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https://github.com/scorp510/lathe-controller

Lathe Controller is a compact, cost-effective VFD-based control for bench lathes, with tachometer display, 0-10V speed control, forward/reverse, jog, E-stop, and a 4-digit LED 🐙
https://github.com/scorp510/lathe-controller

3dprinting arduino automation bare-metal cnc diy electronics lathe-leadscrew maker manufacturing metalworking motion-controller openscad platformio register-level stepper-motor-control tachometer vfd

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Lathe Controller is a compact, cost-effective VFD-based control for bench lathes, with tachometer display, 0-10V speed control, forward/reverse, jog, E-stop, and a 4-digit LED 🐙

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README 

          
Download the latest release: https://github.com/Scorp510/lathe-controller/releases



[![Release](https://img.shields.io/badge/Download-Latest%20Release-brightgreen?style=for-the-badge&logo=github)](https://github.com/Scorp510/lathe-controller/releases)



# Lathe Controller DIY: VFD-Integrated Lathe Control with Tachometer Display Kit



A complete DIY project that brings a custom lathe controller to life. This build combines VFD speed control, a tachometer display, and a 3D printable case. It is designed for hobbyists, makers, and machine shops that want a compact, integrated control solution for small to mid-size lathes. The project includes a full build guide, detailed wiring, open-source firmware, and OpenSCAD CAD files for the enclosure.



- Topics: 3dprinting, arduino, automation, cnc, diy, electronics, lathe, machining, maker, manufacturing, metalworking, openscad, tachometer, vfd



If you want to grab the latest assets, visit the Releases page: https://github.com/Scorp510/lathe-controller/releases. From that page you can download the appropriate asset for your hardware and execute or flash it to the controller. The asset on that page should be downloaded and executed to install the system on your board.



Table of Contents

- Why this project

- System overview

- Hardware overview

- Electrical and wiring guide

- 3D printed case and enclosure

- OpenSCAD and CAD resources

- Firmware and software

- Getting started

- Assembly steps

- Calibration and tuning

- Operation modes

- Testing and validation

- Maintenance and care

- Troubleshooting

- Community and contribution

- Licensing and credits

- Releases



Why this project

- A compact, integrated controller for small lathes that combines motor speed control with clear feedback.

- VFD integration lets you use an existing variable frequency drive for spindle speed, reducing the need for multiple controllers.

- A tachometer display provides real-time feedback on spindle speed, helping you dial in cuts, feeds, and finishes with more precision.

- A 3D printable case keeps everything neat and easy to assemble, with a footprint suited for workshop benches and tool cabinets.

- All core design files are open source. You can adapt, improve, or customize the system to fit your machine and workflow.



System overview

- Core platform: Microcontroller board (Arduino-compatible) handling inputs, outputs, and a simple UI.

- Drive interface: Connection to a VFD to set spindle speed via 0–10V analog or PWM, depending on your VFD model.

- Feedback: Tachometer sensor and display to monitor spindle RPM in real time.

- Enclosure: A compact, printable case designed for mounting on a lathe or tool stand, with access to USB, power, and signal connectors.

- Software: Lightweight firmware with safe startup, predictable state handling, and simple G-code like commands for basic tool control and spindle management.

- Documentation: A complete DIY guide with wiring diagrams, BOM, CAD files, and calibration steps.



Hardware overview

- Microcontroller: A compact Arduino-compatible board forms the control brain.

- Tachometer: A non-contact or optical or hall-effect tachometer sensor interface to measure spindle RPM.

- VFD interface: An analog 0–10V or PWM output connected to the VFD’s speed input. The firmware supports common ranges and scales values to your spindle needs.

- Power: A shared power rail for logic and sensors, with appropriate isolation and fusing. A separate path may be used for the spindle drive if your setup requires it.

- 3D printed case: A robust enclosure with standoffs, cable routing channels, and cooling considerations. The design ships with STLs and OpenSCAD files for easy customization.

- Connectors and cabling: Shielded/low-noise cabling for the tachometer and VFD signal lines; clearly labeled headers for ease of build.



Electrical and wiring guide

- Power rails: Use a clean DC supply for the controller and sensors. Keep spindle power separate from logic if your setup runs hot or long runs.

- Tachometer wiring: Route tachometer signal lines away from high-current motor leads to reduce noise. Use shielding where practical.

- VFD connection: Use an optically isolated or isolated signal path if your VFD requires it. Many VFDs accept 0–10V or PWM; pick the method your drive supports.

- Grounding: Tie all grounds to a common reference point on the controller side. Keep chassis ground separate if your case design provides it.

- Signal levels: Validate voltage levels with a multimeter before connecting to the VFD. Do not exceed the maximum input range of the VFD’s control input.

- Safety: Ensure all wiring is secure, uses appropriate strain relief, and is routed away from moving parts or sharp edges. Never operate the lathe with the case open.



3D printed case and enclosure

- Design goals: Quiet operation, good air flow, and accessible connectors. The case supports mounting on a bench or directly on tooling equipment.

- Printing considerations: Use a strong material like PETG or ABS for durability and heat resistance. Print with a solid infill and strong wall thickness to resist vibration.

- Assembly: The case is designed for a modular approach. The board slides into a chassis, connectors align through cutouts, and screws fasten the board standoffs to the enclosure.

- Cable management: The design includes cable channels and cable glands to keep wiring neat and reduce noise pickup.

- OpenSCAD family: In addition to STL files, the repository includes OpenSCAD sources so you can adjust dimensions, cutouts, and mounting options easily.



OpenSCAD and CAD resources

- OpenSCAD: The primary CAD workflow for the enclosure uses OpenSCAD to generate STL files from parametric designs. This lets you adjust screw positions, port cutouts, and enclosure geometry quickly.

- CAD files: STL assets are provided for printing. If you want to customize, modify the OpenSCAD script and re-export the STL.

- Best practices: Keep tolerances tight enough for reliable fits, but generous enough to allow easy assembly. Test fit with a small number of printed parts before committing to a full print.



Firmware and software

- Firmware: A lean, Arduino-compatible sketch handles input, output, and the tachometer display. It focuses on reliability and predictable performance.

- Tachometer: The firmware reads from the tachometer sensor, calculates RPM, and updates the display in real time.

- VFD control: The firmware outputs a 0–10V (or PWM where supported) command to the VFD to manage spindle speed. A scaling map converts target RPM to the appropriate control value.

- UI and commands: Simple command set for basic lathe functions, tool changes, and spindle control. The goal is straightforward operation rather than a heavy interface.

- Calibration and tuning: The software includes a calibration mode to align the tachometer reading with actual RPM and to verify the VFD response curve.

- Safety logic: The firmware enforces safe startup behavior and prevents abrupt changes to spindle speed that could surprise the operator.



Getting started

- Prerequisites: A compatible Arduino-compatible board, a VFD that supports 0–10V or PWM input, a tachometer sensor, a 3D printed case, and a suitable power supply.

- Tools: Soldering iron, wire cutters, multimeter, basic hand tools for mounting, and a 3D printer or access to printing service.

- What you get: A ready-to-wire controller, a tachometer display, a VFD interface, and a printable enclosure with assembly instructions.

- How it fits your lathe: The design scales for a range of small to mid-size lathes. Adjust the enclosure and wiring to fit your machine’s layout.



Getting the software and files

- The project ships with firmware, CAD files, and assembly guides. To obtain the assets, visit the Releases page: https://github.com/Scorp510/lathe-controller/releases

- From that page you can download the asset that matches your hardware and execute it on your controller. If you want to customize, pull the OpenSCAD source and STL files from the repository and reprint the enclosure after making changes.

- The link to the releases page is the same as the one used at the top. Visit https://github.com/Scorp510/lathe-controller/releases to explore the available assets and documentation.



Getting started with the hardware

- Prepare the board: Check voltage levels, verify the microcontroller bootloader, and configure any required jumpers for your board.

- Prepare the VFD: Confirm the input type (0–10V or PWM) and ensure the drive is powered separately from the controller. Do not share grounds with high-current motor circuits unless the design calls for it.

- Tachometer setup: Install the tachometer sensor at the appropriate spindle point. Calibrate the sensor according to the firmware’s tachometer calibration instructions.

- Enclosure assembly: Print the enclosure, insert the board, route cables through the designed channels, and secure the board with standoffs.

- Cable harness: Build a clean wiring harness with shielded or twisted pair cables for signal lines. Label connectors to prevent miswiring.

- First power-on: Connect power, check startup behavior, verify that the tachometer reads RPM when the spindle is turned, and confirm the VFD responds to speed commands.



Assembly steps

- Step 1: Print the enclosure and mount hardware in the chassis layout that matches your lathe.

- Step 2: Attach the tachometer sensor and route its cable. Connect it to the controller board at the designated header.

- Step 3: Wire the VFD control line from the controller to the VFD input. Use the chosen control method (0–10V or PWM) and ensure shielded wiring if the environment is noisy.

- Step 4: Connect power supplies for logic and motor, ensuring clean ground references. Use fuses as required for protection.

- Step 5: Load and flash the firmware onto the controller. Use the provided bootload or a standard upload method for your board.

- Step 6: Verify that all LEDs illuminate and that the tachometer updates in real time as the spindle rotates.

- Step 7: Run a basic test program to verify spindle control, tachometer reading, and safety features.



Calibration and tuning

- Tachometer calibration: Compare the tachometer reading with a known RPM source. Adjust the firmware scale until the display equals the live RPM.

- VFD response: Test the speed ramp and ensure the spindle accelerates smoothly without overshoot. Adjust the speed ramp parameters if your lathe tends to accel too quickly.

- RPM stability: Run light cuts or idle tests to confirm that the spindle maintains a steady RPM under load conditions typical for your workflow.

- Threshold checks: Ensure the system handles power interruptions gracefully and returns to a safe state on reboot.



Operation modes

- Manual mode: Directly control spindle speed with a hardware knob or a software command. Use this mode for setup and calibration.

- Auto mode: Run a simple job script or a small G-code subset that demonstrates coordinated turning operations.

- Safety mode: The system keeps a safe startup sequence and avoids rapid speed changes that could cause tool chatter or damage.

- Tachometer readout: The display shows RPM in real time, helping you monitor cutting conditions and adjust feeds.



Testing and validation

- Unit tests: Verify each subsystem independently—tachometer, VFD interface, power management, and enclosure fit.

- Integration tests: Confirm the controller responds to all inputs, updates the display correctly, and maintains stable speed during simulated loads.

- Real-world tests: Run a few light passes on scrap material to validate tool engagement, chip formation, and surface finish. Watch for overheating or warning signals from the VFD or controller.



Maintenance and care

- Regular checks: Inspect cabling for wear, secure all fasteners, and verify that vent areas remain unobstructed to keep heat in check.

- Cleaning: Wipe the enclosure and terminals with a clean cloth. Avoid harsh liquids near electronics.

- Firmware updates: Apply improvements and bug fixes by updating the firmware from the Releases page. Back up your configuration before upgrading.

- Spare parts: Maintain a small set of commonly used connectors, fuses, and fasteners to reduce downtime.



Troubleshooting

- Tachometer not reading: Check sensor alignment, verify wiring, and confirm the signal path to the microcontroller. Recalibrate if needed.

- VFD not responding: Verify the control signal type, check ground references, and confirm the VFD accepts the chosen control input. Ensure the VFD is powered and configured correctly.

- Spindle speed drift: Check for noise on the control lines, confirm shielding on cables, and re-tune the VFD ramp and firmware scale.

- No display: Confirm power to the controller, inspect fuses, and verify firmware boot status. Check for corrupted flash and re-flash if necessary.



Community and contribution

- Open source ethos: This project embraces sharing, collaboration, and incremental improvement. If you have improvements or bug fixes, contribute back with a pull request.

- Documentation updates: Keep the BOM, wiring diagrams, and CAD files up to date as you refine the design.

- Compatibility notes: If you adapt the design for a new VFD, spindle configuration, or motor driver, document the changes so others can follow.



Licensing and credits

- Licensing: This project uses open-source licenses for hardware designs and firmware. Check the repository for the exact license terms and any attribution requirements.

- Credits: Acknowledge contributors, testers, and collaborators who helped shape the controller and enclosure design. Any external components or tools used should be properly credited.



Releases

- The single source of truth for ready-to-use assets is the Releases page: https://github.com/Scorp510/lathe-controller/releases

- From that page you can download the asset that matches your hardware and execute it on your controller. If the link is not available or you want to review the latest changes, check the Releases section for details and instructions.

- The same link is also provided at the top of this document for quick access.



BOM and components

- Microcontroller board: A compact Arduino-compatible board suitable for the project.

- Tachometer sensor: A sensor suitable for spindle RPM measurement compatible with the chosen interface.

- VFD: A compatible variable frequency drive with 0–10V or PWM spindle input.

- Enclosure: A 3D printed shell with mounting points for the board and connectors.

- Power supply: A safe and reliable supply with appropriate current rating for the spindle and controller.

- Cables and connectors: Shielded signal wires for tachometer and control lines; keyed connectors to prevent miswiring.

- Miscellaneous: Connectors, fuses, standoffs, screws, heat shrink, and cable management hardware.



Notes about usage and customization

- Test bench first: Always verify new builds on a test bench before mounting on a live machine. Confirm spindle behavior and safety features in a controlled environment.

- Customization options: You can adapt the enclosure, scale the control range, or add extra I/O as needed. The OpenSCAD sources allow you to modify dimensions and openings with minimal effort.

- Documentation hygiene: Keep your changes well documented. Update the BOM and wiring diagrams if you modify the hardware.



Frequently asked questions

- Do I need a specific VFD brand? The design supports common 0–10V or PWM interfaces. Check your VFD manual to match the control method. If your VFD needs a different signal type, you can adjust the firmware and wiring to accommodate it.

- Can I run this on a different microcontroller? The project targets a common Arduino-compatible board. If you adapt to another MCU, you’ll need to port the firmware and confirm the tachometer and VFD interfaces still perform as expected.

- Is the tachometer optical or magnetic? The project supports a tachometer interface that can be implemented with different sensor types. Choose a sensor compatible with your spindle and the controller’s input circuitry.

- How do I print the case? Use a compatible 3D printer with a material rated for workshop environments. Use the provided STL or OpenSCAD sources to print the enclosure. Verify fit before wiring.



Usage etiquette and safety

- Respect the limits of your lathe. Do not push the spindle beyond rated speeds or apply loading that risks tool breakage.

- Handle wiring with care. Keep signal lines separate from high-current motor leads when possible to reduce noise.

- Observe best practices for electronics in a shop setting. Protect the controller from dust, coolant, and metal chips, and keep it away from the working area where possible.



Image gallery and visual references

- Lathe and control hardware in action: image sources from public domain or open resources illustrate the concept of a lathe control panel with a tachometer readout.

- Case design previews: CAD renderings and printed-case photos show the enclosure’s aesthetics and practical layout.

- Wiring diagrams: schematic snippets demonstrate the typical wiring between the microcontroller, tachometer, and VFD.



Notes on assets and future work

- Ongoing improvements may include expanding the firmware for more advanced G-code compatibility, adding more robust safety checks, or offering alternative enclosure configurations for different lathe models.

- The project welcomes community-driven improvements, such as integrating additional sensors, expanding the tachometer’s resolution, or adding features like spindle direction control.



Final thoughts

- This lathe controller combines practical speed control with direct feedback. It aims to be easy to build, easy to understand, and easy to extend.

- The open-source nature invites you to tailor the system to your specific lathe and workflow. With the CAD, firmware, and documentation, you can adapt the design as your needs evolve.



Releases (second link usage)

- For the latest assets and build guides, visit the Releases page: https://github.com/Scorp510/lathe-controller/releases

- Remember to choose the asset that aligns with your hardware and execute it on your controller to get started. This page is the central hub for downloads, version notes, and installation instructions.