I have a problem, which I THINK can be addressed electronically. However, I am unsure of the method (or correct device) needed to get there from here.
The Problem: My Porter Cable Router works it's little heart out, carving Oak pieces for me for days on end. And it wears out the motor brushes with some frequency. Most of my carvings are 3D, which take HOURS to cut- therefore I leave the machine running unattended at times. And it seems that it is always during these times, that the motor brushes wear out on the Router. When I return to check on the machine's progress, and find it still moving the Router along the tool path which now has a broken bit (since the motor brushes wore down enough to stop the Router motor from turning).
The Solution: ??? I know that there should be a way of installing some type of motion detector (perhaps an encoder of some type) on the Router chuck, which would trigger a Fault in Mach3 and stop the program's execution until the Reset button is clicked. This would be a tool-saver! For if the Router motor stops turning, and Mach continues to run, it invariably plunges the tool into the work piece, which results in a broken bit Each and EVERY TIME the motor brushes fail (since the Router motor stops turning)!
Does anyone have a useful solution for this problem? I have thought about using an encoder, to provide feedback to Mach3- but the problem is Where to mount one? A Router motor is not like a Spindle, with an external shaft on top (which could be used to mount an encoder). Therefore, it must be some type of device which could be mounted onto the chuck collar. Ideas? Anyone?
All help would be appreciated!