EW-BILDUNGSCLUB FERNLEHRBRIEF

MEHR WISSEN MEHR ERFOLG POWER

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High-frequency technology

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 High-frequency technology
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 High-frequency technology

Contents
High-frequency technology
Foundations 4
Alternating current 4
Rotary current 4
Voltage 5
Current 5
Frequency 5
Power 5
Active power 5
Reactive power 5
Apparent power 5
Power factor 6
Electric motors 6
Three-phase motors 6
Synchronous motors 6
Asynchronous motors 7
EC motors 8
Shielding 8
Rotational speeds 9
Torque 9
Control methods 9
Rotation control 9
Stalling-torque control 10
Load capability 10
Cooling 10
Heat emission 10
Forced cooling 11
Surface cooling 11
Direct open-circuit cooling 12
Indirect open-circuit cooling 12
Gearing 12
Spur gearing 12
Planetary gearing 12

HF systems 13
Power demand 13
Simultaneity factor 13
Sample calculation 13
Frequency selection 14
Mains group 14
Converter systems 15
Static converters 15
Dynamic converters 15
Switching stations 16
Reactive-current compensation 16
Wiring systems 16
Skin effect 16
Electromagnetic emission 17
Installation requirements 17
Dimensioning 17
Sample calculations 18
Electric safety 20

3
 High-frequency technology

Foundations
AC voltage
There are major technological differences
between handheld high-frequency power U Period duration
tools and the common power tools with uni- +
versal motor used by tradesmen and in the
DIY sector. They use three-phase alternat-
U
ing current, also known as rotary current, as 0
t
their power supply. Due to the increased fre-
quency of the rotary current for these tools
they are also known as high-frequency U
- 0 90 180 270 360
power tools although this term is technical-
ly not quite correct. The term high-frequen- EWL-HF002/P

cy actually refers to alternating currents in

the range of radio frequencies. Technically
correct, the alternating currents used in the
case of the so-called high-frequency (HF)
power tools are referred to as alternating
currents of increased frequency or rotary AC DC
currents of increased frequency. Still, the
Single-phase alternating current
term HF power tool has been established in
the market for a long time and is therefore U
+
generally accepted.
In order to understand the special charac-
0
teristics of HF power tools, one has to know t
the meaning of the technical terms
U
-
alternating current
rotary current Three-phase alternating current
(rotary current)
frequency
U 1 2 3
voltage +

current
0
apparent power t

active power U
-
120
reactive power
Phases offset by 120
cosine phi(power factor)
EWL-HF003/P

as well as their definitions and significance.

Alternating current Voltage

Alternating current is a current which
changes in quantity and direction. Its volt-
age passes through zero as the polarity
changes.
Rotary current
Rotary current is a system of three alternat-
ing currents offset against each other by
120.
Electric voltage (U) is a measure for the dif-
ference in potential between the poles of an
electric source of energy. Its unit of meas-
urement is volt (V) .
The transfer of electric energy from the point
of generation to the consumer is accompa-
nied by losses in the power lines which re-
duce the voltage at the consumer end.

4
 High-frequency technology
Current
If a voltage is applied in a closed electric
circuit, electric current (I) will flow through
the connected consumers according to
their resistance. It is measured in ampere
(A). The current heats up electric conduc-
tors and appliances and causes voltage
losses. Its calculated quantity is used to-
gether with the voltage to determine the
electric power.
Frequency
In electrical engineering, frequency ( f )
refers to the number of periods (voltage
changes) per unit of time. The unit of meas-
urement is hertz (Hz). In the majority of
countries around the world the public pow-
er supply has a mains frequency of 50 hertz
(Hz). In some countries like the United
States 60 Hz is the standard frequency.
Power
The most important criteria to assess the
performance of a consumer is its output
power (P), i. e. its capacity to absorb electric
energy and convert it to another form of
energy. The unit of measurement for power
is watt (W).
The power supplied by the source of ener-
gy (input power) is distinguished on the ba-
sis of its type and functional principle in
active power
reactive power
apparent power
The power calculation uses the following
formula symbols
current I measured in A (ampere)
voltage U measured in V (volt)
power P measured in W (watt)
In addition there are three different power
specifications:
apparent power PS in VA or kVA
active power P in W or kW
reactive power Pq in var
Active power
Active power generates a directly usable ef-
fect in electric consumer products, e.g. the
temperature increase of a heater coil, the
emission of light from a lightbulb or the work
of an electric motor. The consumed active
power is therefore converted into heat, light
or mechanical work.
The active power is calculated as follows
(example):
P = U
I
cos = 230 V
3 A
0.8 = 552 W
J
Reactive power
Reactive power is needed to build up the
magnetic fields in the coils of electric mo-
tors, transformers and series inductors, e.g.
for fluorescent lamps. Reactive power is not
actually consumed. It flows back and forth
between the generator and the consumer
and functions like a catalyst it is not con-
sumed itself, but without it nothing will work.
The reactive power indicates how much of
the apparent power can be utilised. It con-
stitutes an extra load for the wiring since it
commutes back and forth between con-
sumer and generator.
The reactive power is calculated with the
following formula:
Pq = U
I
sin J
Q = g PS - P
2 2
The power factor cos indicates which por-
J
tion of the apparent power can be effective-
ly used.
Apparent power
The apparent power is the geometric sum of
active and reactive power. It can be cal-
culated as the product between voltage and
current. The active power is smaller by
the power factor cos than the apparent
J
power.
The apparent power is calculated with the
formula:
PS = U
I = 230 V
3 A = 690 VA
5
 High-frequency technology
Power factor cosine J (phi)
All inductive consumers, such as motors,
generators and transformers, have a power
factor, cos (cosine phi). The power fac-
J
tor cos indicates which portion of the
J The rotor can come in one of several ver-
apparent power can be effectively used.
The power factor can be expressed as the
ratio between active and apparent power.
P largely determined by these rotor types.
cos =
J
PS
Power tools with universal (collector) mo-
tors have a power factor of approximately
0.9 1.0 which can be neglected.
Machines and machine tools with rotary and
alternating current motors have a power
factor of approximately 0.8 which has to be
taken into account at all times.
Electric motors
Electric motors convert electric energy into
mechanical energy. They consist of a sta-
tionary part (stator, pole shoe) and a rotating
part (rotor, armature). Electric coils (wind-
ings) generate magnetic fields in stator and
rotor which create a force between stator
and rotor, thus producing the torque at the
rotor. In order to be able to conduct the mag-
netic fields both the stator and the rotor (or
parts thereof) are made of iron. In case of
temporary magnetic currents (alternating
voltage) this iron core must be constructed
of several mutually insulated metal sheets.
The spatial arrangement of the coils and
their electric circuitry has lead to different
electric motor designs. The differences in
their performance characteristics are in
some cases quite considerable and there-
fore they are used in different application
areas.
Three-phase motors
The stator of a rotary-current motor consists
in its simplest version of three windings,
usually, however, of a multiple of three
which are symmetrically arranged around its
periphery. The three phases of the rotary
current generate a rotating magnetic field
(rotary field) whose number of revolutions
per unit time results from the frequency of
the rotary current and the number of pole
pairs.
6
The rotational speed cannot be modified by
changing the applied voltage, but only by
changing the number of pole pairs and/or
the frequency of the rotary current.
sions: the so-called squirrel-cage rotor
(slipring rotor), cage rotor or the so-
called magnet wheel. The characteristic
properties of rotary-current motors are
Consequently, three-phase motors are di-
vided up into
synchronous motors
asynchronous motors.
Synchronous motors
The stator of a synchronous motor contains
copper windings on an iron core. In the rotor,
which in the case of the synchronous motor
is called magnet wheel, the poles are mag-
netised with the help of direct-current coils
or permanent magnets. The necessary di-
rect current is supplied to the magnet wheel
via sliprings and carbon brushes. The iron
core of the magnet wheel need not be made
of mutually insulated laminated metal
sheets since it is d.c.-operated. Therefore it
can be made of solid stock whereas the sta-
tor whose coils are operated with alternating
current must be made of metal sheets. If the
magnet wheel rotates at the same speed as
the rotary field (in synchronism) a torque is
generated which is dependent on the angle
of the magnet wheel. In case this synchro-
nism is lost (rotational speed from rotary field
in stator and rotational speed of rotor) unac-
ceptably high currents will flow.
For this reason synchronous motors would
be unable to start by themselves. With con-
structive auxiliary measures, a type of auxil-
iary cage (asynchronous motor), self-start-
ing is possible. As is the case with asynchro-
nous motors, the rotational speed of a self-
starting synchronous motor can be modified
only by changing the number of pole pairs
and/or the network frequency, but not by
changing the voltage. Both synchronous and
asynchronous motors reverse their rotational
direction by exchanging two phases.
Self-starting synchronous motors are used
for applications requiring a driving mecha-
nism with constant rotational speed inde-
pendent of load.
 High-frequency technology

Asynchronous motor The construction of an asynchronous motor

is very simple. It is nearly maintenance-free
In addition to a stator with its windings the
and not subject to wear, low-cost and has
simplest version of an asynchronous mo-
outstanding properties especially during
tor is equipped with a rotor consisting of a
stationary operation. It is one of the most
laminated iron core with aluminium or cop-
frequently used electric motors in drive en-
per bars cast or pressed into its slots.
gineering.
These bars are connected on both front
edges of the rotor by rings of the same
material and therefore electrically short-
Three-phase-current circuit types
circuited. If you look at these bars without
the iron core, they resemble a kind of cage Three-phase system
which is why this type of rotor is also L1
known as a cage rotor. However, if the L2
rotor is made up of a laminated iron core L3
with windings in its slots we are talking N
about a so-called squirrel-cage rotor or Voltage Voltage
slipring rotor because the windings are 230V 400V
each each
short-circuited either directly by carbon
Star connection
brushes on the slipring ends or indirectly
by electric resistors. Differences between L1 V1
the rotor speed and the rotational speed of V2
V2
the rotary field induce voltages in the N
V1
short-circuited windings or bars. These in W2
L3 W1
turn produce currents which generate the
rotor torque .
L2
The deviation of the rotor speed from the
230V are present at each
speed of the rotary field gives the motor its consumer coil (motor).
name: the speed characteristics are asyn- The neutral conductor is
connected to the neutral point
chronous. in the event of asymmetrical load.

This particular deviation is called slip. The Star connection

higher the slip, the higher the losses in the
L1 V1
motor and the heat development. For prac- W2
tical purposes asynchronous motors must W1
L3 V2
be dimensioned in such a fashion that their
V2 V1
EWL-INT004/P

slip at rated load is less than 5 %. L2

Since the slip is at its highest during starting 400V are present at each
from standstill, very high power losses are consumer coil (motor).
experienced at the start due to the very high
starting currents which place a heavy strain
on the mains power supply and also the
motor windings. For this reason a so-called Wechselstrommotor
Key components
Die wichtigsten of a DC motor
Bestandteile eines W
star-delta connection is required for larger 1 2 3 4 5
asynchronous motors with an operating
voltage of 400 volt.
The start takes place in star connection. 1 Front motor bearing
During this phase 230 volts are applied to 2 Fan wheel
EWL-EM005/G

3 Rotor (iron core with encapsulated

the windings (in a 230/400 volt system). aluminium rods)
The current is accordingly smaller. Once 4 Rear motor bearing
5 Stator (with iron core and copper windings)
the motor has attained its rated speed the
windings are connected in delta. Now they
are supplied with 400 volt and the motor
can deliver its full torque under load.

7
 High-frequency technology
Asynchronous motors for high-frequency
power tools
Instead of using rotary current of the network
frequency 50 Hz the drive motors for HF
power tools are operated with rotary current
of increased frequency of 200 or 300 Hz. By
increasing the frequency the rotational
speed of the motors can also be increased.
The motors of high-frequency power tools
are therefore much smaller while delivering
the same power which makes them suitable
for use in handheld power tools.
Electronically commutated three-phase
motors (EC motors)
Synchronous motors can only be operated
with rotary current, but not with direct cur-
rent, since direct current does not generate
a rotary field in the stator windings. If three-
phase motors still have to be operated with
direct current, it has to be first transformed
into rotary current by a power inverter. By
using modern semiconductor and control
technology this can be realised for nearly all
performance ranges. The most important
components of the electronically commu-
tated DC motor (EC motor) are a magnet
wheel activated by a permanent magnet, a
sensor which detects the position of the
magnet wheel within the stator and supplies
the control and performance electronics
with data on rotational speed and position.
The magnet-wheel-dependent commuta-
High-frequency
body-grip impact wrench
2
3
4
5
6
7 3 Fan wheel
8
tion of the current in the stator windings
produces a rotary-current-like rotary field
whose rotational speed (frequency) can be
adjusted and modified across a wide range
by electronic control or alternatively by the
level of voltage applied to the power invert-
er. In addition, the motor performance char-
acteristics can be influenced by adjusting
the commutation angle.
If you disregard the expense for control and
performance electronics EC motors have
the following advantages: high operational
flexibility, low power-to-weight ratio, wide
speed adjustment range, dynamic braking.
They are quiet-running and not subject to
wear except for the magnet wheel bearing.
Their field of application ranges from appli-
cations in electronics and in machine tools
to drive motors for submarines.
Shielding
The operation of electric motors with alter-
nating current of increased frequency gen-
erates electromagnetic interfering radiation
(radiated noise). For this reason the motors
must be magnetically shielded. This is
achieved by enclosing the motors in a met-
al casing. Therefore, and in contrast to pow-
er tools with universal motors, HF power
tools will always have a metal casing. In
cases where this is useful for ergonomic
reasons, the (inner) metal casing is
sheathed by an (external) plastic casing.
1
1 Switch
2 Asynchronous motor
4 Planetary gearing
5 Impact system with
EWL-HF001/P
V-groove control
6 Tool fitting
7 Tool
 High-frequency technology

Rotational speeds
Power and speed in dependence on load
When the stator winding of the motor is
Output Speed
connected to the three-phase mains, a power (W) (rpm)
magnetic field is formed with the character- peak output
istic property to rotate in the motor due to
the arrangement of the winding. This is output power
called a rotary field which is dependent on
the number of pole pairs and the frequency.
The smallest possible number of pole pairs, 3-5% speed
for example, and a frequency of 50 Hz re-
sults in a rotary field or rotor speed of 3000
rpm, a frequency of 200 Hz 12000 rpm and rated power

EWL-HF003/G
300 Hz 18000 rpm.
The speed drop at rated load amounts to input power (W)
only 35 %, and the peak power is approx-
imately 21/2 times the rated power. Short-
term overloading is possible if the maximum
winding temperature is not exceeded in the Electric machines
AC motor
process. (asynchronous motor)

Frequency and rotational speed in n idling speed

dependence on the number of pole
rotational speed

pairs of the motor

pole pair motor motor motor motor motor
count speed speed speed speed speed
of at at at at at
motor 50 Hz 60 Hz 200 Hz 300 Hz 400 Hz*
rpm rpm rpm rpm rpm
1 3000 3600 12000 18000 24000 load MK M
2 1500 1800 6000 9000 12000 The rotational speed changes very
4 750 900 3000 4500 6000 little as the load increases.
When the so-called breakdown
6 500 600 2000 3000 4000 torque Mk is reached, the motor
* often used frequency in military engineering and air- will stop.
EWL-EM004/P
craft and space technology

Torque
As the load is increased the rotor falls be-
hind the rotary field of the stator, i. e. the slip
increases too. The motor tries to compen-
sate this by increasing the current which
leads to an increase in torque. Therefore,
the torque increases as the load becomes
higher. However, this increase has its limita-
tions. If the load is increased further and a
certain maximum torque, the so-called
stalling torque, is reached the slip becomes
so large that the rotor is unable to follow the
rotary field. The motor torque breaks down
abruptly and the motor stops.
Control methods
High-frequency power tools are usually op-
erated at a fixed rotational speed. The tool
speed depends on the number of pole pairs
of the motor, the frequency and the trans-
mission reduction ratio.
In principle, the rotational speed can be
controlled by varying the frequency through
an electronic power inverter. HF power tools
for screwdriving can limit their torque by
making use of the higher motor current in
case of increasing load.
Rotation control
In order to change the direction of rotation
one has to reverse the direction of rotation
of the rotary field. In three-phase motors
this is done by swapping two phases on the
stator winding.

9
 High-frequency technology

Load capability of electric motors

Reversal of rotational direction in a
3-phase AC motor The load capability of an electric motor is
polarity reversal of field winding generally limited by the heat losses gener-
ated in it. The heat loss is physically deter-
L1
mined by its efficiency and can not be pre-
L2 vented altogether. For practical purposes
L3 this means that a motor whose heat losses
are not dissipated continues to heat up until
the winding insulation melts and the motor
L1 burns out as a result of the winding short-
circuit. The heat loss has to be able to leave
L2
the motor. The better the heat loss is re-
L3 moved from the motor, the less or the slower
it will heat up and the less or the later will it
tend to burn out.
EWE-009.3/G

rotor (armature)
electro magnet (pole shoe) Efficiency

30% 10%

Stalling-torque control 60%

If the load of the rotary-current motor is in-

creased until the stalling torque is reached,
the current increases in accordance with the 100%
load in a characteristic way. This current in-
crease can be utilised for control purposes.

EWL-EM012/G
This requires an external control device. The 100% Power input
current consumption in proportion with the -30% Heat losses in motor
torque is compared with an adjustable val- -10% Friction losses in the gear
= 60% Power output
ue. When the motor current reaches the
preset value, the power supply to the tool is
switched off and the motor stops running.
Cooling
Two methods are mainly used for heat dis-
Stalling-torque control
sipation, or expressed more in line with
practical application, for cooling:
Stalling torque
heat emission (convection)
Torque

forced cooling with fan

Load Heat emission

This function is like a radiator: the motor
emits the heat to the surrounding compo-
Current

Switch point
nents and the air. The effect is very limited
since the motor is usually very compact and
built into a machine housing with cooling air
EWL-HF004/P Load slots which for reasons of safety (contact
with live or rotating components) cannot be
as large as necessary. Heat emission has
therefore only a very minor cooling effect.

10
 High-frequency technology

Forced cooling with fan The following cooling methods for motors
with forced cooling have gained accep-
A fan ensures much better cooling. By
tance:
special construction of the air ducts the
cooling air stream can be optimised in surface cooling
such a fashion that the heat dissipation is
improved even if the fanning power is low. direct open-circuit cooling
For constructive reasons the fan wheel in indirect open-circuit cooling
power tools is always mounted on the ro-
tor shaft and therefore it rotates at the
same rotational speed as the motor. The
fanning power is dimensioned to ensure Cooling variations of different
electric motor types
that the heat loss generated by a motor at Motor cooling (examples)
the rated power (= 100 % full-load power) Universal motor
is dissipated in such a fashion that the Inner cooling (direct cooling)
motor will not overheat even in case of 1 2 3 4
continuous operating duty. If the motor is
loaded beyond its rated power the addi-
tional heat loss can no longer be com-
pletely dissipated and the motor will
sooner or later overheat and burn out un-
less the load is reduced. A disadvantage AC motor
for the motor cooling at motor speed is Surface cooling
2 3 4 5 6 1
that the rotational speed drops with in-
creasing load. Here you have a contra ef-
fect:

The hotter the motor becomes, the worse

the cooling power since the fanning pow-
er drops dramatically with decreasing
speed.
The fanning power changes in square with
the rotational speed. For practical pur-
poses this means that the fanning power,
for example, at half the speed is not re-
duced to 50 %, but to 25 %! If the over-
load condition persists the motor will
eventually burn out.
A larger motor can accommodate more
heat and can be overloaded for longer pe-
riods than a smaller motor. On the other
hand, it takes longer to cool back down.
Smaller size motors have a larger surface
area in comparison to their volume and do
not take as long to cool down.
After overloading the motor must be given
the opportunity to run at less than the
rated load for some time, at best at idling
speed, in order to cool down again.
Bosch Industrial Tool
Direct, dust-proof cooling
1 2 3 4
1 Ventilator 2 Stator (pole shoe)
3 Rotor (armature) 4 Housing
5 Cooling fins 6 Air duct
Air flow direction EWL-EM013/G
Surface cooling
In the case of surface cooling the cooling
air is blown by an externally installed fan
through air guides over the heavily ribbed
motor housing. The inside of the motor
housing is usually completely enclosed.
This cooling method is insensitive to dust,
but not very effective since the motor heat
has to penetrate to the housing surface first.
This cooling method is typical for stationary
machines.

11
 High-frequency technology
Direct open-circuit cooling
Direct open-circuit cooling means that the
cooling air is blown directly through the mo-
tor. This method is highly effective since the
air flows directly through the rotor and the
stator. The disadvantage is that dust in the
air is also blown through the motor and can
damage the windings in the long run. Direct
open-circuit cooling is typical for power
tools with universal motors whose collec-
tors become very hot during operation due
to their working principle.
Indirect open-circuit cooling
This cooling method implies that cooling air
circulates between motor housing and sta-
tor winding. And since the main heat in
three-phase motors is generated by the sta-
tor windings, this cooling method is best for
this type of motor. It has the advantage that
the dust usually carried by the cooling air is
kept from coming into contact with rotating
motor parts and that the service life of mo-
tors cooled in this fashion is much extend-
ed. This cooling method has proven highly
beneficial for HF tool motors.
Transmission
Apart from very few exceptions, the rated
speed of the motor which is determined
by the pole number and the network fre-
quency, differs from the desired rotational
speed of the application tool (spindle
speed). For practical purposes gear drives
are used to adapt the two rotational
speeds to each other. Depending on appli-
cation and machine type, certain transmis-
sions are especially advantageous. The
following types are used:
spur-gear units
planetary-gear units
12
Spur-gear units
Spur-gear units represent the archetypal
transmission type and require only few
components. Their axles are arranged in
parallel. Several transmission stages
(speeds) can be connected in series, every
stage implementing a reversal of rotational
direction. If the difference in diameter be-
tween two gear wheels of one stage is very
large, the smaller gear wheel is called a pin-
ion. Spur-gear units are low-cost, but they
require a relatively large amount of space.
Each pair of gear wheels has only a few
teeth engaged at once and high torque
transmissions require the use of large gear
teeth.
Bevel-gear units also belong to the spur
gearing type.
Gear types
spur gear
EWL-GET001/G
planetary gear
Planetary-gear units
In its simplest form planetary gearing con-
sists of a sun wheel, a ring gear wheel and
the bracket-mounted planetary gears. The
arrangement is coaxial, with clutches and
brakes on the ring gear wheel or the brack-
et of the planetary gears, one can achieve
different transmission speeds which can be
shifted under load.
Planetary-gear units always have several
teeth and gear wheels engaged under load.
For comparable loads planetary-gear units
can be dimensioned smaller than conven-
tional spur-gear units.
 High-frequency technology
HF systems
In comparison to the public power supply
network high-frequency systems have to be
regarded as autonomous installations with
their own source of energy and particular
consumers. Therefore they have to be
planned as a self-contained system.
Power demand
HF system are equipped with their own
source of energy, a frequency converter.
The secondary power output of the convert-
er or alternatively its size is determined as
follows:
The intended high-frequency power tools
are grouped by motor size and number, and
then their rated power consumptions are
added together. The sum of the rated cur-
rents is multiplied with the operating volt-
age and the factor gVVV
3 to calculate the total
apparent power consumption of the tools.
This is the formula:
3
U
I = 1.73
U
I
PS = gVVV
The apparent power value calculated in this
fashion has to be multiplied by the simul-
taneity factor G in order to determine the
secondary power output of the converter.
The simultaneity factor G represents the op-
erating ratio of the tools since usually not
all tools are operated at the same time.
Simultaneity factor
The simultaneity factor indicates how many
tools in an installation are operated on aver-
age at the same time. The simultaneity fac-
tor depends on the application area of the
tools. The following are experience values
for the simultaneity factor G:
car body making 0.45
motor construction 0.30
apparatus engineering 0.40
machine tool and mould making 0.25
structural steel engineering 0.50
foundries 0.60
These values only apply if there are a large
numbers of machines. If the machine num-
ber is low the simultaneity factor is deter-
mined by the largest and most frequently
used tools.
During the planning of a high-frequency
power tool system the frequency converter
is always dimensioned with a reserve. Due
to the starting currents during switch-on,
particularly in case of small-scale systems
the reserves have to be calculated such that
the power output is at least twice as high
as the rated power consumption of the
most powerful of the connected high-fre-
quency power tools. This is necessary to
ensure the perfect starting of the tools. In
addition, the voltage drop in the frequency
converter will not be quite as strong in case
of a short-term overload.
Sample calculations
In a foundry 3 high-frequency angle grinders
200 V, 300 Hz, 10 A are to be operated in
conjunction with 3 high-frequency straight
grinders 200 V, 300 Hz, 6.4 A. (The current
and voltage values are taken from the cata-
logue data)
Calculation:
Group 1:
3 angle grinders 3
10 A = 30.0 A
Group 2:
3 straight grinders 3
6.4 A = 19.2 A
Sum 49.2 A
13

The apparent power is calculated as fol-
lows:
PS = 1.73
U
I
PS = 1.73
200 V
49.2 A
PS = approximately 17023 VA
PS = approximately 17 kVA
This value is then multiplied by the simul-
taneity factor G = 0.6 for foundries:
Converter apparent power:
PS
G = 17 kVA
0.60 = 10.2 kVA
In this case a converter with 11 kVA output
power is chosen to allow for a power re-
serve of approximately 10 %.
Frequency selection
Rotary current of increased frequency of 200
or 300 Hz allows handheld tools to deliver
high electric output power with a low motor
weight. With increasing frequency of the ro-
tary current the motor speed increases at the
same ratio and with it the output power of the
asynchronous motor. The speed is limited by
the maximum permissible peripheral veloc-
ity (operating speed) of the tools.
This optimum power-to-weight ratio is one
of the features of high-frequency power
tools operated at a frequency of 200 to
300 Hz. Larger transmissions are required in
the case of larger differences between
motor and operating speed. As a result, the
weight saving of the rotary-current drive
motor is neutralised by the higher weight of
the transmission gears.
High-frequency systems equipped exclu-
sively with grinders should be operating
with 300 Hz. This ensures favourable trans-
mission speeds at high rotational speeds.
Operating frequency and machine weight
Weight (kg)
optimum
0 100 200 300 400
Frequency (Hz)
EWL-HF001/G
14
High-frequency technology
Mains groups
Six combinations have gained acceptance
as mains groups (frequencies with allo-
cated voltage). The ideal, most frequently
used mains group is group 2. In this group
a tool for 300 Hz, 200 volt can be operated
(without modifications) on 200 Hz, 135 volt
without problems and vice-versa. If possi-
ble one should therefore choose a voltage
of 135 V for 200 Hz and 200 V for 300 Hz.
The operation on different voltages within
the same mains groups is possible be-
cause the frequency-dependent imped-
ance (a.c. resistance) of the stator wind-
ings allows a lower current to flow through
the windings at the higher frequency than
at the lower voltage of the lower fre-
quency. And, since the product of current
and voltage, the power consumption, re-
mains the same in both cases, the motor
will not be overloaded.
However, one has to note that the motor
speed changes according to the applied
frequency. In the case of grinding tools
this change in speed can affect safety and
has to be taken into account at all times!
Mains groups
frequency frequency
200 Hz 300 Hz
Mains groups
group number voltage voltage
1 265 V
2 135 V 200 V
3 72 V 110 V
4 72 V
7 42 V
10 42 V
Ideal mains group
If two voltages are specified in one mains group this
means that one and the same power tool can be op-
erated on both voltage/frequency combinations.
(Exception: grinding tools higher frequency = higher
rotational speed!)
total
weight
weight
of
transmission
weight
of
motor
500
 High-frequency technology

Converter systems As a rule, frequency converters with a pow-

A converter system for high-frequency pow-
er tools can be dimensioned along different
criteria which have to suit the operational
requirements. You can always choose be-
tween different solutions by comparing their
advantages and disadvantages. The follow-
ing converter types are used for HF power
tools:
static converters
dynamic converters
Static converters
This converter type, also known as power
inverter, initially rectifies the applied mains
voltage which is then electronically con-
verted to the desired frequency. Power in-
verters work with power semiconductors
and do not have any moving parts subject
to wear.
Static converters are mainly used for
smaller systems up to approximately 5 kW.
Since they function without noise genera-
tion, they can be placed directly at the
workplace.
er output of over 4 kVA should not be con-
nected directly to the mains, but through a
star-delta switch. A direct power-on pro-
duces a short-term current inrush which
could place a heavy strain on the wiring
leading to converters of more than 4 kVA
and trigger the series-connected fuses. If a
star-delta connection is used the current in-
rush is reduced since in comparison to di-
rect connection only one third of the current
will flow. The star-delta switch is used to
switch the windings of the drive motor
through star (starting mode) to delta (oper-
ating mode). A frequency converter to be
operated on a 400-V system with a star-
delta switch must above all be designed for
400 V in delta. If the converter is only di-
mensioned for 230 V in delta, it can only op-
erate in a 400-V system directly in star, i. e.
without being started by using the star-delta
switch. This must be taken into account
during the dimensioning of a new HF sys-
tem.
Converter
(single-wave converter)

Dynamic converters
Dynamic converters, also known as rotat-
ing converters, consist of a motor operating
at network frequency and a generator pro-
ducing the high-frequency. They are the
most frequently used converters for HF
power tools. EWL-HF005/P

A combination of an asynchronous motor

and a synchronous generator is the best
technical solution. The converters are so-
called single-shaft machines, i. e. motor and
generator are assembled to form one unit
with a common drive shaft.
The formula to calculate the output frequen-
cy is:
f2 = f1
p2 /p1
f1 = input frequency of the three-phase
mains
f2 = output frequency for high-frequency
power tools
p1 = number of pole pairs of drive motor
p2 = number of pole pairs of generator

15
 High-frequency technology

Switching stations
skin effect
In order to increase the economic efficiency
of a plant, two or more small converters electromagnetic emission
controlled by a switching station are usual-
ly preferred to one large converter. These effects have an influence on the di-
Frequency converters can be connected in mensioning and construction of the cables
parallel to compensate for peak loads. This and the type of installation.
ensures an optimum adaptation to the ap-
plied tools. Frequency converters with syn-
chronous generators allow the operation of
units with different performance values Skin effect
without having to take special measures.
The term skin effect describes the charac-
Another advantage of switching stations is teristic property of an electric current to
that they allow the temporary shutdown of move to the surface of the conductor as the
individual converters to carry out repair and frequency increases. In extreme cases (at
maintenance without having to deenergise very high frequencies) this has the effect
the entire system. that current will flow only on the surface
(skin) of the conductor while the cross-
sectional surface inside the conductor be-
Reactive-current compensation haves like an insulator. This is also known as
the inductive resistance of a conductor.
Every inductive consumer has its associat- The diameter of a conductor for higher fre-
ed inductive reactive current which does not quencies must therefore be larger to com-
perform any effective work and only puts an pensate for the effectively lost conductor di-
extra strain on the cables. Frequency con- ameter.
verters and high-frequency power tools are
also inductive consumers.
The compensation of the reactive current on
the secondary or output side of a converter Skin effect
is only possible with great effort since each
Direct current
tool would have to be compensated individ-
ually. Depending on the number and output
power of the individual high-frequency
power tools one has to reckon with a total
Conductivity of total conductor
power factor cos of 0.5 to 0.85. On the pri-
J cross-section
mary or input side of a frequency converter
the power factor cos can be improved con-
J High-frequency
siderably by compensating the reactive cur- alternating current
rent in the drive motor and the generator. By
connecting suitably dimensioned capaci-
tors to the system it is possible to compen-
sate the reactive power on the primary side
of the converter during idling completely for Conductivity only on fringe of conductor
practical purposes and under load to such cross-section

an extent that the power factor increases to Ultra-high-frequency

more than cos = 0.9.
J alternating current

Wiring systems
EWL-HF006/P

The wiring systems for HF systems differ

basically from the wiring systems for com- Conductivity only on surface of
mon network frequencies of 50 or 60 Hz. conductor
Reasons for this are the effects of increased
frequencies:

16
 High-frequency technology

Electromagnetic emission Installation requirements

Cables which carry alternating currents emit
electromagnetic waves. For practical pur-
poses they act like sending aerials. The
electromagnetic emission can, especially in
case of higher frequencies, produce mal-
functions in sensitive electric equipment
(e. g. radio and television interference). The
aerial effect can be suppressed by proper
electromagnetic shielding of the cable. As a
rule, this is achieved by an earthed metal
screen (braided shield) in the cable sheath.
The HF distribution network must not have
any connection with the existing 50-Hz
power supply network. For this reason, spe-
cial CEE plug-in connectors in accordance
with DIN 49462/63 and DIN 49465 are re-
quired for frequencies between 100 and 300
Hz. The colour of plug-in connector hous-
ings, couplings and wall-mounting socket
outlets is green. The special design of these
plug-in connectors prevents existing 50-Hz
plug-and-socket devices being combined
with plug-in connectors or portable socket
outlets.

Electromagnetic radiation Mobile or permanently installed cables can

be used for the distribution network be-
Unshielded cable
tween the frequency converter and the indi-
2
vidual high-frequency power tools, depend-
ing on the requirements.
The transmission of high output power at
low voltage is uneconomical in complex
systems. Either the installation costs are too
1 high due to the large conductor cross-sec-
Aerial effect tions or transformers are required which re-
duce the higher voltage at the operating lo-
Shielded cable cation of the tool. Given the preconditions
constant transmission power, fixed voltage
drop and uniform cable length the cable
5 cross-section changes according to the
1 4 voltage, i. e., half the voltage requires four
3 times the conductor cross-section.
2

No aerial effect
Dimensioning of the wiring system
1 Conductor
EWL-HF007/P

2 Insulation The straightforward dimensioning of an HF

3 Braided screen
4 Insulated sheath wiring system is best based on standard ta-
5 Earthing bles and nomograms. In this fashion it is
quite easy to determine the required cross-
sections according to the following illustra-
tions. The conductor cross-sections are cal-
culated on the basis of the permissible
voltage drop of 5 % due to the ohmic re-
sistance, the permissible temperature in-
crease and the voltage drop due to the in-
ductive resistance (skin effect). The
procedure is described in the following ex-
amples.

17
 High-frequency technology

Sample calculations Example 1

Cable cross-section in dependence of
voltage and cable length
Take the value of the transmitted output
power and, depending on the type of cur-
rent, proceed from left or right horizontally
to the intersection with the voltage line, from
there go vertically down to the intersection
with the line for the cable length (simple
length) and then again horizontally to the left
or right. (Ill. HF 008/G)
Cable cross-section in dependence of
voltage and power factor
The cross-section determined in the previ-
ous diagram is now tested for temperature
increase. Take the value of the transmitted
output power and proceed from the left hor-
izontally to the intersection with the voltage
line, from there go vertically down to the in-
tersection with the line for the power factor
cos , then horizontally to the right to read
J Calculated cable cross-section in accor-
off the cross-section depending on the ca-
ble type. (Ill. HF 009/G)
Cable cross-section in dependence of
frequency and inductive resistance
If in the case of rotary current, a cable
cross-section of more than 10 mm2 was de-
termined in the previous diagrams, the in-
ductive voltage drop is taken into account
by transferring the exact value into the next
diagram where you proceed from the hori-
zontal baseline vertically upwards to the in-
tersection with the curve for the frequency
and then horizontally to the left or right.
Of the determined cable cross-sections on-
ly the larger value is decisive for the dimen-
sioning of the cable.
Transmission of 4 kW, 72 V rotary current,
cos = 0.8, cable length (one-way): 10 m
J
Calculated cable cross-section in accor-
dance with ill. HF 008/G: 2.75 mm2
Calculated cable cross-section in accor-
dance with ill. HF 009/G: 4.8 mm2 (select-
ed cross-section: 6 mm)
The cable cross-section of 2.75 mm2 calcu-
lated in accordance with ill. HF 008/G and
HF 010/G is insufficient, it would lead to an
excessive temperature increase in the
cable.
A check in accordance with ill. HF 010/G is
not required, since the cross-section is less
than 10 mm2.
Example 2
Transmission of 3 kW, 220 V single-phase
alternating current, cos = 0.9, cable length
J
(one-way): 100 m
Calculated cable cross-section in accor-
dance with ill. HF 008/G: 4 mm2
dance with ill. HF 009/G: 0.9 mm2
According to ill. HF 008/G a cross-section
of 4 mm2 is required. This measure is the de-
cisive one since the result for the cable in
accordance with ill. HF 009/G is only 0.9
mm2 and for that reason there is no great
risk of overheating.
Example 3
As for example 1, however 200 Hz rotary
current at 100 m cable length, calculated
cable cross-section from ill. HF 008/G:
27 mm2
This value has to be checked in accordance
with ill. HF 010/G. In this case the larger
cross-section of 50 mm2 has to be chosen.
Cable cross-section in dependence of
frequency and inductive resistance

mm2
The inductive resistance is especially no- 150
ticeable in the case of larger cable cross- 120
200 z
z

150 H z
Hz
300 H
400 H

Hz

95
sections. These in turn are required in case
50

70
of low voltage or higher frequency.
50

For the calculation of the curves in the illus- 35

trations a consumer power factor cos of J 25

0.7 was assumed. In the case of single- 16

phase alternating-current systems with a
10
power factor cos = 1 the inductive resist-
J 5
EWL-HF010/G

ance can be neglected even for larger cable 6

cross-sections. (Ill. HF 010/G) 5 6 8 10 20 30 40 50 100

mm2

18
 High-frequency technology

Cable cross-section in dependence of voltage and cable length

kW kW

power to be transmitted in case of direct or single-phase alternating current

40 20
35 15

20 10
power to be transmitted in case of rotary current

15 7.5

10 5.0
8.0 4.0

0V
2

20
0V
6.0 50 3.0
1
0V

0V
38

V
22
4.0 2.0

0
11
0V
3.0 1.5

V
23

72
5 V
11
0V

2.0 1.0

42 V
25

48
5V

36 V
1.5 12 0.75

V
5V
26

5V
13

1.0 0.5

V
36
0.8 0.4
0V
15

0.6 0,3

0.4 0.2

mm2 mm2
70 70
50 50

35 35
h
gt
len

0m

25 25 c
80
le
00 cab

0m
y
wa

40

16 16
m
e-
on

0m
10

0m

20

10 10
60

0m
0m

10
30

m
60

6.0 6.0
0m
15

m
30

b 4.0 4.0
m
80

m
15
m

2.5 2.5 a
40

5m
20

1.5 1.5
m

EWL-HF008/G
10

1.0 1.0

Cable cross-section in dependence of voltage and power factor

current
Rotary
Single-phase alternating current

kW A mm2
20
Rubber-sheathed cable

10
3
26
8.0 5V
50 4
6.0 15
Power to be transmitted in case of rotary current Direct current

10 0V 38 0V 5
permanent

5.0
installation

8.0 0V
25 6
4.0 0V
6.0 4 8
13
3.0 5V
2.5 10
4.0
2.0 72
0.75 1.0
3.0 3 V 15 1.5 1.5
1.5 22
0V 20 1.5 2.5
2.0 12
1.0 5V 25 2.5 4.0
20
0V 30
0.8 4.0 6.0
48 11 40
0.6 1.0 V 5 V 6.0 10
0.5 50
0.0 24
0.4 V 60 10 16
=1

42 11
0. 8
s

0.6 V
0.

0 V 80
6
co

0.3 0.5 16 25
0.25 36 100 35
0.4 V 25
EWL-HF009/G

0.20 35 50
0.3 150
0.15 50
200 70
0.2

19
 High-frequency technology

Electric safety for HF systems

EWL-HF008/P
(rotary current of increased frequency) Neutralisation
L L L P
The electric safety of HF power tools is pro- 1 2 3
E
vided by the protective conductor in accor-
R
dance with EN 50144, safety class I. The B

star or zero point is brought out from the

star-connected secondary winding of the
converter. The zero point is earthed (earth- M

ing resistance RB 2 ohm) and connected
through the protective conductors with the
metal housing of the power tools in such a
fashion that in the case of 265 V operating R
B

voltage the danger voltage between phase

and earth is in the worst case only R =<2
B

265 V
= 153 V
1.73
Error-current deactivation
In the case of operating voltages of 135 V or L2 P
72 V the danger voltage between phase and E
L1 L3
earth is only I
R
E

135 V I
= 78 V
I
1.73
or
72 V
= 42 V R
B
1.73
L2 P
whereby 1.73 represents the interlinking L L3
E
factor gVVV
3 for three-phase rotary current. 1
I
R
E

The effectiveness of the protective earth

connection has to be ensured by using suit-
I
ably robust and in their electrical construc- I-I f
f
tion faultless plug-in connections as well as
robust cables.
Just as important is regular and careful E

maintenance. R
L2 P B
E
The construction of the power tool itself L1 L3
must satisfy the high demands of an indus-
M
trial production facility.
R
In standard cases you can follow the above
ne
r li
description, i. e. the safety precaution pro- Wa
te

tective multiple earthing in accordance

with VDE 0100 10 N. S
W P
In the case of 265 V/200 Hz rotary current
I<
one can choose residual-current earth-leak-
age circuit breakers (r.c.c.b.) for 45 mA.
Residual-current earth-leakage circuit
breakers for rotary current of other voltages
and frequencies have to be ordered sepa-
rately from the manufacturers in question! R =< 2
B
Beyond that the standard precautions for 3- EWL-HF009/P
phase systems apply.

20
Available Correspondence Seminars
Type Subject New Order no. booklet
code

Sales The demand analysis: Setting the future course for success V 1.1
The Offer: The rignt sales proposition at the right time is the problem V 1.2
solution for the customer
Sensory Perception: A Picture can say more than a thousand words. V 1.3
The combination offer: The whole is more than the sum of its parts V 1.4
After Sales Service: Small gestures great effects V 1.5
The Bosch-Formula: Providing customer-centred advice and V 1.6
assistance through sales specialists
Explaining customer benefits during tool presentations: V 2.1
Router and System accessories
Explaining customer benefits during tool presentations: V 2.2
Router potential for stationary Operation
Explaining customer benefits during tool presentations: V 2.3
Power Tools for sanding
Explaining customer benefits during tool presentations: V 2.4
All about the mini grinder
Explaining customer benefits during tool presentations: V 2.5
Powerful working with the angle grinders
Explaining customer benefits during tool presentations: V 2.6
Impact free working with diamond drilling Systems
Explaining customer benefits during tool presentations: V 2.7
Diamond drilling Systems Part 2, Concrete grinders, wall chasers
and slot cutters.
Explaining customer benefits during tool presentations: V 2.8
Jigsaw and tenon saw in action
Technical Focus on the wood crafts Part 1: Recognising opportunities 1 609 901 Z 18 V 3.1
Focus on the wood crafts Part 2: Tuition system, Routing, Planing 1 609 901 Z 25 V 3.1
Craft in Vision Part 1: Working in Masonry - Materials and Tools 1 609 901 Z 31 V 3.2
Craft in Vision Part 2: Power Tools for Working in Masonry 1 609 901 Z 32 V 3.2
Metalworking Part 1: Materials and Tools 1 609 901 Z 38 V 3.3
Metalworking Part 2: Power Tools and Applications 1 609 901 Z 39 V 3.3
Electronc Measuring Technology: Basic Principles 1 609 901 Z 40 P3
Bosch Green: Drilling, grinding and sanding 1 609 901 Z 41 P1
Bosch Green: Sawing, routing, joining 1 609 901 Z 42 P2
Power tools and accessories 1 609 901 Z 43
Diamond Accessories 1 609 901 Z 73
Cordless 1 609 901 Y 07
Measuring instruments 1 609 901 Y 10

Please copy this sheet, state the number of copies you need, and send it in or fax to:
Power Tool Training Club Mollenbachstrae 3335 D-71229 Leonberg, Germany Fax +49 (0) 71 52-9 78 20-24

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EW-BILDUNGSCLUB FERNLEHRBRIEF
MEHR WISSEN MEHR ERFOLG POWER
TOOL TRAINING CLUB CORRESPON Power Tool
Training Club

DENCE SEMINAR GREATER KNOW

LEDGE GREATER SUCCESS CLUB
FORMACION OUTIL ELECTROPORTATIF
FORMATION VENDEURS EW-BILDUNGS
CLUB FERNLEHRBRIEF MEHR WISSEN
MEHR ERFOLG POWER TOOL TRAINING
CLUB CORRESPONDENCE SEMINAR
GREATER KNOWLEDGE GREATER
SUCCESS CLUB FORMACION OUTIL
ELECTROPORTATIF FORMATION VEN
DEURS EW-BILDUNGSCLUB FERN
LEHRBRIEF MEHR WISSEN MEHR
ERFOLG POWER TOOL TRAINING CLUB
CORRESPONDENCE SEMINAR GREA
TER KNOWLEDGE GREATER SUCC
ESS CLUB FORMACION OUTIL ELECTRO
PORTATIF FORMATION VENDEURS
EW-BILDUNGSCLUB FERNLEHRBRIEF
MEHR WISSEN MEHR ERFOLG POWER
TOOL TRAINING CLUB CORRESPON
DENCE SEMINAR GREATER KNOW
LEDGE GREATER SUCCESS CLUB
FORMACION OUTIL ELECTROPORTATIF
FORMATION VENDEURS EW-BILDUNGS
CLUB FERNLEHRBRIEF MEHR WIS
SEN MEHR ERFOLG POWER TOOL ROBERT BOSCH GMBH 2003
Power Tool Division

TRAINING CLUB CORRESPONDENCE Sales Consulting Training

SEMINAR GREATER KNOWLEDGE
EW/SCT
P.O.B. 100156
D-70745 Leinfelden-Echterdingen
http://www.bosch-pt.de
http://www.ewbc.de

GREATER SUCCESS CLUB FORMACION

OUTIL ELECTROPORTATIF FORMATION EW/SCT-FLB
Order no. 1 609 901 Y68
09/03 (S)

VENDEURS EW-BILDUNGSCLUB FERN

LEHRBRIEF MEHR WISSEN MEHR ERF