HAFB - Benchtop Bandsaw Upgrade
Team: Jeff Kelly, Edrick Pitman and Duncan Wallace
Project Description
Modified a benchtop bandsaw for use on a mobile workstation to have variable speed control. This allows more materials to be cut on the bandsaw.
Design:
- 3 phase motor
- Variable Frequency Drive (VFD)
- Integrated new pulley and control panel
Performance Review
| Requirement, Constraint, or Goal | Target | Threshold | Actual Performance |
|---|---|---|---|
| Cuts steel with no damage to bandsaw blade by speed of blade | 500 ft/min | +/- 100 ft/min of target | Cuts steel cuts smoothly when VFD at 10 Hz, results in a blade speed of 500 ft/min. |
| Cuts aluminum with no damage to bandsaw blade by speed of blade | 2500 ft/min | +/- 100 ft/min of target | Cuts aluminum smoothly when VFD at 50 Hz, results in a blade speed of 2500 ft/min. |
| Adjustable speed (while saw is running) | 100–2750 ft/min | N/A | Lowest frequency: 1.5 Hz, blade speed of 75 ft/min. Highest frequency: 60 Hz, blade speed of 3000 ft/min. |
| Maximum size of upgrade device | N/A | 1.5 ft³ | VFD motor only takes up slightly more space than the original motor. Meets constraint. |
Bandsaw Upgrade Speed Chart
| Frequency of VFD | Blade Speed (±25 ft/min) |
|---|---|
| 10 Hz | 500 ft/min |
| 20 Hz | 1000 ft/min |
| 30 Hz | 1500 ft/min |
| 40 Hz | 2000 ft/min |
| 50 Hz | 2500 ft/min |
| 60 Hz | 3000 ft/min |
Material and Recommended Speed
| Material | Cutting Speed | Recommended Frequency |
|---|---|---|
| Stainless Steel | 500 ft/min | 10 Hz |
| Aluminum | 300+ ft/min | 50 Hz |
HAFB Table Configuration
Analysis and Testing Description:
Different materials and in various thicknesses were cut to ensure the bandsaw would meet the original criteria.
As a final test, a sample material that couldn’t be cut with the original bandsaw was provided by HAFB. The upgraded bandsaw was able to cut through the material cleanly and without issue.
Lessons Learned:
- Learned how to efficiently coordinate timing of a project to meet deadlines.
- Learned how to gather relevant data from manuals and datasheets.
- Learned how to set up a working system design without previous prototypes to rely on.
Future Work:
Future work for the project includes testing the bandsaw at higher frequencies by adjusting the limits on the VFD for expanded capabilities.