Electric Bead Roller

[Brucker]

After a couple years using a manual bead roller, I decided it was time for an electric power upgrade. I had been saving my pennies for a Mittler Bros (http://www.mittlerbros.com/ ) model, but still can't justify another couple thousand dollar equipment purchase at the moment. And having a bunch of sheet metal working coming up on my schedule, I decided to fab one using components I had laying around the shop. Basically just adding an electric motor to the Woodward Fab (http://www.woodward-fab.com/ ) manual roller I currently use. Then, if it works out well, I will machine a couple new die sets to fit the Woodward fab assembly as I have only found one company out there that offers some for sale.

Believe it or not, rolling complex designs manually brings the suck, but it can be done. Here is an example of one of the more complex designs I have rolled:



Here is my manual bead roller assembly that I am starting with. You may notice a couple custom parts I had already made for it. A mounting bracket for my fab table and a adjustable back stop. As you can see, this machine gets a lot of use.







I had an extra used DC motor and controller on the shelf from a previous project. This Leeson setup should work wonderfully as you can adjust the motor output speeds from 0-1750 rpm. And it is reversible.





I will then add a foot operated power switch to the motor assembly so I can use both hands to manipulate the material being formed.



Will be using a couple sprockets and some roller chain to transfer the power. And yes, this is a little bit over kill, but it's what I had extras of sitting on the shelf from a previous go kart project.



For the new stand, I decided again to use some materials I had instead of buying new. I started with an older roller stand that we had too many of sitting unused, just taking up precious space.



I cut apart the stand and kept the parts I would be using.



Will add a couple new casters into the mix. Again these were leftovers from another project.

[Brucker]

First order of business was to make a simple, yet strong motor mount. I cut a few pieces of angle and flat and then modified them and welded them together to make the needed mount. The photos should be fairly self explanatory:

[EKXJ87]

That awesome love the repurposed material, that why I never throw anything away some day I'll us it! lol
So will you set the speed on the control box and then work the foot pedal?

[Patrolman]

Cool setup! Is it really from 10 to 100RPM? Or is the speed something different?

[Brucker]

EKXJ87 previously posted:

[Brucker]

Patrolman previously posted:

[Brucker]

With the motor mount finished, I turned my attention to the stand. I had already scavenged some parts from an older adjustable roller stand:



Then cut a few more pieces from some leftover drops:



And then drilled and tapped a couple holes for the new stem casters:





And with most of the pieces for the base of the stand cut, I quickly mocked them up to make sure the plan I had in my head was going to work:

[Patrolman]

Brucker previously posted:

[Hypoid]

Brucker previously posted:

[Brucker]

Didn't have much time to throw at this project today. Was hoping to be done with the entire project this weekend, but had another project take priority unexpectedly. But made a little progress and got the base of the stand welded together.

Started by attaching the motor mount to the main post:



Once it was welded, I cut and attached a tube between the two to act as a big gusset to the top of the mount:



Once both the mount and the gusset were welded as much as possible and had a chance to cool, I flipped the assembly over. Clamped it back down to the table and finished welding it all together.







I started to assemble the rest of the base, clamping each piece to the table of to other parts of the assembly. Then welded it all together.









Once cooled after welding solid:

[Brucker]

Found a little more time tonight to throw at this project. I mounted the motor into it's mount to double check fitment. It looks like it belongs there so I think I am headed in the right direction.



Next up was the mount found the roller itself. After a quick couple of measurements, I made up a chop list and started the saw cutting all the needed pieces. And then started to tack weld them together.











Once everything was tacked together, I removed the roller from the mount for final weldment.

[Brucker]

I turned my attention back to the base. This time to add the casters. Welded the two fixed rollers to the front (this should help the entire assembly stay in one position since the caster can not swivel under load), and the the two swivel caster to the outriggers.





Started to assembly it all back together again:









And that is as far as I got tonight. It is starting to really take shape now. Just need to make the chain assembly and a couple more mounts. One for the controller and then some for different die sets. I may end up ordering a different sprocket for the roller side as it would offer a little more adjust ability at the lower RPM's I will be running. But all in all, I am happy with the way it's turning out so far. Not bad for just throwing a bunch of leftovers at this project.

[Cr33p3r]

Sweet project Aaron!

[Brucker]

1freaky1 previously posted:

[88Toy]

Can't wait to see the artwork that comes from this!

[Brucker]

88Toy previously posted:

[Brucker]

The larger sprocket finally arrived! Got it mounted to the roller side and then made the chain assembly. Hooked the chain up and took the tension out of the chain by adjusting the height of the roller. And then tested the newly assembled electric roller out for the first time.

Works great! Real test will come when we start heavily using it.

Still need to finish a couple things up but this roller sure is turning out nicely!

[Brucker]

Finally got around to making a controller mount. Started with a flat piece of 14 ga steel and then used the roller to run to beads vertically to make the piece more rigid.





Bent up a section of 3/16" solid rod and welded it around the perimeter of the new panel for reinforcement.







And welded it into place on the stand

[Brucker]

I was now able to turn my attention to the wiring and mounting of the controller. I disassembled the controller and cleaned up both cords by shortening to the correct length and cutting out damaged areas to existing cords.











Took off this much extra cable between the motor and the controller, about 20ft:



All finished up for now. Probably should still make a chain guard, but I would like to put some time in with the machine to work out any bugs before I add anything else. But for now, the finished product:

[Jim]

I've enjoyed following the project.

IMO, a full, beefy chain guard would be out of character for the tool (and the environment). How about something minimal - two side plates, with a single rod, plates welded to rod, for holding the plates to cover the single pinch point of each gear? The rod would terminate on the frame to hold the plates.