Putting an end to the WORST kind of gears.

Summary

In this video, the creator embarks on a project to build an electronic gearbox for their metal lathe, aiming to eliminate the tedious task of changing gears. They detail the process of using an optical rotary encoder to track spindle rotation, a stepper motor for precise control, and custom software to manage the complex ratios required for threading and feeding. The project involves overcoming technical challenges, including real-time pulse tracking and synchronization, culminating in a functional electronic gearbox that significantly streamlines the lathe operation.

Takeaways

• 🔧 The video discusses the challenges of using change gears on a metal lathe, which are often messy and time-consuming to adjust.
• ⚙️ The primary function of change gears is to convert motion from the lathe spindle to its lead screw and feed shaft in specific ratios for operations like thread cutting.
• 🚫 The video creator decided to build an electronic gearbox to avoid the hassle of manual gear changing, aiming for a more efficient and clean operation.
• 💡 The project involves using an optical rotary encoder to track spindle rotation, a motor to drive the lead screw, and a control system to manage the feed rates.
• 📈 The video highlights the complexity of the project, including real-time tracking of encoder pulses and the mathematical challenges of converting these into motor step pulses.
• 🛠️ The use of an interrupt-driven approach is mentioned to quickly and reliably track spindle rotation, which is crucial for the electronic gearbox's operation.
• 🔢 The video creator discusses the implementation of Brum's line algorithm to handle the conversion of encoder pulses to motor steps, especially for non-integer ratios.
• 🏭 The project required the integration of various components, including a closed-loop Nema 24 stepper motor, to ensure precise control of the lead screw and feed shaft.
• 🔩 The video details the mechanical assembly of the electronic gearbox, including the use of a mounting plate, encoder, and motor, all designed to be easily reversible.
• 🎵 The video ends with a humorous note about the potential for a 'Kill Bill' theme, reflecting the creator's satisfaction with the completed electronic gearbox project.

Q & A

What is the primary function of change gears on a metal lathe?

The primary function of change gears on a metal lathe is to convert motion from the lathe spindle to its lead screw and feed shaft in specific ratios for operations like thread cutting and power feeding.

Why did the creator decide to build an electronic gearbox for their lathe?

The creator decided to build an electronic gearbox to avoid the hassle of changing change gears for every change in operation, which they found to be time-consuming and cumbersome.

What are the three main components required for the electronic gearbox project?

The three main components required for the electronic gearbox project are an optical rotary encoder to track spindle rotation, a motor to drive the lead screw, and a control system to process encoder pulses and generate step pulses for the motor.

What is the purpose of the optical rotary encoder in the project?

The optical rotary encoder is used to keep track of the spindle's rotation and convert its motion into digital signals that can be processed by the control system.

What is the significance of the encoder outputting a signal over 1,999 times per revolution?

The encoder outputting a signal over 1,999 times per revolution allows for precise tracking of the spindle's position and rotation speed, which is crucial for accurately controlling the feed rates during machining.

What is the role of the motor in the electronic gearbox system?

The motor in the electronic gearbox system is responsible for driving the lead screw, providing the necessary motion for cutting threads and making powered movements, without relying on the spindle's power.

How does the creator address the issue of different feed pitches required for various operations?

The creator addresses the issue of different feed pitches by using a closed-loop stepper motor and a control system that can calculate and adjust the motor steps based on the desired feed pitch, allowing for a wide range of ratios.

What is the 'Brum's line algorithm' mentioned in the script, and how is it used in the project?

Brum's line algorithm is a method used to approximate straight lines in digital space. In the project, it is used to handle the conversion of encoder pulses into step pulses for the motor, particularly for non-integer feed ratios, to ensure accurate and synchronized motion.

Why did the creator switch from a 16 MHz Arduino Nano to a 600 MHz Teensy 4.1?

The creator switched to a 600 MHz Teensy 4.1 because the 16 MHz Arduino Nano was not fast enough to process the high frequency of encoder pulses, which was necessary for maintaining synchronization between the spindle and the motor.

How does the closed-loop stepper motor contribute to the reliability of the electronic gearbox system?

The closed-loop stepper motor contributes to the reliability of the system by having its own encoder, which allows the driver to know the motor's position accurately. This enables precise control and the ability to correct any discrepancies in motion, ensuring consistent and accurate machining.

What is the purpose of the control panel and display in the electronic gearbox system?

The control panel and display in the electronic gearbox system allow the user to select and display the desired feed pitch and gearbox ratio easily. This user interface makes it convenient for the operator to control the lathe's threading and feeding functions without manual gear changes.