Posted by Neil A on 28/08/2020 21:41:04:
… I am concerned about the brushed motor that it uses.
It would seem from various posts on this forum that brushed motors are more liable to overheating and failure if used for prolonged periods, particularly at low speeds. Unfortunately these are usually quite common operating conditions when turning a component. Brushless motors don't seem to have the same problem.
… Is there a duty cycle that must be observed?
…
The worst possible motor to put on a lathe is the Universal AC/DC type, yet they're useful on tiny lathes spun at high speed.
Second worst motor is the AC Single Phase motor. Complicated, with run and start windings, capacitors and maybe a centrifugal switch. They vibrate, have poor starting torque, and can't be speed controlled. Their advantage is they run straight off domestic single phase electricity. Despite a shower of disadvantages, this type of motor has given satisfactory service on lathes and other tools for decades.
The first 'good' motor for a lathe is the brushed DC type. Good torque characteristics. The disadvantage is the brushes wear out, as does the commutator. Eventually. Run in 'let the tool do the work mode', brushes last a long time and are easily replaced. Same motor pushed hard by an angry gorilla in a hurry will soon burn out; the brushes overheat and the commutator and windings take a thrashing. Get the motor hot enough, and magic smoke will appear, or the controller will pop!
For many years the best motor for a lathe was a 3-phase AC motor. They are considerably simpler, more robust, smoother and more reliable than a single-phase motor. There are no brushes to wear out. And they can be speed controlled with a VFD, which also solves the problem of getting 3-phase electricity into a home-workshop.
Relative new boy on the block is the brushless DC motor. Close relatives of the AC 3-phase motor rather than a brushed DC motor. Not really DC at all – they're poly-phase motors driven by DC pulses produced by an electronic controller. They have excellent characteristics.
As a rough guide, I'd mark single phase 4/10, brushed DC 7/10, 3-phase 8/10, 3-phase+VFD 9/10, and brushless 10/10. They're all OK.
Duty cycle! An industrial machine costs between 6 and 30 times more than a hobby machine. Part of the extra cost is spent on the motor, which will be generously rated for hard continuous work in a production environment. Hobby machines are rated on the assumption that they will work relatively gently with time to cool off between cuts. It's what most amateurs do: take a few minutes setting up in the chuck, then a cut, pause to measure, then another cut or reset the job etc.
It is easy to overwork a hobby machine particularly if the operator is a bad-tempered gorilla in a hurry! (Surely not, hobbyists are all gentlefolk, striving for precision and finish, not rough hackers.)
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My rule of thumb is to 'let the tool do the work'. Rather than force cutters through metal I set depth of cut, feed-rate, and rpm to suit the material and the machine. By ear, the machine is run so I can hear the motor is working short of labouring. Must never sound distressed. If a lot of metal is being removed, I pause to let the motor cool down.
How much can be expected of a hobby machine depends on the model. Mini-lathes are relatively delicate. In contrast my WM280 has a fan-cooled 1500W 3-phase motor that I've never got warm. The 1100W brushed DC motor in my WM18 is more vulnerable to abuse so I take more care with it. So far no problems. Easier to damage a small machine than a big one, but never forget hobby machines are what they are.
Conclusion: if the goal is a bomb-proof motor, you need an industrial machine. Otherwise brushless and 3-phase have an edge over brushed motors, in that order but they all need to be treated with respect. As they will all do hobby jobs, I wouldn't agonise over the motor. Note the single-phase motors I consider inferior to brushed DC haven't significantly reduced the ability of Myford owners to do good work over the last 70 years.
Dave