Brushless Dewalt DCW600 Mod ( Mod-walt? )

So I think Home Depot messed up. They had two overlapping sales. I was supposed to get a 4 piece tool set + two additional tools for $399 dollars. However if those two free tools were two of the ones listed in this other sale you got $70 dollars off. It looks like they fixed this in their computers afterwards though. I ended up getting something like $1200 dollars worth of Dewalt tools for $330. The Dewalt DCW600 Brushless Trim router was one of the the extra tools.

Being interested in running Brushless Spindles and having some troubles with the Makita + ODrive combination (ODrive Developers are looking into those) I figured I would give the Dewalt a try.

Number one thing I found out is they are very hard to get apart. You have to remove all the screws and then use a 19mm socket to undo the nut that is below where the collet is. Then you need to get something long and pokey and put it into where you put the endmill. Make sure it is something that won’t harm the surface. Then you need to beat on that pokey thing for like an hour to drive the plastic inner housing out. Being careful not to lose the four metal pins that are keeping the two plastic parts from rotating (I lost one of them).

I found technical drawings and specs on the UK Dewalt site for the tool: http://service.dewalt.co.uk/DEWALT/GB/en-GB/Product/ProductDetail?id=14919

Despite Dewalt’s marketing they spec it at 18V instead of the 20V they have all over the package. Apparently when the batteries are fully charged and not plugged into a load they read 20V, but as soon as you put a load on it, it drops down to 18V. At 18V it is a 930W motor which implies it can handle a little over 50A of current.

It is using industry standard connectors for things like it Hall array sensor which means connecting to a different ESC to it should be fairly simple… once I get the epoxy they used to keep the connector from vibrating loose off.

The illumination LEDs have a resistor already inline which means I can probably put 3.3V or 5V across them and they will just light up.

The motor wires from the ESC are soldered onto terminals on the motor armature so disconnecting the ESC will require some soldering skills.

Overall it looks promising. Wont know though till I hook it up to my ODrive and see how it performs.

#EDIT: LEDs actually take 18V across them. That will make things interesting.

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So I got it wired up to the ODrive and running. It has a whine to it that I don’t like. Wondering if I trashed a bearing getting it apart which would suck. Here’s a video:

Forgive the shakiness. Trying to film and adjust parameters is difficult.

Over all for having not been tuned it’s performing well.

Any thoughts on the whine?

Edit: it only makes the whine when spinning the proper direction. When spinning the other way is quiet.

Have you tried changing the chopper frequency in the drive?

It is definitely mechanical.

Found the problem. The wires for the LEDs had gotten caught in the stator. Glad I figured that out before a short. Ended up cutting the wires. I will worry about getting the LEDs working some other time.

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So I am shipping the Dewalt to one of the ODrive devs. They are going to figure out what is causing the issues.

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Good that they’re that involved, If you want to go maths-pun you could call your mod the dWalt

(not sorry)

Yeah and I am keeping the modkita because I have a working (but strange) 4.12 config. THe dewalt just doesnt work. The devs were actually happy to be able to test their stuff out on something other than hobby motors.

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