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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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#1
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I bought a magnetic chuck off ebay. It was a good deal but it came
with the wrong rectifier. And it's not worth the hassle trying to return it. So, I was wondering if a lamp dimmer, with enough wattage capacity, could be used with a rectifier to power the chuck. Also, for the demagnetization of the chuck isn't the best way to achieve this is to apply ac and slowly decrease the power? I know that to use the demagnetizer I have the part must be slowly drawn away from the unit. Thanks, Eric R Snow |
#2
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I don't know what DC voltage a mag chuck needs. So you might need a
transformer in addition to the lamp dimmer and rectifier. Dan |
#3
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On 16 Jun 2005 13:33:14 -0700, "
wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. Eric |
#4
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Eric R Snow wrote:
On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Pete C. |
#5
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Pete C. wrote:
Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. I don't see any inherent reason why a full wave bridge rectifier after the dimmer won't work. Try it. You could also use just a full wave bridge rectifier with an appropriate sized light bulb in series with the chuck coil to reduce the applied voltage. A filter capacitor across the chuck coil might be needed if it acts a little buzzy running on just the rectified AC waveform. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Too expensive, unless you've already got a spare one. A 120 to 18 or 24 volt transformer wired up as an autotransformer to subtract its secondary voltage from the 120 line will reduce the AC voltage to around 100 volts pretty cheaply. Jeff -- Jeffry Wisnia (W1BSV + Brass Rat '57 EE) "Truth exists; only falsehood has to be invented." |
#6
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Jeff Wisnia wrote:
Pete C. wrote: Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. I don't see any inherent reason why a full wave bridge rectifier after the dimmer won't work. Try it. I didn't say it wouldn't work, just that it did not reduce the voltage. If you want to try this approach, don't use a light dimmer, use a fan speed control. Only a couple $ more and they are at least designed to deal with an inductive load. You could also use just a full wave bridge rectifier with an appropriate sized light bulb in series with the chuck coil to reduce the applied voltage. A filter capacitor across the chuck coil might be needed if it acts a little buzzy running on just the rectified AC waveform. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Too expensive, unless you've already got a spare one. A 120 to 18 or 24 volt transformer wired up as an autotransformer to subtract its secondary voltage from the 120 line will reduce the AC voltage to around 100 volts pretty cheaply. I've got an entire milk crate full of 1 kw variacs. A few 2 kw kicking around as well. Pete C. |
#7
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![]() "Eric R Snow" wrote ![]() the best way to achieve this is to apply ac and slowly decrease the power? (clip) ^^^^^^^^^^^^^^^^^^ If you're talking about demagnetizing the chuck, meaning allowing it to let go of its load, you may not have to be that elaborate. The technique of a "tapering" AC field is needed when you need to get rid of ALL the residual magnetization. And it is usually applied to the type of steel that holds a field with the power off. Your chuck was probably designed not to hold a residual field. Try just interrupting the power and see what happens. |
#8
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On Thu, 16 Jun 2005 14:52:25 -0700, Eric R Snow
wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. Eric The fullwave rectified voltage delivered to an inductive + resistive load is the mean value of the RMS input i.e 0.9 x RMS volts. so rectified 110/120v AC supply will be fine. Although the rectified voltage applied to chuck is half sine waves, the inductance is so high that the current flow is close to pure DC. No capacitor should be fitted as it is not needed and its presence would upset the 0.9 Vin relation. To avoid inductive arcing, switching should be on the AC side of the rectifier. If you want to play with a lamp dimmer - it depends on detail design. Some will accept an inductive load some will refuse to dim and just deliver full output. Damage to the dimmer is unlikely. Demagnetising by applying 60HZ Ac to the chuck is a non-starter. Because the chuck inductance is so high more than a thousand volts would be needed. Using the dimmer and successsive polarity reversals is a miserable business because it needs lots of graded reversals. The following kludges work pretty well:- Remove the rotor from a fractional horsepower motor and remove the piece slowly from on or near the stator teeth. Restack the laminations of a power transformer so that a stack of"E" laminations remain. Remove workpiece slowly from on or near the exposed ends of the"E". Raid the dump for a defunct colour TV and remove the demagnetising coil that is located on the bulbous flare of the tube. Twist it back on itself so that it forms a triple loop instead of the original single loop (this the same twist as the one used for tidily storing spare bandsaw blades). Pass the workpiece slowly through the triple loop. These are all short term rated demagnetisers - if power is applied for more than 30 sec they'll get pretty hot. Jim |
#9
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On Fri, 17 Jun 2005 13:52:37 +0100, wrote:
lots of sensible comments You stole the words out of my keyboard G Mark Rand RTFM |
#10
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On Thu, 16 Jun 2005 19:10:04 -0400, Jeff Wisnia
wrote: Pete C. wrote: Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. I don't see any inherent reason why a full wave bridge rectifier after the dimmer won't work. Try it. You could also use just a full wave bridge rectifier with an appropriate sized light bulb in series with the chuck coil to reduce the applied voltage. A filter capacitor across the chuck coil might be needed if it acts a little buzzy running on just the rectified AC waveform. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Too expensive, unless you've already got a spare one. A 120 to 18 or 24 volt transformer wired up as an autotransformer to subtract its secondary voltage from the 120 line will reduce the AC voltage to around 100 volts pretty cheaply. Jeff Thanks Jeff for the reply. That autotransformer idea might be best. I do have a variac but it gets used for all sorts of jobs and I don't wanna tie it up for just one machine. Eric |
#11
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On Thu, 16 Jun 2005 22:23:58 GMT, "Pete C."
wrote: Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Pete C. So the dimmers keep more and more of the waveform on either side of the peak as the power is increased? And they always reach peak voltage? I thought that they started conducting at zero and used more and more of the voltage until peak voltage is reached. But after reading your post that doesn't make sense to me. Eric |
#12
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On Thu, 16 Jun 2005 23:53:58 GMT, "Pete C."
wrote: Jeff Wisnia wrote: Pete C. wrote: Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. I don't see any inherent reason why a full wave bridge rectifier after the dimmer won't work. Try it. I didn't say it wouldn't work, just that it did not reduce the voltage. If you want to try this approach, don't use a light dimmer, use a fan speed control. Only a couple $ more and they are at least designed to deal with an inductive load. You could also use just a full wave bridge rectifier with an appropriate sized light bulb in series with the chuck coil to reduce the applied voltage. A filter capacitor across the chuck coil might be needed if it acts a little buzzy running on just the rectified AC waveform. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Too expensive, unless you've already got a spare one. A 120 to 18 or 24 volt transformer wired up as an autotransformer to subtract its secondary voltage from the 120 line will reduce the AC voltage to around 100 volts pretty cheaply. I've got an entire milk crate full of 1 kw variacs. A few 2 kw kicking around as well. Pete C. Pete, How do the fan speed controls work? And, you wanna get rid of any of those variacs for cheap? Eric |
#13
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#14
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![]() "Eric R Snow" wrote in message ... On Thu, 16 Jun 2005 22:23:58 GMT, "Pete C." wrote: Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Pete C. So the dimmers keep more and more of the waveform on either side of the peak as the power is increased? And they always reach peak voltage? I thought that they started conducting at zero and used more and more of the voltage until peak voltage is reached. But after reading your post that doesn't make sense to me. Eric Nope -- the triac turns on some time after the zero-crossing. That time is usually simply determined by a simple RC circuit that delays the trigger (lags). You may not always get the peak -- if it is turned way down, it may actually turn on sometime after the peak, but it does not turn off until the next zero crossing. There are different circuits used for things like heater control that do switch on at the zero crossing to minimize spikes etc, but they work on a "burst" of cycles as it were. They may use a 1 hz "cycle time" and vary how many cycles during that 1 second period are actually turned on but the typical light dimmer/speed control works with a delayed phase angle firing of a triac - makes them electrically "noisy". They work well for lights because you are varying the "average power" under the portion of the curve (sine wave) that it is turned on - works well with lights. Not so well for a rectified supply because until you delay past 90 degrees, you are still getting the peak (and high current pulses when it turns on). mikey |
#16
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Whatever you build to power your mag chuck put an isolation transformer
between it and the mains, lest you become the best path to ground. |
#17
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Eric R Snow wrote:
On Thu, 16 Jun 2005 23:53:58 GMT, "Pete C." wrote: Jeff Wisnia wrote: Pete C. wrote: Eric R Snow wrote: On 16 Jun 2005 13:33:14 -0700, " wrote: I don't know what DC voltage a mag chuck needs. So you might need a transformer in addition to the lamp dimmer and rectifier. Dan Oh. The mag chuck needs 100 vdc. Part of the reason for the dimmer is to limit the voltage to the chuck. But I suppose a transformer would be OK. I just want to know if a rectifier connected to something that expects a resistive load will ruin the device. The lamp dimmers use phase control dimming with triacs. They turn on the triac part way into the half cycle of the AC, so they do not in any way limit the peak voltage. They actually eliminate the first part of the waveform rising (or falling) from the zero crossing point, generating quite a switching transient which is what causes filament buzz. I don't see any inherent reason why a full wave bridge rectifier after the dimmer won't work. Try it. I didn't say it wouldn't work, just that it did not reduce the voltage. If you want to try this approach, don't use a light dimmer, use a fan speed control. Only a couple $ more and they are at least designed to deal with an inductive load. You could also use just a full wave bridge rectifier with an appropriate sized light bulb in series with the chuck coil to reduce the applied voltage. A filter capacitor across the chuck coil might be needed if it acts a little buzzy running on just the rectified AC waveform. Try a variac (variable autotransformer), they will actually reduce the voltage supplied to your rectifier. Too expensive, unless you've already got a spare one. A 120 to 18 or 24 volt transformer wired up as an autotransformer to subtract its secondary voltage from the 120 line will reduce the AC voltage to around 100 volts pretty cheaply. I've got an entire milk crate full of 1 kw variacs. A few 2 kw kicking around as well. Pete C. Pete, How do the fan speed controls work? And, you wanna get rid of any of those variacs for cheap? Eric I've not dug into the fan versions much. I believe they work in much the same way as the lamp dimmers, but probably use higher rated triacs and larger snubbers to deal with the inductive load. The may also use reverse phase control with a switching device other than a triac. In reverse phase control instead of turning on after a delay into the half cycle, the device turns off after the delay which lets the voltage gradually come up (or down) from zero crossing before being cut off. A little more info: http://www.lutron.com/technical_info...mingBasics.pdf Seems to indicate that dimmers rated for magnetic low voltage lighting might work as well. Still more info: http://home.howstuffworks.com/framed...ghtdimmer.html As for the variacs, I have to track down where they are. I think they are still at my other facility which I will not be at for a while (1,700 miles away). If I can get my hands on them I'd be happy to send you one since I'll never use all of them. Pete C. |
#18
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On Fri, 17 Jun 2005 07:39:55 -0700, Eric R Snow
wrote: Snip Jim, I have a demagnetizer. The thing is, when parts are ground on an electromagnetic they stick when power is removed. All the chuck controls I've used have a demagnetizing button that helps to get the part off the chuck. I have seen chuck controls without this feature but have never used one. Maybe that's why chuck controls are so expensive? It's because of the demagnetizing electronics? Thanks, Eric I've never used one of these chucks so I can't be sure how they're organised. Thoroughly demagnetising a workpiece on an electromagnetic chuck would need a sequence of decaying amplitude polarity reversals. This is could be carried out by sequencing two or three Triacs or SCRs. Possibly a pair to control polarity reversal and one to program the amplitude - sounds a bit expensive. One posible kludge is to remember that much of the remanent magnetism is a fixed amount as it originates from hysteresis in the chuck iron. If this were entirely true (OK with mild steel workpiece - not OK with a large lump of alnico) a carefully chosen single pulse of reverse polarity would be enough to unstick the workpiece. Don't know enough about your chuck to tell you how much but a lot less than 100v - start with only a few volts and increase it bit by bit until it does the job. Don't forget to be certain that the chuck body is properly grounded. Used dry, the insulation failure hazard is about the same as with an electric motor. However, if you're going to use it wet with suds coolant I second comment that an isolation transformer is a sensible addition Jim |
#19
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In article ,
Leo Lichtman wrote: "Eric R Snow" wrote ![]() the best way to achieve this is to apply ac and slowly decrease the power? (clip) ^^^^^^^^^^^^^^^^^^ If you're talking about demagnetizing the chuck, meaning allowing it to let go of its load, you may not have to be that elaborate. The technique of a "tapering" AC field is needed when you need to get rid of ALL the residual magnetization. And it is usually applied to the type of steel that holds a field with the power off. Your chuck was probably designed not to hold a residual field. Try just interrupting the power and see what happens. On my Sanford grinder with the EM chuck, the "demagnetize" position of the switch just applies pure AC to the coil, which does a good enough job to release the workpiece. Enjoy, DoN. -- Email: | Voice (all times): (703) 938-4564 (too) near Washington D.C. | http://www.d-and-d.com/dnichols/DoN.html --- Black Holes are where God is dividing by zero --- |
#21
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Although the lamp dimmer does not limit the peak voltage, they do
control the power and should work fine. If I were doing it I might make a stop for the lamp dimmer so it could not be set too high. If you use a lamp dimmer , fullwave rectifier , and a cap you can get 163 volts. Dan |
#22
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My experience with lamp dimmer has been that they work fine with
inductive loads. This does not mean that all lamp dimmer will, just that all the ones I have used have worked. Dan |
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