET safety
under test, use a portable volt-ohm-milliammeter (vom) to make
MOSFET resistance measurements. A vtvm must never be used in
testing
MOSFETs.
While you can follow most of these recommendations in your home
shop (substituting a good ground for the ships hull), in our
experience you shouldnt have much trouble while testing them in
circuit if you just use a little common sense (dont pat your cat
while making these tests).
If the measurement between any two pins is 0 ohms, the MOSFET
has failed.
Pin 1 Pin 3
1. Set the VOM to the 200K Ohms scale. If your VOM does not have
a 200K ohms scale, set it to the nearest scale to 200K ohms.
2. Confirm that the red lead is in the red connector on the VOM
and that the black lead is in the black connector.
3. With the red probe on the lower numbered pin, measure the
resistance from pin 1 to pin 3. The reading should be about 50K
ohms.
4. With the red probe on the lower numbered pin, measure the
resistance from pin 1 to pin 2. The reading should show
infinity.
5. With the red probe on the lower numbered pin, measure the
resistance from pin 2 to pin 3. The reading should show
infinity.
6. With the black probe on the lower numbered pin, measure the
resistance from pin 1 to pin 3. The reading should be about 50K
ohms.
7. With the black probe on the lower numbered pin, measure the
resistance from pin 1 to pin 2. The reading should show
infinity.
8. With the black probe on the lower numbered pin, measure the
resistance from pin 2 to pin 3. The reading should be about 120K to
140K ohms.
These tests are summarized in the table below:
Between PinsRed on lower numbered pinBlack on lower numbered
pin
1350K ohms*50K ohms*
12Infinity ohmsInfinity ohms
23Infinity ohms120K-140K ohms
*The 50K ohms readings between pins 1 and 3 are measuring
resistance on the circuit board. This same measurement with the
MOSFET out of the circuit will indicate infinity
CIRCUIT OPERATION
The control circuit is consisting of an error amplifier speed
amplifier, a current amplifier, voltage controlled oscillator, a
trigger circuit and a full wave bridge converter.
The A.C motor is powered by an A.C converter, depending upon the
firing angle of the SCR. The current supplied by the SCR will be
lagging with the applied voltage, so speed control can be achieve
by the varying the firing angle of the SCR.
The speed and current amplifier provided with regulated constant
D.C. voltage. When the speed is set to a value by means of
potentiometer, the error amplifier gives a voltage. The output from
the error amplifier is amplified by a speed amplifier; the output
from the speed amplifier drives a current amplifier. The output of
the current amplifier provides a D.C voltage to the oscillator
circuit depending on the amplifier of the input voltage available
at the VCO.
BLOCK DIAGRAM
1- PHASE A.C. IN
APPLICATIONS
Industrial application Machinery Application Power Generation
station Power Transmition StationADVANTAGES
Speed control upto 1 H.P A.C motor
Speed variation is smoothly.
This circuit is a Closed loop control system
In this circuit Isolation transformer is used so that the A.C
motor is products
SCR firing angle is varied automatically
By slight modification of this circuit, the single phase
induction motor speed also varied.
DISADVANTAGES
This circuit produce the sinusoidal A.C voltage only, not the
pure A.C voltage The noise produced by the motor is high due to
voltage variation The efficiency of the motor is decreased due to
input voltage is varied by the SCR circuit.ConclusionThus the power
saving system has been designed and it is verified experimentally.
This system will save the electrical power used for the lathe
system almost 20%.This is an simply and economically beneficial
design and can be used for all small and large scale industry.
Further work has been continued in the future to rectify the
limitation.
CONTROLLED
RECTIFIER
AC/DC
CONVERTER
M
TRIGER
CIRCUIT
VCO
ERROR
AMPLIFIER
FEED BACK
AMPLIFIER
AMPLIFIER
CURRENT