I talked to three custom gear houses today, they say its nearly impossible to make a female part to slip over the helical gear. Looks like I will be welding or gluing.
I will probably try epoxy first. If I can get a machined part to slip over the motors gear, and extrude the epoxy up though the hollow shaft, that would be a ton of surface area.
Failing that I will have to weld.
I hope to be running the motor in sensorless vector. I don't know how successful I will be in tricking the 2hp drive into thinking its a 2 horse motor instead of 90 horse. I may have to run in Volts / Hz mode, in which case Im not sure I can do regen brake. I may not get sensorless vector working right away, I can also do encoder feedback with the drive. I might also be able to get the hall sensors working on the motor.
I could just run the 90 horse motor at 2 hp. I was thinking I could bolt up the motor and a bench grinder to a workbench and grind everything square.
I think this flange is the only thing I can't buy my way out of. Even drive line shops say they can't weld it because it won't fit in their machine. Looks like Im going to do this myself.
Originally Posted by Denniscnc
I was looking at your site and I think for best results on mounting the flange to the motor shaft is like you said get it machined but fit over the teeth, most likely the teeth are hardened so machining might be a pain especially with tooth interruption. Then once it's welded bolt the motor to a lathe if you have access to one and machine the flange face and back since the motor has a lot of torque that will be nothing for it and this way it will be perfectly perpendicular to the shaft.
And since it's a 3ph induction motor and if the shop has 3ph power that will solve the power supply problem.
Is there any feedback from the motor to the controller?