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Discussion Starter · #1 ·
Have you ever seen what is pictured? Now be honest do you ever open up things to see what's inside? Come on tell us..... no one else will ever know.

For todays fun and games I have a series of pictures showing the inside of something. You have to figure out what it is and tell us about it.

Be the first one with a correct answer and you get 200 points and if someone wants to explain how this works I'll give them 3000 points but you have to give some good details that us common people can understand. I will give out the 3000 points twice if two people want to try their hand at it.

Good luck

Ed
 

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It is a variable speed control unit for a single speed router. I am not an electrician but here's my attempt at explaining how it works. Your routers power cord is plugged into the speed control and the speed controller is plugged into a standard 115v/15amp circuit. The speed controller has a switch which controls the amount of voltage which is passed to your router. The circuit board pictured in your 2nd and 4th pictures have the required electrical components to increase voltage as the external switch is moved from the low speed position to the high speed position.
A router with built in speed control does the same thing and an external variable speed control unit is not necessary. My PC 7539 has a built in variable speed control and is used when using the very large router bits. Here's an excerpt from the owners manual:


DO NOT USE ROUTER BITS
with a diameter in excess of 2-1/2" at RPM





above 13,000. Router bits up to 3-1/2" in diameter can be used when

speed control is set for 13,000 RPM or less.

(picture attached)

Bill
 

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I always travel a different path, so my answer is a control box for a wood burner. The dial is a potentiameter to vary the burners temperature. The wires appear to have additional insulation for the large amp draw, and there is an over heat reset button. I also think the size of the box is larger than desireable for a variable speed control, but the big size helps people justify spending big bucks for their wood burner. Or maybe it's from NASA. Bob
 

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Ed I know, it is a superhetrodyne transistor radio, it was in kit form and sold in the late 50's and early 60's by radio shack. I think the brand name was "Realistic". :D :D

Dave
the "Doctor"
 

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Not sure what you are looking for in an explanation but your first picture is of a fuse holder. The fuse is in line with the variable output voltage circuitry and hopefully will protect the whole thing from catastrophic failures like shorts or overloads.
The second picture is of the printed circuit board that contains the components that are used to make the output voltage variable. Components like resistors, diodes, capacitors and a Diac.
The third picture is of a Triac or Alternistor. This is the solid state power device that actually switches the AC voltage on / off every half cycle of the 60 Hz power. To reduce the voltage to the load (router, light bulb, soldering iron or what ever) the circuit delays the turn on of the AC source to the load every half cycle by variable delays determined by the position of the dial on the variable resistor called a potentiometer. This whole method of controlling the voltage to the load is called “Phase Control”.
The third picture is of some of the components mounted on the Printed circuit board that are used to control when the Triac or Alternister is turned on in each half cycle.
By reducing the voltage to a router, any universal motor, you cause the magnetics in the motor to “slip” which in turn reduces the power available which reduces the torque and horsepower which reduces the speed.
I tried not to get too technical and but still explain how these “speed controls” work.
 

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Discussion Starter · #9 ·
delroy33 said:
it looks like a variable speed control that can be used also with a single speed router.
Sorry it took me so long to get back to this..... a lot happening for me but the good news is you have the correct answer. You should see your points tonight..... great work!

Winner!

 

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Discussion Starter · #10 ·
ChevyNomad said:
Not sure what you are looking for in an explanation but your first picture is of a fuse holder. The fuse is in line with the variable output voltage circuitry and hopefully will protect the whole thing from catastrophic failures like shorts or overloads.
The second picture is of the printed circuit board that contains the components that are used to make the output voltage variable. Components like resistors, diodes, capacitors and a Diac.
The third picture is of a Triac or Alternistor. This is the solid state power device that actually switches the AC voltage on / off every half cycle of the 60 Hz power. To reduce the voltage to the load (router, light bulb, soldering iron or what ever) the circuit delays the turn on of the AC source to the load every half cycle by variable delays determined by the position of the dial on the variable resistor called a potentiometer. This whole method of controlling the voltage to the load is called “Phase Control”.
The third picture is of some of the components mounted on the Printed circuit board that are used to control when the Triac or Alternister is turned on in each half cycle.
By reducing the voltage to a router, any universal motor, you cause the magnetics in the motor to “slip” which in turn reduces the power available which reduces the torque and horsepower which reduces the speed.
I tried not to get too technical and but still explain how these “speed controls” work.
It works for me..... Let me add just a couple of things.

And if anyone else want to go for the second award of big points please do so. I'll keep that option open for another week or so.

The part that is mounted on the cover is a ST BTA41-600B Triac.....

While the amount of horsepower is lowered the router will have enough power to do most of the projects you throw at it while also reducing the rpm to a safer speed to work at. The router will get warmer because they are designed with "fan" cooling.... designed to work the higher rpm and thus you should keep this in mind..... These also attempt to mantain the speed you set.... and I would guess if you spend more money you could find ones with added feed back circuits or maybe newer models that are cheaper????. This one is few years old now and now that I have variable speed routers I don't use this much anymore.....

A special thanks to ChevyNomad for taking the time to detail some of this for us!

Ed
 

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SCR speed control of universal motor

I just ran across this post and since I know how these circuits work, I thought I'd explain some of the details for those who are interested.

AC Routers, drills, dremel tools, and similar equipment have what's called universal motors in them. Universal motors are actually dc motors. The SCR component in the third picture works like a diode, it conducts during half of the ac cycle, and does not conduct during the other half cycle. It cuts on and off at the frequency of the ac voltage.

At full speed it acts just like a diode. It turns on when the voltage crosses zero, and remains on untill the voltage crosses zero in the opposite direction.

Now unlike a diode, the SCR has a third lead called the gate which controls whether the device conducts at all or not. If there is a sufficient voltage applied to the gate then the device conducts dc like a diode as explained. If the gate signal is below a certain level, then the device is like an open switch and it does not conduct at all.

The speed of a dc motor depends on the (average) voltage applied. At full speed, the average voltage of one whole half sine wave is applied to the motor. If we turn the speed control knob down, it adds some resistance to the SCR gate signal so that the SCR turn on point is delayed untill some time after voltage crosses zero. With the added resistance, the gate signal must rise to a higher voltage (which occurs later in the cycle) to reach the threshhold gate voltage where it turns on. So it turns on later in the cycle.

By nature, the SCR then conducts (with or without a gate signal) untill the voltage again crosses zero, where it automatically cuts off (like a diode). When the turn on point is delayed (the turn off point does not vary) the effective average voltage is thus reduced so the motor runs slower.

So the SCR cuts on and off at the frequency of the AC, and the speed control knob affects the duty cycle (and therefore the average voltage) of the (pulsing) dc applied to the motor.

An interesting feature of this type of circuit (and motor) is that the gate signal is also affected by the back emf of the motor in such a way that it serves to automatically (try to) maintain a constant speed. If you set a drill to run real slow and try to slow it down with your hand, it will try to maintain speed by increasing its torque. This has to do with the peculiar way that universal motors are wound. But that's another subject... That's also why these speed controls only work with universal motors. Due to the way the universal motor is wound (with 2 coils per pole), it does affect the SCR gate voltage, which makes the SCR speed control possible. Normal DC motors (with one coil per pole) cannot produce a usable signal to trigger the SCR gate.

Incidentally, back emf is relative to the actual motor speed. It is the motor turning which produces back emf in the first place. So you can imagine how a motor turning at a specific speed can have a specific effect on an SCR gate
to lock the speed at a specific rate. And how adjusting the knob can retard the effect of the back emf on the gate to slow down the motor.

The variable speed control in a drill is the same type of circuit as for a router. Router speed controls are rated for tens of amps whereas drill speed controls are only good for a few amps.
 

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It works for me..... Let me add just a couple of things.

And if anyone else want to go for the second award of big points please do so. I'll keep that option open for another week or so.

The part that is mounted on the cover is a ST BTA41-600B Triac.....

While the amount of horsepower is lowered the router will have enough power to do most of the projects you throw at it while also reducing the rpm to a safer speed to work at. The router will get warmer because they are designed with "fan" cooling.... designed to work the higher rpm and thus you should keep this in mind..... These also attempt to mantain the speed you set.... and I would guess if you spend more money you could find ones with added feed back circuits or maybe newer models that are cheaper????. This one is few years old now and now that I have variable speed routers I don't use this much anymore.....

A special thanks to ChevyNomad for taking the time to detail some of this for us!

Ed
Where can I see thes pics you speak of. I want to build some of these.
Rick::happy:
 

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That thread is 4 years old, and reible no longer visits here.
Yep what Mike said...

Old thread but here is the datasheet for the TRIAC

http://www.st.com/stonline/books/pdf/docs/7469.pdf

There is a better choices than a basic TRIAC for single phase motor controllers based on chopping the phase. You can use an "alternistor" which is a TRIAC with better commutation characteristics (sold by TECCOR / LITTELFUSE). Needs less beefy external snubber circuit for inductive loads. Another choice would be IGFET but you may need a more sophisticated drive circuit and multiple FETs.

Good luck with your project Rick109. But unless you really, really want to build your own are are cognizant of the dangers and problems associated I'd suggest you buy a quality commercial unit (ala MLCS and others).
 
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