MESA 7i96 AC Servo spindle setup

Awesome then! Definitely going this route! Thanks a lot man.

My servo is 2500RPM only, so I am planning to use poly-V belt drive with two pulleys in order to make spindle RPM at least 5000. Need to turn those gears from aluminum (on my mini lathe), which is on order and badly delayed. So I have to entertain myself with something else for now! With that said I am planning to aim at 1:2.5 ratio there. But as I said, positional control isn't really necessary at this time. I also like the lock feature actually, this will allow me to easier change tools hopefully, as spindle wont rotate freely at tool change. Now with my cheap AC motor there it freely rotates so I have to use two tools to release end mill, and then I need to use the third hand to make sure the mill doesn't fall into my iron table and shatter.

My servo also gets super hot even without a load. I ran it yesterday at 2500RPM for about 10 minutes and it got into 80C area. Is your servo getting same hot too?

That temp isn't horrible. I have a 1.8kw as well as a spindle on a small machine for years now and run it at full speed for hours on end. It's usually around 160 deg f.

I would personally go with a timing belt setup for the spindle. It will be a bit noiser but you want to make sure all that power is delivered to the tool. How complex is the mounting for the belt setups you would like to use? Misumi does custom bores to order for timing pulleys.

80C is more like 190F tho. And that is on a floor with no pulley and no load even... 

For bores I actually prefer to do them myself, this way I can match them perfectly with my shaft, as I have a lathe. I considered a 3M setup, but aside from noise those pulleys are hard to get and expensive and shipping time is super long. On top of that machining them with good concentricity will be a huge challenge if I buy from chinese junk market, and so far everything I have seen on amazon and ebay is a total junk, mcMaster prices are ridiculous for this type and they often sell same junk. And for spingle pulley I an gonna need to customize it myself regardless, because its angled shaft on my machine. I cant imagine how to do that on a finished 3M pulley, as they are not concentric outside. Then I saw people using Poly-V profiles and thought thats a great idea actually, less nosie, plenty of grip, while pulleys are super easy to make on a lathe. Belt is also self centering unlike most timing belts that wobble left and right always. Well, anyways, that was my logic and why I chose Poly-V setup. Ordered all material on midweststeelsupply.com website. Their prices are actually one of the best I could find, but sneaky people took my order and only next day sent me an email about additional 10-12 business days delay. Now I have to wait quite a bit to get this all setup.

As far as Misumi is concerned, they are nice as an option when you dont have tools to do it yourself, but if you have machines it is way easier to do it yourself and will save a lot of money for you, as for what I need material alone is already over a $100.

I mistook your statement to mean your lathe was on order.

For my setup I used aluminum XL timing pulleys. Pretty cheap and everyone has them. I did my first round from Misumi and have done some others with a 4 jaw chuck.

My temp is on a well broke in servo motor. When I first broke in the setup I had some temps climb up pretty high. After a run in period it all settled down.

Oh I see, that break in period makes sense and I didn't think of that. Good point! I'll check Misumi for pulleys now actually, as my supplier seems to not going to be able to deliver my metal order anytime soon anyways. Thanks for the tips!