Dynomax Spindle Blog

What is frequency drive commissioning and do I really need it?

At Dynomax, frequency drive commissioning is a service we offer where our electrical engineers “set up” the drive and all it’s menus and settings so that is will work as expected when you get it in your facility.  You can think of it as plug and play.  If the drive was to arrive without being commissioned you would need someone on your end to program all the settings and menus at that time.

When we perform the commissioning we also know that everything will be working and tested to it’s maximum speed prior to leaving our facility.  If you decide to commission the drive on your own we still test the spindle, but we would use our drives with our settings and of course can’t guarantee that it will work that way in your plant because we wouldn’t be able to say how your drive was set up.

Some drives are more complicated and have more potential pitfalls than others, which is why our price (and time) can vary for commissioning services.

For more information, contact one of our friendly spindle associates at 847.680.8833 today!  

In some applications it can be of vital importance to stop a spindle very quickly.  For some operators, safety is the main concern; for others it’s helping to reduce cycle time.  In any case there are industry proven methods to stopping a spindle in seconds…or less.

In all cases, a variable frequency drive (VFD) must be used.  To stop a spindle’s rotation the VFD converts physical energy into electrical energy and dissipates it through built in resistors.  To accomplish this the VFD takes large increases in load.  If the VFD was not sized properly for the spindle it is driving the drive could trip, which would allow the spindle to rotate freely.  To avoid this problem, engineers must provide a VFD that is much larger (and more expensive) that what will be normally required.

A better solution does exist and it involves the use of a braking package.  Normally including a brake chopper and a brake resistor, the braking package works in tandem with a properly sized VFD to dissipate unwanted energy and stop the spindle as quickly as possible.  In this configuration, the spindle’s rotational energy is “chopped up” into more easily digestible amounts that are then dissipated through the brake resistors.  For example, a 1 HP spindle running at 15,000 rpm with a VFD and braking package can be completely stopped in less than 1 second.  For more detailed information, please contact a Dynomax engineer.

Knowing how much power is required to perform a machining operation is useful when planning new machining operations, or for optimizing existing machining operations.  It is also vital information to have when properly selecting a spindle.  The available power on any machine tool spindle limits the size of the cut it can take.  When large amounts of metal must be removed from a work piece, it is advisable to estimate the cutting conditions that will utilize the maximum power from the machine.  Some machining operations will require only light cuts for which the machine obviously has enough power; in these cases estimating the power required may not as necessary for success.

Whenever possible the maximum power available on a machine tool should be use when heavy cuts must be taken.  The cutting conditions for utilizing the maximum power should be selected in the following order:

1) Select the maximum depth of cut that can be used;

2) Select the maximum feed rate that can be used;

3) Estimate the cutting speed that will utilize the maximum power available on the machine.

This sequence is based on obtaining the longest tool life of the cutting tool and at the same time obtaining as much production as possible from the machine.  The life of a cutting tool is most affected by the cutting speed then by the feed rate, and least of all by the depth of cut. The maximum metal removal rate that a given machine is capable of machining from a given material is used as the basis for estimating the cutting speed that will utilize all the power available on the machine.

In the opinion of any spindle designer, the ultimate spindle would have the following characteristics:

1. Unlimited Speed

2. High Power

3. Long Life

4. Self-Balancing

5. Self-Diagnostic

As unattainable as these qualities may sound, they will be fulfilled in future spindle designs.  Advances in bearing technology such as magnetic and fluid bearings will permit previously unattainably high speeds as these non-contact bearing systems will exhibit no mechanical wear, a leading cause of existing bearing failure.  Superconducting materials and new motor technologies are being developed to provide higher power in more compact packages with less heat.  Electronic sensors are coming online that will monitor all aspects of a spindles operation, including cutting loads.  Any imbalance can instantly be compensated for as the spindle is running and diagnostic information can be relayed to the CNC control for protective action.

When new technology becomes available, you can count on Dynomax to be on the cutting edge.  Since we design our spindles inhouse, we are constantly looking for new and innovative ways to improve our product using the latest engineering and technical knowledge.  Check back often to see what’s new in the spindle industry.  

Welcome to the inaugural post on Wayne’s Repair Tips.  In this section we will periodically discuss issues related to machine spindle repair and operation.  Over the past 30 years in the machining industry, I have learned plenty of tricks and tips for installing, running, and repairing machine spindles so make sure you check back often.  The topic for today’s post is “The Importance of Preventative Maintenance.”

We all know that our spindles won’t last forever, but given proper care they can last a lot longer.  While it is best to leave major repairs to the experts, there are several preventative steps an operator can take to lengthen spindle life.  The schedule below is an outline of suggested actions and when to do them:

Daily

• Wipe down spindle with clean rag.  If using air avoid direct high-pressure spray on the spindle nose and be sure spindle is running with air purge operating to protect the spindle from flying debris.  Always wear safety glasses while performing this step
• Clean the taper
• Lubricate drawbar collet

Weekly

• Check air pressure
• Check oil levels
• Check water separator and filters
• Check rotary union for general condition
• Check motor manually for smooth run and vibration free operation

Monthly

• Check filters for contamination
• Check coolant is at acceptable level & proper mixture
• Check hoses for consistency and general condition

Every 3 – 6 Months

• Perform run-in procedures on spare spindles to prevent damage from inactivity

Every 6 Months or Every 2,000 Hours of Operatio

• Install new air filter
• Install new filter for oil-water separator
• Install new filter for motor cooling circuit

Remember that not all the steps listed above will apply to all spindles.  Also remember that additional maintenance may be required if your spindle is equipped with a drawbar system or additional cooling system.  

As I mentioned earlier, you should leave all serious repairs to the trained professionals at Dynomax, but these preventative measures will help to minimize downtime and increase profitability for your machine spindle assemblies.

If your spindle is still covered under the original Dynomax 1 year warranty, please call us at 847.680.8833 prior to performing any maintenance above and beyond the items listed, as it may affect warranty status.  All maintenance should be performed on stopped machines (unless cleaning spindle with high-pressure spray, then read above) with all moving parts in the secure position.  Dynomax, Inc. cannot be liable for any on-site maintenance or troubleshooting actions.

Dynomax, the industry leader at producing the highest quality spindles on the market, has released a brand new website at dynospindles.com. We have incorporated all new features to make finding the right spindle for your job easier than ever before!

Spindle Creator - our brand new interactive RFQ system that allows you to spec out spindles any way you need them. No more database searching to find what you need… just go ahead and tell us what you want, we will get back to you within 24 Hours Guaranteed.

Web Specials - An easy to find place at dynospindles.com, where we have: New Releases, Popular Products, and Great Web Specials!

As always Dynomax is ready to help service other spindle brands that you have in operation:

Spindle Brands Repaired and Serviced - Dynomax services hundreds of diffrent types of spindle brands. This is a easy to follow guide to find out if we repair your spindles. If you can’t find your’s, just give us a call

Our Process - Find out just how Dynomax goes about repairing your spindles! From start to finish we show you what goes on at our Multiple facilities!s

So go Check It Out!!! http://www.dynospindles.com

We look forward to talking with you, and we hope you like the new site!

Sincerely,
The Dynomax Team.

P.S. Need to talk to us? Everyone Loves Paul, email him at pflanagan@dynospindles.com or call 847.680.8833 to speak to a Dynomax Representative!