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Contents
High-frequency power tools 4
How it all began 4
Handheld high-frequency power tools 5

Service life 5
Constant speed 5
Overload characteristics 5
Ergonomics 5
Work safety 5
Operating costs 5
Tool types 5
Drills 6
Thread-cutting machines 7
Screwdrivers 7
Construction types 8
Body-grip screwdrivers 8
Pistol-grip screwdrivers 8
Centre-grip screwdrivers 8
D-handle screwdrivers 8
Cross-handle screwdrivers 8
Angle screwdrivers 8
Torque screwdrivers 9
Rotary-impact screwdrivers 10
Stalling-torque screwdrivers 10
Grinding tools 12
Straight grinders 12
Vertical grinders 15
Angle grinders 15
Building tools 17
Vibrating machines 17
Demolition hammers 18
System accessories 18
Measuring sensor 19
Test and control devices 19
Impact frequency adjuster 19
Spindle extension 20
Spring pulleys 20
3
How it all began

In the 1930s not only universal power tools
were used in large numbers for the first time,
but also high-frequency power tools, possi-
bly in even larger numbers. Lets have a look
at a contemporary report from the year
1938:
Drilling of rivet holes

Wherever rough operating conditions prevail,
universal power tools are on the retreat. This hap-
pened well before the first high-frequency power
tool was launched on the market namely
through tools powered by compressed air . This
tool type was capable of conquering a large num-
ber of application areas, until the demand for more
economical and reliable operating characteristics
led back to the use of electric drive motors. How-
ever, it was only after their operating frequency
was increased that three-phase motors could be
used to drive power tools. The frequency increase
was first realised in 1923 by Ernst Heubach & Co,
Berlin, whose patents were acquired in 1932 by
Robert Bosch GmbH.
Calculations have shown that the optimum
weight of motor and transmission can be Thread-cutting on locomotive boiler
achieved at frequencies between 250 and 300
Hz. This has to be considered during the planning
of high-frequency systems: fast-running, small
machines are best operated on 300 Hz, slow-run-
ning, heavy-weight machines are best operated
on 200 Hz.
The only German manufacturer of high-frequen-
cy power tools, Robert Bosch GmbH, Stuttgart,
has developed an extensive range of tools based
on practical experience. More than 100 different
HF machines offer professional operators a near-
ly inexhaustible range of possible applications.
(Source: German large-scale manufacturers, 1938) Assembly of passenger car motor
4
Handheld high-frequency power Ergonomics

tools Three-phase motors have much reduced
The installation costs of a HF system repre- operating noise which has a positive effect
sent a high initial investment which is not al- especially in large-scale industrial produc-
ways economical for a craftsmans busi- tion where many HF power tools are in
ness. Handheld high-frequency power tools use.
are therefore mainly used in industrial oper-
ations. The main factors for this are: Work safety
service life Due to the interlinking factor in three-phase
systems the voltage to earth of an operating
constant speed voltage of 200 volt amounts to only 153 volt
overload characteristics and with an operating voltage of 135 volt
only 78 volt which is much less in compari-
ergonomics son to 230-V power tools with universal
work safety motor. And since industrial operations often
involve the processing of metal in a metal-
operating costs dominated environment, this is an addition-
al safety factor.
Service life Operating costs

The three-phase motors used in HF power The running operating costs of a HF system
tools have neither a collector nor carbon are very favourable since they do not require
brushes. Therefore they are not subject to energy storage facilities like, for example, a
wear. If the lubricant in bearings and trans- compressed-air system. They require very
mission is replaced at regular intervals and little maintenance. There are no leakage
with skilled application one can achieve an losses as in compressed-air systems. Addi-
average service life of several decades. This tional consumer connections can be in-
makes HF power tools highly suitable for stalled with little effort. The relatively high
continuous operating duty, including shift- initial investment costs will pay off soon.
work, in industry.
Constant speed
A characteristic property of three-phase
motors is their constant speed across a Tool types
wide load range which makes speed regu-
lation obsolete. For practical purposes this In principle, every power tool can be
means that their application tools operate equipped with a HF motor. For practical pur-
within the optimum speed range at all times poses, however, this is limited to the follow-
and therefore yield the best possible work ing tool segments:
progress. Especially when sanding or grind-
drills
ing, HF tools are highly efficient and eco-
nomical. thread-cutting machines, screwdrivers
sanding tools
Overload characteristics special tools
HF power tools under load suddenly stop
when the so-called stalling torque is In addition, demolition hammers as well as
reached which is an unmistakable indication internal and external vibrating machines
to the tool operator of an impending over- with HF motors are used in the building in-
load condition. dustry.
5
Performance
Rotational speed
Drills
Construction type
categories
Drill diameter
PNW-T07
HF drills are in comparison to drills with uni-
alu
5
7
9
10
10
10
13
13
13
23
versal motors of the same performance cat-
egory much smaller in size.
steel
Because of the commonly low rotational
2
3
4
5
6
8
10
12
13
16
speeds during drilling, machines used pri-
950 watt 1450 watt
750/350
marily for drilling - and screwdriving in in-
cross-handle
dustrial plants usually have an operating fre-
quency of 200 Hz. The low motor speeds
500/200
which can be realised with this frequency al-
low the use of simple transmissions.
Typical construction types are pistol drills in
2200/
the lower to medium performance range,
1500
machines with D-handle or cross-handle in
the medium to high performance range.
500
D-handle
850
Drills different designs
(not true to scale)
600 watt
1500
Pistol-grip
80...120 m/min Alu
2000
1500/
900
D-handle
2400/
1600
20... 25 m/min steel up to 600 N/mm2
1000
400 watt
1350
pistol grip
Cross-handle
2000
EWL-HF010/P
3700
for cutting speed
2500
250 watt
3300
Selection of HF drills
4000
Construction type
Rotational speed
alu
5
7
9
10
10
10
13
13
13
23
Drill diameter
Performance
categories
steel
2
3
4
5
6
8
10
12
13
16
6
Thread-cutting machines Screwdrivers

Thread-cutting machines are used in as- Next to grinding tools screwdrivers form the
sembly engineering to cut internal threads most comprehensive tool segment in the HF
into pre-drilled components. A frequent area sector. They are mainly used for assembly
of application is the resizing of threads after purposes in series production facilities. The
follow-up treatment of workpieces (coating, various screwdriver types differ in working
varnishing) to restore their operability. principle and design. The great variety of
Thread-cutting machines resemble drills, possible screwdriving conditions necessi-
but in contrast to drills they are equipped tates the use of many different types.
with an automatic reversing transmission. Because of the commonly low rotational
The reversing transmission is controlled by speeds during screwdriving, machines used
the pressure applied to the machine . Dur- primarily for screwdriving in industrial plants
ing idling the spindle returns automatically usually have an operating frequency of 200
to counterclockwise operation. When the Hz. The low motor speeds which can be re-
machine is set upon the workpiece and alised with this frequency allow the use of
lightly pushed forward the spindle stops simple transmissions.
turning. When the pressure is increased the
spindle starts turning clockwise. During this
phase the thread cutter is turned into the
thread. When the pressure is reduced after Screwdrivers different
the thread has been cut the tool spindle re- designs (not true to scale)
turns to counterclockwise operation and the Body-grip
thread cutter is turned back out of the screwdriver
thread. If the thread-cutting machine is op-
erated in a drill stand with a properly adjust-
ed depth stop the rotating direction is re-
Pistol-grip
versed automatically which makes the cut-
ting of threads in blind holes possible.
Tapper
Function of the automatic clutch Centre-grip
X
1
X
2
D-handle
3
Cross-handle
X
4
1 no-load operation = counterclockwise Angle screwdriver

rotation
EWL-G017/G
2 slight pressure = standstill

3 feed pressure = clockwise rotation
EWL-HF011/P
4 draw back = counterclockwise rotation

X clutch travel of shaft
7
Constructions and types Centre-grip screwdrivers

For ergonomic reasons and on account of Centre-grip screwdrivers allow the applica-
the often very complex applications, high- tion of higher torques since the correspon-
frequency screwdrivers come in different ding restoring torques can be absorbed
constructions and types such as: more ergonomically. Standard torque val-
ues range between 10...50 Nm.
body-grip screwdrivers Centre-grip screwdrivers are available in the
centre-grip screwdriver following performance categories:
angle screwdrivers k 250 watt
Because of the restoring torques produced k 260 to 550 watt

by some of the types on account of their
functional principle, they have to be careful-
ly selected within the performance catego-
ry in question. D-handle screwdrivers
The D-handle is usually located around the
tool axis. It ensures good central guidance
Body-grip screwdrivers
of the tool. Higher torques, however, require
Body-grip screwdrivers are used in places use of an auxiliary handle to master the
where a low width across corners is re- restoring torque without problems.
quired. They are especially suitable for very
small screwdriving applications in precision
mechanics or in hard-to-reach places. In as- Cross-handle screwdrivers
sembly lines they are often used for vertical
screwdriving. Higher torque values also produce higher
restoring torques which affect the tool user.
Body-grip screwdrivers are available in the They can only be safely handled with a
following performance categories: cross-handle for both hands. Usually the
handles are offset by 90 from the central
k 80 watt
axis and staggered along the length of the
k 125 watt tool. Since cross-handle screwdrivers are
heavy-duty machines of the upper perform-
k 180 watt
ance categories, they are usually suspend-
k 250 watt ed in their centre of gravity by spring pulleys.
In the upper performance categories the

available torque is usually limited to values
between 0.1...10 Nm to avoid potentially un- Angle screwdrivers
pleasant restoring torques harmful to users Angle screwdrivers are used in narrow
of screwdrivers with ratchet clutch. places and where body-grip screwdrivers
or centre-grip screwdrivers cannot be used.
Angle screwdrivers consist of a body-grip
Pistol-grip screwdrivers
screwdriver with attached angle piece. The
Screwdrivers in pistol-shape resemble the long leverage between the grip areas and
shape of drills common for universal tools. the screwdriver spindle ensures safe han-
They are easy-to-operate and machines of dling of very high torque values. Standard
equal torque delivery ensure more er- performance categories are:
gonomic working if the screwdriving
process is horizontal. k 170 watt
k 260 watt
k 400 watt
Their torque ranges from 10...100 Nm.
8
Screwdriver types
Cutoff screwdriver:
Corresponding to their purpose and appli- Function and working principle
cation, high-frequency screwdrivers with
different working principles are used which Turning Switched off
make them particularly suitable for their par-
ticular application. The most important
working principles are:
cutoff screwdrivers
torque-limit screwdrivers
rotary-impact screwdrivers
M
stalling-torque screwdrivers
These working principles are available in dif- t

Progression of torque
ferent designs and combinations.
FM
EWL-VST008/G
Torque screwdrivers with cutoff clutch 0,1 0,2 0,3
t (s)
Progression of assembly tension force

Torque screwdrivers with cutoff clutches
function according to the working principle
of a ratchet clutch. Here the torque is also
limited by an adjustable dog or roller clutch. Torque screwdrivers with cutoff clutch
The difference to a ratchet clutch is that the and cutoff bypass
clutch halves remain separate after the first
release. As a result, there is no torque de- This version of the torque screwdriver with
pendence on the screwdriving time. Noise cutoff clutch extends the application area of
generation and clutch wear are very low. this screwdriver type. The higher torque
However, the constructive demand is rather achieved by cutoff bypass allows the man-
high and therefore cost-intensive. They are ual adjustment of the torque to suit special
mainly used in screwdriving conditions re- screwdriving conditions with a varying de-
quiring superior torque precision, for exam- mand for torque. Typical examples are
ple, for machine screws with nuts. sheet-metal screws, self-drilling screws,
Teks and wood screws. The deactivation of
The automatic cutoff clutch is adjusted on the cutoff clutch makes the opening of cor-
the basis of previous trials, set to suit the roded or super-tight screw connections
specific screwdriving condition and then possible.
fixed in this position. This ensures that it
cannot be changed by the tool operator dur- The deactivation of the cutoff clutch also
ing application. means that the full restoring torque acts on
the user. The torque values can therefore
not be set too high.
Torque screwdrivers with ratchet clutch

Torque screwdrivers with ratchet clutch are
the most common screwdriver type. The
ratchet clutch can be adjusted. When the
torque set by the clutch spring is reached
the clutch halves are separated by slanted
dogs, rollers or balls. As long as the screw-
driver is in operation and pressed forward,
torque peaks as high as the preset torque
act on the screw which is good for the po-
tential settling behaviour of the screw. Short
9
or long ratchet intervals have a limited influ- held high-frequency power tools can reach
ence on the torque level since the rotary im- torque values up to 2000 Nm.
pacts increase the torque slightly.
Ratchet clutches are low-cost, sufficiently Rotary-impact screwdriver:
function and working principle
accurate and low-wearing if properly con-
structed. The release moment cannot be set driving in rotary-impact
as high as you like since it is transferred to
the user through the machine. If the return
torque becomes too high the screwdriving
process can become unpleasant or too hard
to bear. For this reason, torque screwdrivers
with ratchet clutch have a maximum torque
of approximately 30 Nm. M
Ratchet screwdriver:
function and working principle
t
turning slipping torque progression
FM
EWL-VST 009/G
t (s)
1 2 3 4
assembly tension progression
M
Stalling-torque screwdrivers
t
torque progression In the case of the stalling-torque screwdriv-
er the motor cuts out when a predetermined
FM
current value is reached which is in propor-
tion to the desired torque. Stalling-torque
screwdrivers require an external controlling
EWL-VST007/G
device which monitors the motor current,

0,1 0,2 0,3
t (s)
compares it with an adjustable value and ini-
assembly tension progression tiates the motor cutout. When the motor
current reaches the preset value, the power
supply to the tool is switched off and the
Rotary-impact screwdrivers motor stops running.
Rotary-impact screwdrivers are equipped
Stalling-torque control
with an isolated mass-impact hammer mill
and there is practically no restoring torque
effective on the user even in case of high
Stalling torque
torque. The torque takes effect impact by
Torque
impact which is accompanied by a charac-

teristically loud noise. The rotary-impact
torque is constructively predetermined.
Torque limitation takes place through the Load
number of rotary impacts (impact frequen-
cy) or through limiting elements (torsion
Current
bars) placed between screwdriver spindle Switch point

and socket spanner. High-quality rotary-im-
pact screwdrivers are robust and durable.
For practical purposes the maximum possi-
ble torque is limited by the weight of the EWL-HF004/P Load
hammer mill and the machine size. Hand-
10
Selection of HF screwdrivers
Screwdriver type screwdriver with adjustable cutoff clutch screwdriver with adjustable ratchet clutch screwdriver with rotary-impact screwdriver Screwdriver type
stalling-torque control
Application for screw connections with high torque for standard screw connections with average for average to high for high to very high torques Application
precision torque precision torques
Characteristic maximum torque limited due to reactive effect on torque limited due to reaction angle drive ensures good almost reaction-free Characteristic
properties user. torque control properties
User influence no user influence on torque. user influence on torque no user influence low user influence User influence
Construction type body-grip screwdriver pistol centre- body-grip screwdriver pistol centre- D- angle- angle- angle- body- body- centre- D- cross- Construction type
grip grip handle drive drive drive grip grip grip handle grip
Performance 80 W 125 W 170 W 250 W 200... 200 W 80 W 120 W 180 W 250 W 250 W 600 W 170 W 260 W 400 W 80 W 170... 260... 850 W 950 W Performance
categories 400 W 250 W 550 W categories
screw torque torque screw
diameter diameter
quality DIN VDI DIN VDI quality
8.8 (2230) (2230) 8.8
0.1 Nm 0.1 Nm
M2 M2
M 2.2 M 2.2
M 2.5 M 2.5
1 Nm 1 Nm
M3 M3
M 3.5 M 3.5
M4 M4
M5 M5
M6 M6
10 Nm 10 Nm
M8 M8
M 10 M 10
M 12 M 12
100 Nm 100 Nm
M 14 M 14
M 16 M 16
M 18 M 18
M 20 M 20
M 22 M 22
M 24 M 24
1000 Nm 1000 Nm
M 30 M 30
11
Grinding tools Straight grinders

HF grinding tools are renowned for their out- Straight grinders form the largest segment
standing sturdiness and high output power of HF grinders. Motor and tool spindle are
with the smallest dimensions. Since in case arranged in line and the motor and spindle
of indirect cooling the cooling air does not housing serves as the tool handle. The spin-
come into direct contact with rotating motor dle neck of high-power straight grinders has
parts, their operation is also possible in very a special shape and serves as auxiliary han-
dusty environments without reducing their dle. These straight grinders must be operat-
durability by much. ed using both hands at all times. Low-pow-
Grinding tools can be divided up into three er straight grinders can be capable of very
main groups: high rotational speed of up to approximate-
ly 50,000 rpm, their small dimensions allow
straight grinders sensitive working in precision mechanics as
well as tool and mould making. Straight
vertical grinders
grinders are almost exclusively fitted with
angle grinders grinding points or rotating files (milling
points). They are usually operated with one
HF vertical grinders form a rather minor hand. The spindle neck of straight grinders
model segment. of the high performance range serves as an
Because of the commonly high rotational additional handle. These grinders must be
speeds during grinding, machines used pri- operated using both hands at all times.
marily for grinding in industrial plants usual-
ly have an operating frequency of 300 Hz.
The higher motor speeds which can be re-
EWL-HF012/P
alised with this frequency allow the use of Straight grinders different
designs (not true to scale)
simpler transmissions.
SLF-T03
high removal rate
surface grinding
long service life

hard materials
for aluminium
soft grinding
application
casting skin
universal
universal
universal
50,000 rpm, 125 W

peripheral
25...50
25...50
25...50
20...40
15...40
10...20
5...40
20...40
25...50
20...40
speed
m/s
degree of
hardness
M
O
H
18,000 rpm, 400 W

K
L
J
I
Labelling and characteristic properties of grinding points
synthetic resin
synthetic resin
bonding
ceramic
ceramic
ceramic
ceramic
ceramic
ceramic
ceramic
ceramic
18,000 rpm, 1.800 W

special fused alumina
special fused alumina
standard corundum
mixed corundum
mixed corundum
mixed corundum
mixed corundum
silicon carbide
silicon carbide
silicon carbide
abrasive
4,800 rpm, 3.000 W

dark brown
white/blue
red/white
pink/blue
colour
brown
green
green
white
grey
pink
12
Selection of HF grinders (1)
Type Straight grinders
Rotational speed 50,000 30,000 18,000 12,000
Performance categories 100 W 250 W 500 W 100 W 250 W 500 W 500 W 1,000 W 1,500 W 1,800 W 250 W 500 W 1,000 W 1,500 W 1,800 W
mould grinding, deburring
grinding points
tungsten-carbide milling cutters
serrated grinding wheels
internal grinding
grinding points
grinding discs, conical
rough grinding (snagging)
grinding discs, straight
snagging wheels
cutting discs
emery grinding (sanding)
fibre discs
serrated wheels
brushes
cup brushes
polishing
lambswool bonnets
wet grinding
cup brushes
Abrasive Grain Hardness Bonding Texture

Letter symbol Meaning Letter symbol Meaning Letter symbol Meaning Letter symbol Meaning Letter symbol Meaning
A standard corundum 6... 24 coarse A; B; C; D extremely soft V ceramic

B synthetic resin 0 closed
AN standard corundum 30... 60 medium E; F; G very soft
AD special fused alumina red H; I; J; K soft BF synthetic resin
80... 180 fine fibre-reinforced
AR special fused alumina pink L; M; N; O medium
200...1200 very fine 14 open
AW special fused alumina white P; Q; R; S hard
ADW mixture AD + AW T; U; V; W very hard
AWN mixture AW + AN X; Y; Z extremely hard
ARN mixture AR + AN
CN silicon carbide green
CU silicon carbide grey
Z zirconic corundum
13
SLF-T05
Selection of HF grinders (2)
14
Type Straight grinders
Rotational speed 10,000 9.000 8.600 6.800 5.700 4.800
Performance categories 1,200 W 1,800 W 1,000 W 1,200 W 1,800 W 1,500 W 2,000 W 3,000 W 2,000 W 3,000 W 2,000 W 3,000 W
grinding points
internal grinding
grinding points
snagging wheels
cutting discs
fibre discs
serrated wheels
brushes
cup brushes
polishing
lambswool bonnets
wet grinding
cup brushes
Vertical grinders Angle grinders

Vertical grinders are used for surface grind- HF angle grinders correspond in construc-
ing and are operated in vertical position. tion and handling to angle grinders with uni-
Motor and tool spindle are arranged in line, versal motors. Their typical power output
the holding points for the user are located at ranges between 500...3800 watt. HF angle
right angles to the tool housing in the form grinders are used for applications requiring
of a centre grip or pistol grip. High-perform- robust performance characteristics and
ance vertical grinders are equipped with two high output power.
handles which are also arranged at right an-
gles to the tool housing and at an angle
against each other. In this fashion even very Angle grinders different designs
high restoring torques can be safely mas- (not true to scale)
tered. Their performance categories range
from 800 watt to 1300 watt.
Angle grinder
500 W
Selection of HF vertical grinders
Type Vertical grinder
Rotational speed 6,000 5,500 3,500
Performance categories 1,000 W 1,300 850 Angle grinder
mould grinding, deburring 3,000 W
grinding points
internal grinding Wet grinder
1,800 W
grinding points
grinding discs, conical Polisher
snagging wheels 1,800 W
cutting discs EWL-HF013/P
fibre discs
serrated wheels
brushes
cup brushes
polishing
lambswool bonnets
wet grinding
cup brushes
Assignment of rotational speed

to grinding disc diameter
Disc diameter Typical rotational speed
Vertical grinder mm inch rpm
100 4 12000
115 41/2 11000
125 5 11000
150 6 9300
180 7 8500
230 9 6500
300 12 5000
EWL-HF014/P
15
Selection of HF angle grinders
16
Type Angle grinder
Rotational speed 12,000 8,500 6,500 5,000 4,200 1,750
Performance categories 500 W 1,000 W 1,000 1,500 2,000 3.000 1,000 W 1,500 W 2,000 W 3,000 W 3,000 W 3,800 W 3,000 W 1,200 W
grinding points
internal grinding
grinding points
snagging wheels
cutting discs
fibre discs
serrated wheels
brushes
cup brushes
polishing
lambswool bonnets
wet grinding
cup brushes
Building tools
In addition to power tools with universal mo- Internal vibrator
tors the following types of HF power tool are
used in the building trade:
vibrating machines
demolition hammers
5
Vibrating machines form by far the largest
1
segment of HF building tools. Due to the re-
3
quired small unit dimensions of internal vi- 2
brating machines and their high power de- 4
mand at the same time, an operating fre- 1 Motor
EWL-HF015/P
2 Unbalanced mass
quency of 200 Hz has come out on top. 3 Steel jacket
4 Steel cap
5 Connecting hose
Vibrating machines
Vibrating machines are used to compact
concrete with vibrations. The vibrating
process drives air bubbles out of the poured
concrete and fills voids in complex moulds External vibrator
and formwork to improve the homogeneity
of concrete and to increase its strength. The
two types
internal vibration machine

external vibrating machine
are used. The two types are designed differ-

ently. The vibration time depends on the 4
concrete mixture and is limited to prevent
the aggregate mixture from separating. 3 5
Application areas of vibrating machines

Vibrator External vibrator Internal-
type vibrator
oscillation 1,500 3,000 6,000 12,000 12,000
frequency
operating 50 Hz 50 Hz 200 Hz 200 Hz 200 Hz 5 2
frequency
1 Vibrator housing 1
EWL-HF016/P
2 Rotor
application 3 Stator winding
compacting 4 Electrical connection
site concrete 5 Adjustable unbalanced mass
concrete
prefabricated
parts
block making
machines
bulk
materials
mould
making
loosening
silo emptying
filtering
systems
17
Demolition hammers System accessories

HF demolition hammers are highly robust Just like power tools with universal motor,
on account of the positive characteristics high-frequency power tools require exten-
of their rotary-current motor and require sive accessories for the fulfilment of their
little maintenance. They are usually laid specific working tasks. Primarily these are
out for an operating frequency of 200 Hz. the usual application tools such as drill bits,
They can therefore run on the same rotary- abrasives and screwdriver bits which can be
power generators which are commonly used for many purposes. In addition, there
used for vibrating machines. In addition, are the so-called system accessories for HF
400-Hz versions are also available. They power tools which are mainly used for in-
allow operation on the 400 Hz on-board dustrial applications. In particular, these are
systems which are often used in the mili-
tary field. measuring sensors
test equipment
control devices
Demolition hammer
switchgear
spindle extensions
spring pulleys
Test and control devices

EWL-HF017/P
Special demands in reference to the main-

tenance of specific limiting values are
placed on screw connections for machine
components pertinent to safety. This re-
quires the continuing examination of the
tightening torques or alternatively the per-
manent monitoring of the screwdriving
process. Monitoring can take place manu-
ally or by data processing protocols. Testing
requires
measuring sensor
test device (evaluation and display unit)
control device
The measured signal can also be used to

control the screwdriving process. The typi-
cal measuring range covers torque values
between 01...2000 Nm.
18
Measuring sensor
Detecting element (sensor)
The measuring sensor is placed between
the screwdriver bit (or socket spanner) and 4 3
1
the drive spindle. The measuring sensor
usually contains a torsion bar which is twist-
ed in proportion to the transferred torque.
The mechanical twist is converted by sen-
sors into an electric signal and transferred to
the test device. The demands on the meas- 2
ured signal are high. Temperature variations, 1 Sensor
2 Input (from screwdriver)
interference fields and vibrations must be 3 Output (to plug-in socket)
4 Measuring lead
excluded. EWL-HF018.2/P
Foil strain gauges or magnetic sensors (Hall

sensors, eddy-current sensors) are used for
this purpose.
Torque tester
(monitor)
Test device
The measuring sensor delivers an analogue
or digital signal which is displayed in the test
device. Certain limiting values can be en-
EWL-HF018.1/P
tered in the test device for comparison to
the received measured signal. The compar-
ison can lead to switching operations which
monitor the screwdriving process.
Control device Control unit
In addition to testing and monitoring func-

tions, the signal from the measuring sensor
can also be used to directly control the
screwdriving process. For this purpose the Screwdriver type
measured signal is transferred to a control 1 2
device which ends the screwdriving process TRIGGER Vc
5 6
EWL-HF019/P
when the measured signal reaches a pre-set MAINS

3
2
4
Operation Md
limit in the control device. TORQUE
1
Screwdriving
in sec
Impact frequency adjuster

Rotary-impact screwdrivers allow the ad-
justment of the tightening torque by chang- Impact frequency adjuster
ing the number of impacts, the so-called
impact frequency. This requires a control-
gear unit. The no-load current consumption
of the screwdriver is entered into the con-
trol-gear unit during the screwing-in
process. At the beginning of the rotary-im-
EWL-HF020/P
pact phase the power consumption of the

screwdriver increases. This current increase
triggers a time measurement. After a pre-set
period of time has elapsed, the control-gear
unit interrupts the power supply.
19
Spindle extensions Spring pulleys

In mechanical engineering there are often Spring pulleys are used to hold the high-fre-
working situations during the subsequent quency tool within reach of the user and to
machining of cast and welded components compensate the machine weight at the
which require the use of an extension for the same time. Typically the high-frequency
tool spindle. These include, for example, power tools (usually screwdrivers) are sus-
work on air and gas ducts in turbines. In ad- pended from the ceiling in the production
dition to the actual spindle extension high area with spring pulleys. Their tensile force
demands are also placed on the concentric- can be adjusted precisely to match the
ity. This requires in contrast to flexible shafts weight of the machine and allows you to
rigid and at the same time high-precision move it in vertical direction with very little
bearings. Spindle extensions which fulfil effort. The suspension cord rolls up inside
these demands form separate and au- the spring pulley accordingly. As a conse-
tonomous machine components. They are quence the user requires very little vertical
attached rigidly to the driving machine, the force to operate the tool, fatigue is much re-
shaft is connected through a flexible cou- duced by this.
pling with the tool spindle.
Straight grinder with Spring-pulley on assembly line

spindle extension
1
2
3
4 2
EWL-HF021/P
1 Straight grinder 3
2 Spindle extension
3 Tool fitting
4 Tool
1 Spring-pulley roller
2 Suspension cord
3 Tool EWL-HF022/P
20
20 Questions
1. What is high-frequency rotary current for power tools?
2. What are the advantages of rotary current in comparison to compressed air?
3. Which operating voltages do HF power tools have?
4. What is a synchronous converter?
5. Which frequency should be chosen?
6. Which mains group should be chosen?
7. How is the energy demand of HF power tools determined?
8. What is the average power-on period?
9. What is the simultaneity factor?
10. Why is a special wiring system needed?
11. What sort of three-phase motors are used in HF power tools?
12. What does the rotational speed of a three-phase motor depend on?
13. Why is the three-phase motor so robust?
14. What are the special advantages of HF power tools?
15. Why are HF power tools electrically safe to use?
16. How high are the operating costs of HF power tools?
17. What are the characteristic properties of HF drills?
18. Where are the different screwdriver types used?
19. Which types of HF grinders are there?
20. Which system accessories are available for HF power tools?
21
20 Answers
1. What is high-frequency rotary current for power tools? number of pole pairs, for example, and a frequency of 50 Hz re-
High-frequency rotary current for HF power tools is a three-phase sults in a rotor speed of 3000 rpm, a frequency of 200 Hz 12000
alternating current with a frequency range of 200400 hertz (Hz). rpm and 300 Hz 18000 rpm.
2. What are the advantages of rotary current in comparison to 13. Why is the three-phase motor so robust?
compressed air? Three-phase motors for HF power tools are asynchronous mo-
Rotary current can be easily transported across large distances, tors. This type of electric motor has a very simple construction.
distribution networks are simple to install. On and off switching It comes without a collector or carbon brushes. Therefore it is
suffice to immediately initiate or cut off the flow of energy. The nearly maintenance-free and does not wear.
distribution network is maintenance-free.
14. What are the special advantages of HF power tools?
3. Which operating voltages do HF power tools have? The special advantages of HF power tools in comparison to
The most frequent operating voltages are 135 volt and 200 volt. power tools with universal motors can be summarised by the
Other possible voltages are 72 volt and 42 volt. following criteria:
service life
4. What is a synchronous converter? constant speed
These converters are so-called single-shaft machines, i. e. mo- overload characteristics
tor and generator are assembled to form one unit with a com- ergonomics
mon drive shaft. They are compact, have a good efficiency ra- work safety
tio, are technically simple and therefore very robust. operating costs
5. Which frequency should be chosen? 15. Why are HF power tools electrically safe to use?
The motor speed increases at the same rate as the frequency Due to the interlinking factor in three-phase systems the volt-
of the rotary current increases. The motor speed has to be age to earth of an operating voltage of 200 volt amounts to on-
adapted to the spindle speed by a transmission. The spindle ly 153 volt and with an operating voltage of 135 volt only 78 volt
speed of grinding tools is usually high, a frequency of 300 Hz is which is much less in comparison to 230-V power tools with uni-
recommended for them. Screwdriving and drilling tools usually versal motor. And since industrial operations often involve the
have lower spindle speeds. A frequency of 200 Hz is recom- processing of metal in a metal-dominated environment, this is
mended for them. Accordingly one should choose a frequency an additional safety factor.
which suits the majority of tool types used in the HF system.
16. How high are the operating costs of HF power tools?
6. Which mains group should be chosen? The running operating costs of a HF system are very favourable
The ideal, most frequently used mains group is group 2. In this since they do not require energy storage facilities like, for exam-
group a tool for 300 Hz, 200 volt can be operated (without alter- ple, a compressed-air system. They require very little mainte-
ations) on 200 Hz, 135 volt without problems and vice-versa. If nance. There are no leakage losses as in compressed-air systems.
possible one should therefore choose either a voltage of 135 V Additional consumer connections can be installed with little effort.
for 200 Hz or 200 V for 300 Hz. The relatively high initial investment costs will pay off soon.
However, one has to note that the motor speed changes ac-
cording to the applied frequency. In the case of grinding tools 17. What are the characteristic properties of HF drills?
this change in speed can affect safety and has to be taken into HF drills are in comparison to drills with universal motors of the
account at all costs! same performance category much smaller in size. Because of
the commonly low rotational speeds during drilling, machines
7. How is the energy demand of HF power tools determined? used primarily for drilling - and screwdriving in industrial plants
By the addition of all individual consumptions according to the usually have an operating frequency of 200 Hz. The low motor
technical specifications of the manufacturer and by including all speeds which can be realised with this frequency allow the use
correction factors. of simple transmissions.
Typical construction types are pistol drills in the lower to medi-
8. What is the average power-on period? um performance range, machines with D-handle or cross-han-
Usually not all HF tools are operated at the same time. Due to dle in the medium to high performance range.
interruptions between individual applications they are switched
on and off as required. This varies depending on the tool type. 18. Where are the different screwdriver types used?
Grinding tools usually operate for longer periods of time, screw- The screwdriver types are selected according to their special
driving tools usually have extended breaks. The average value, area of application. Their application can be roughly described
usually converted to the period per hour during which the tool as follows:
is switched on, is called the average power-on period. torque-limit screwdrivers: low to average torque values. Man-
ufacturing businesses, assembly
9. What is the simultaneity factor? cutoff screwdrivers: low to average torque values. Manufac-
If a large number of HF consumers are installed in a plant, ex- turing businesses
perience shows that all consumers are never used at the same torque screwdrivers with cutoff clutch and cutoff bypass: low
time since most operations take place after one another and in- to average torque values. Assembly and installation works re-
dependent in duration of each other. The proportion of time dur- quiring variable torque settings for different screwdriving con-
ing which theoretically all consumers are used simultaneously ditions and the occasional opening of frozen bolts and nuts.
is known as the so-called simultaneity factor and enters the cal- stalling-torque screwdrivers: low to average torque values.
culation in conjunction with the power-on period as a factor re- manufacturing businesses.
ducing the air demand. rotary-impact screwdrivers: high to very high torque values.
Assembly, structural steel engineering, vehicle construction,
10. Why is a special wiring system needed? service
The wiring systems for HF systems differ basically from the
wiring systems for common network frequencies of 50 or 60 Hz. 19. Which types of high-frequency grinders are there?
The reasons for this are the effects which become noticeable at Typical grinder types are:
higher frequencies: straight grinders
skin effect angle grinders
electromagnetic emission. vertical grinders
These effects have an influence on the dimensioning and con- Within the group of high-frequency grinders, straight grinders,
struction of the cables and the type of installation. especially with small and smallest dimensions, are the predom-
inant tool type. Vertical grinders are mainly used for heavy-du-
11. What sort of three-phase motors are used in HF power tools? ty and rough work (foundry) in the upper performance range,
The drive motors for HF power tools are asynchronous motors. while angle grinders in the medium performance segment can
Instead of using rotary current of the network frequency of 50 be used universally.
Hz they are powered by rotary current with an increased fre-
quency of 200 or 300 Hz. By increasing the frequency the rota- 20. Which system accessories are available for HF power tools?
tional speed of the motors can also be increased. The motors The typical system accessories for high-frequency power tools
of "high-frequency power tools" are therefore much smaller include in addition to accessories typical for standard power
while delivering the same power which makes them suitable for tools especially:
use in handheld power tools. measuring sensor
test equipment
12. What does the rotational speed of a three-phase motor depend control devices
on? switchgear
The rotational speed of a three-phase motor depends on the spindle extensions
number of pole pairs and the frequency. The smallest possible spring pulleys
22
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Sales Consulting Training ET LEXICON LEXIQUE

Handheld high-frequency power tools 5

High-frequency power tools

How it all began

Drilling of rivet holes

(Source: German large-scale manufacturers, 1938) Assembly of passenger car motor

Handheld high-frequency power Ergonomics

Service life Operating costs

950 watt 1450 watt

Thread-cutting machines Screwdrivers

1 no-load operation = counterclockwise Angle screwdriver

2 slight pressure = standstill

4 draw back = counterclockwise rotation

Constructions and types Centre-grip screwdrivers

angle screwdrivers k 250 watt

Because of the restoring torques produced k 260 to 550 watt

In the upper performance categories the

Their torque ranges from 10...100 Nm.

These working principles are available in dif- t

Progression of assembly tension force

Torque screwdrivers with ratchet clutch

device which monitors the motor current,

impact which is accompanied by a charac-

bars) placed between screwdriver spindle Switch point

Grinding tools Straight grinders

long service life

50,000 rpm, 125 W

18,000 rpm, 400 W

18,000 rpm, 1.800 W

special fused alumina

4,800 rpm, 3.000 W

Abrasive Grain Hardness Bonding Texture

A standard corundum 6... 24 coarse A; B; C; D extremely soft V ceramic

Vertical grinders Angle grinders

Assignment of rotational speed

internal vibration machine

are used. The two types are designed differ-

Application areas of vibrating machines

Demolition hammers System accessories

Test and control devices

Special demands in reference to the main-

The measured signal can also be used to

Foil strain gauges or magnetic sensors (Hall

Control device Control unit

In addition to testing and monitoring func-

measured signal is transferred to a control 1 2

device which ends the screwdriving process TRIGGER Vc

when the measured signal reaches a pre-set MAINS

Impact frequency adjuster

pact phase the power consumption of the

Spindle extensions Spring pulleys

Straight grinder with Spring-pulley on assembly line