Weld positioner/ table

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I have a steady job that comes into the shop that I need a positioner for. Here goes, the pics are not that good but it will give you an idea of how I am putting it together. The positioner itself is 15"X15" square, 2" drive shaft powered by 1/8 bodine gear drive with 328 inlb of torque. Max speed on shaft is 5rpm. this will have a 19" face plate. the unit is mounted on an old Peterson head surfacer. behind the positioner I have a 2" thick 15" wide 42" long ground plate for smaller precision fit ups. I will get better pics when I get the control and casters mounted.Miller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:Great build.We are on our way to being farmers! Our site is always under construction so check back often for updates.  http://www.philosophyfarmstyle.com/
Reply:nice work.    curious to see what ur welding together with this contrapsion.     looks pretty dam heavy duty and well built.>Innovations are what i leave behind for History
Reply:Christ on a bike that looks good. Just bear in mind top RPM* is not where you need it it's the really low speeds, and that's where it gets interesting as most speed controllers are too crude in chopping up the Hz, so you end up with a jerky movements. Out of interest what are you using for the speed control.If it helps here is my take on one Max RPM on that is 2.06 and it's whey too fast
Reply:Shox DrThe control is a bodine control that matches the motor  (90/130VDC 1/8-1/4hp) and will go to almost 0 without dropping torque. Rotation is very smooth. Once I get the face plate mounted we will see how it works. If I see that I need it even slower I have room to add another shaft for more gear reduction.Miller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:Originally Posted by Thiel-Metal-Fabnice work.    curious to see what ur welding together with this contrapsion.     looks pretty dam heavy duty and well built.
Reply:Looks great. It looks like you have enough room for a larger sprocket if you need to slow it down more.
Reply:OK, I had a few minutes to spare today in between jobs and got the face plate adapter and the face plate mounted. Also got position holes drilled at 0, 45, and 90 degrees for the positioner. Here is one of the parts that that this positioner is being built for.Miller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:I've been wondering if a hole through the shaft is necessary or not.My name's not Jim....
Reply:Originally Posted by BoostinjdmI've been wondering if a hole through the shaft is necessary or not.
Reply:I suppose I am singing to the choir but you need really robust ground brushes between the position-er and your table because the bearings will not take any arcing through them before they  freeze up solid.  Mac
Reply:Originally Posted by Tool MakerI suppose I am singing to the choir but you need really robust ground brushes between the position-er and your table because the bearings will not take any arcing through them before they  freeze up solid.  Mac
Reply:The copper ground strap will work , however it will eventualy get realy rough from constantly arcing.  The best thing I found was to take the brushes from a car starter motor spring brackets and all and mount so they rub on the smooth shaft.  the more brushes the better.  Mac
Reply:Tool Maker,I will look at grounding it the way you are saying, thanksLarryMiller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:I have found that putting the ground directly to the piece in the positioner is the best medicine for this procedure..Make sure the cable will do a 360 without getting caught on something and have at it..You WILL burn the brushes up fast with anything over 150 amps on a constant basis..And 2 RPM on the fastest speed is way too much RPM...You will see that soon enough also.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Zap,Thanks for the info, getting close to trying it out if the customers will slack off a bit. I will post the results.LarryMiller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:Ok guys I got the positioner up and going, I don't have all of the creature features on it that I want yet but my customer is on my back to get some spindles out the door. I used stripped #4 welding lead for the ground, wrapped around the shaft and spring loaded as you can see in the pic. I ran this thing for 30min non stop with no arcs or sparks and no heat build up on the grounding cable. I think I had the machine set at 370ws and 20V. I am very happy with it, if you notice in the pics I have an air opperated foot switch for on and off and the speed control is on a swing away arm. it's not pretty but it functions very well. Better than I figured it would actually.LarryNex post for last picMiller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:Finished spindleMiller XMT 304 CC/CVSyncrowave 180 SDLincoln PowerMig 255XTTermalDynamics 52Lincoln 305GComlpete machine shop to back it up
Reply:I love the fixture / positioner, and the finished (saved) part is great. How much of a pain is it trying to center your parts on the face plate? Really nice setup, Im sure itll be used for lots of other projects also. Every once in a while it would be handy to have a setup like this, looks like I will have to start scrounging around......thanks for sharing.
Reply:You get all the fun jobs......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I've used the same setup on the ground strap, and so for I haven't had any problems. Even used it to cut the top off a Propane bottle the other day. Attached ImagesLast edited by Shox Dr; 10-19-2011 at 04:59 AM.
Reply:Those were great pics.. I like it a lot. Good work weld it like you own it
Reply:I'll take that one for an early christmas present. you can deliver it next week. :-DThere are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger