Greatest boon for metal industry: High-frequency grinding

February 17, 2014 8:30 am

 Huge savings in production can boost your company growth sooner than you expect
In electrical engineering, frequencies above 10 kHz are described as high frequency. For power tools, this is commonly used to describe all frequencies above the standard mains frequency of 50/60 Hz. Modern high-frequency power tools usually operate at a frequency of 300 Hz. Achieving this level requires special frequency converters that bring the power up to the higher frequency. These frequency converters are connected to the national lighting current or three-phase grid.
Why is the current from the socket at a higher frequency? One reason is the need for enhanced performance. By increasing the frequency, one can achieve a higher speed.
Peak performance, robust technologyFEIN high-frequency power tools prove their superiority in many sectors of trade and industry where continuous peak performance is demanded of tools. Compared to both compressed air tools and power tools with universal motors, they possess a wide variety of design-related advantages offering enormous potential for cost reduction.
Permanent peak performance in continuous operation is only possible if the high-frequency power tools are designed structurally as well as a qualitatively to meet peak requirements. FEIN, precision, renowned for its attention to every last detail, is an ideal prerequisite for the manufacture of such machines.
Savings of €500 per day at 15 workstationsIn terms of energy, capital expenditure and maintenance costs, high-frequency power tools are considerably more economical than comparable tools driven by compressed air. In addition, when grinding, they facilitate higher efficiency. This was the conclusion of a study carried out by a university of technology comparing the capability and economic efficiency of both types of drive.
Use of high-frequency power tools means up to …90 per cent less energy costs70 per cent less capital expenditure75 per cent less maintenance costs50 per cent less consumption of grinding discs10 per cent more material removal, i.e. higher labour productivity.
90 per cent less energy costsFor 15 workstations on two-shift operation a cost saving of around € 90,500 p.a. can he achieved
In the current distribution system for high-frequency power tools there are virtually no energy losses, whereas with compressed air systems energy losses occur during the compression of the air due to the compression heat. What‘s more, in practice a 10-20 per cent higher energy requirement can be expected due to leakage – in badly maintained systems even up to 30 per cent or more. The performance of the compressed air motors also changes with the condition of their components which are subject to a process of wear and tear (for example cylinder, rotor, starting discs, blades). This results in continuous losses in performance which in turn manifest themselves in decreasing efficiency and rising energy consumption. On the other hand, the performance of the robust induction motors is always constant – irrespective of wear and tear.

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