Making a soft start
The circuit is assembled on a printed circuit board with dimensions of 45 x 35 mm, the board is laid out as compactly as possible so that it can be built into the body of a tool that requires a soft start. It is better to solder the power wires directly to the board, but if the load power is small, then you can install the terminal blocks, as I did. The board is made by the LUT method, photos of the process are presented below.
It is advisable to tin the tracks before soldering the parts, so their conductivity will improve. The microcircuit can be installed in a socket, then it can be removed from the board without any problems. First, resistors, diodes, small capacitors are soldered, and then the largest components. After completing the assembly of the board, it is imperative to check it for correct installation, ring the tracks, wash the remaining flux.
How to assemble a regulator with your own hands?
A simplified and rather reliable frequency converter for an angle grinder is constructed with your own hands from available electrical parts. Below is a diagram that shows all the required components for mounting on a printed circuit board of the device of interest to us..
So, we need:
- symmetrical triode thyristor (or triac, triac) DIAC (DB3);
- resistor (resistance) R1 (its parameters should be 4.7 kΩ);
- additional triac VT136 / 138 (TRIAC);
- capacitor C1 (400 V, 0.1 μF);
- additional resistance VR1 for 500 kOhm.
A similar scheme operates according to the following method.
- The charging time of the capacitor is modified by an auxiliary resistor (it is called the trimmer). When voltage is applied to the circuit, the triacs are in the closed position, and a zero voltage value is observed at the output..
- In the process of charging the capacitor, an increase in voltage is noted on it, which leads to the opening of the DB3 triac. As a result, the voltage falls on VT136 / 138. This thyristor element also opens up, and an electric current flows through it..
- After that, the symmetrical components are closed again and remain in a similar status until the capacitor is completely recharged in the opposite direction..
- Ultimately, at the conclusion, we acquire a deterministic signal of finite energy that is complex in its configuration. Its exact range is determined by the period of performance of the functions of the circuit capacitor – auxiliary resistance – resistance R1.
Triacs are usually located on a printed circuit board. It is easy to create it from PCB (multilayer extruded plastic is used, consisting of heat-insulating fiber and foil). Individual craftsmen cut the board with a cutter. It is practiced to place the circuit elements using the hinged mounting method. Triystres are mounted only on an aluminum or copper heat exchanger. It plays the role of a good heat sink.
The test of the assembled device is carried out using an ordinary 40-60 W incandescent lamp. Connect it to the circuit and start to regulate the glow power. If the brightness changes, then you have done everything correctly. Now you can start installing the regulator in the shell of the angle grinder. This is not very easy to do, since it is necessary to ensure that the auxiliary device does not interfere with you when using the angle grinder..
You will need to calculate the installation location of the homemade control device yourself, in accordance with the design features of the angle grinder. Installation of the scheme is performed:
- in an additional box mounted on the unit body;
- into the handle of the holder;
- into a small empty niche (it is designed to cool and circulate air masses) in the rear area of the angle grinder.
The circuit itself is connected to the device by integrating it into the electric power supply channel of the angle grinder. With this, you, I suppose, will not have difficulties..
Application in angle grinder
During start-up of the angle grinder (angle grinder), high dynamic loads appear on the tool parts.
Expensive models are equipped with a soft starter, but not ordinary varieties, for example, the Interskol angle grinder. An inertial jerk is capable of pulling an angle grinder out of the hands, and there is a threat to life and health. In addition, when the electric motor of the tool is started, an overcurrent occurs and, as a result, wear of the brushes and significant heating of the stator windings, the gearbox wears out and the cutting disc may be destroyed, which can crack at any time and cause harm to health, and maybe even life. The tool needs to be secured and for this you should make an angle grinder with speed control and a smooth start with your own hands.
What is the angle grinder for smooth start and speed controller?
In modern angle grinders, 2 necessary options are used that increase the characteristics and safety of the equipment:
- speed regulator (frequency converter) – a device designed to convert the speed of the motor in different modes of operation;
- soft starter – a circuit that provides a leisurely increase in engine speed from zero to the limit value when the unit is connected.
They are used in electromechanical equipment, in the structure of which an AC electric motor with a collector is practiced. They help to reduce the wear of the mechanical part of the unit when it is turned on. Reduce the stress on the electrical components of the machine by bringing them into operation smoothly. As studies of the qualities of materials have revealed, a particularly strong development of contacting nodes is produced in the process of a sudden transition from a stationary state to rapid activity. For example, one start of an internal combustion engine in a car is equal to the wear of the piston and a group of sealing rings to 700 kilometers..
How to control angle grinder speed || motor speed control || angle grinder speed regular
When power is applied, an abrupt transition is made from a stationary state to the rotation of a circle at a speed of 2.5-10 thousand revolutions in 60 seconds. Anyone who has used an angle grinder is well aware of the feeling that the tool “flies out of hand”. Just at this moment, most of the accidents associated with the mechanical part of the unit happen.
The rotor and stator windings are equally stressed. An alternating current electric motor with a collector starts up in a short-circuit mode, the EMF already pushes the shaft forward, but the inertia force still does not allow it to rotate. A jump in the starting electric current arises in the coils of the electric motor. Despite the fact that by design they are designed for such work, over time a moment comes (for example, with a voltage drop in the mains) when the winding insulator is not able to withstand and a short circuit occurs between the turns.
With the introduction into the electrical circuit of the instrumentation schemes for adapting a soft start and changing the frequency of rotation of the motor, all the above troubles spontaneously disappear. In addition, the issue of a sudden and significant decrease in voltage in the general power grid during the start-up of the tool is being resolved. Hence, it is clear that household electrical appliances will not be at risk of failure. And the automatic switches on the electric meter will not work and turn off the current in an apartment or house.
The soft start scheme is used in angle grinders of the middle and high price segment, the speed control unit is more and more in professional modifications of the angle grinder. Adjusting the speed makes it possible to process soft materials with an angle grinder, to carry out delicate grinding and polishing, since at high speeds the wood or paint will simply burn out. Auxiliary electrical circuit increases the cost of the toolkit, but extends the service life and the degree of safety in use.
For what purpose is the angle grinder low speed?
The integrated wheel speed control option will make it possible to gently process materials such as wood or plastic. At lower speeds, comfort and safety are increased. This option is most practical in radio and electrical installation, service stations and studios engaged in restoration..
In addition, among professionals who use power tools, there is a judgment that the more trivial the device is arranged, the more reliable it is. And it is advisable to take the additional service “stuffing” out of the bounds of the angle grinder. With this approach, equipment maintenance is greatly simplified. In this regard, some companies deliberately produce portable individual electrical controllers that are connected to the network cable..
The simplest scheme
The soft starter with speed control on the KU 202 thyristor has been widely used due to its very simple design (diagram 1). Its connection does not require special skills. It is very easy to get radio elements for him. This model of the regulator consists of a diode bridge, a variable resistor (plays the role of a U regulator) and a thyristor tuning circuit (supplying U to a control output with a nominal value of 6.3 volts) of a domestic manufacturer.
Scheme 1. Wiring diagram of the indoor unit with speed control and smooth start (electrical schematic diagram)
Due to the size and number of parts, this type of regulator can be integrated into the body of a power tool. In addition, you should remove the handle of the variable resistor and the speed controller itself can be modified by building in a button in front of the diode bridge.
The basic principle of operation is to adjust the speed of the electric motor of the tool by limiting the power in manual mode. This circuit allows the use of power tools up to 1.5 kW. To increase this indicator, it is necessary to replace the thyristor with a more powerful one (information about this can be found on the Internet or in the reference book). In addition, it is necessary to take into account the fact that the thyristor control circuit will differ from the original one. KU 202 is an excellent thyristor, but its significant drawback is its adjustment (a selection of parts for the control circuit). To implement a soft start in automatic mode, circuit 2 is used (soft starter on a microcircuit).
No power loss
A regulator that changes the speed without losing power is almost impossible to make on your own. Such devices with feedback for tracking the value of revolutions and correcting on their basis the current strength are produced only by manufacturers of an angle grinder. You can make or install yourself only regulators on semiconductor circuits, which do not guarantee 100% power conservation when changing the spindle speed..
Connecting the regulator to the angle grinder
The frequency converter is connected to the instrument in series. If there is free space in the handle of the angle grinder, then this device can be placed there. The surface-mounted circuitry is glued with epoxy, which will serve as an insulator and vibration protection. Move the variable resistance resistor with a plastic handle outside to adjust the speed.
How to make a speed controller for an angle grinder with your own hands?
- For what purpose is the angle grinder low speed?
- What is the angle grinder for smooth start and speed controller?
- How to assemble a regulator with your own hands?
- Electronic device testing
- Connecting the regulator to the angle grinder
- Installation of the regulator in the cavity of the angle grinder housing
- How to make a regulator from a dimmer?
If you have an old angle grinder among your tools, take your time to get rid of it. Using a simple wiring diagram, the tool can be improved by adding an option for adjusting the speed. Due to the usual control device, which you can create with your own hands within a few hours, the functions of the tool will significantly expand. By reducing the number of rotations per unit of time, the angle grinder can be used as a sharpening and grinding unit for different types of materials. There will be additional opportunities for using auxiliary equipment and attachments.
What is the angle grinder for smooth start and speed controller?
In modern angle grinders, 2 necessary options are used that increase the characteristics and safety of the equipment:
- speed regulator (frequency converter) – a device designed to convert the speed of the motor in different modes of operation;
- soft starter – a circuit that provides a leisurely increase in engine speed from zero to the limit value when the unit is connected.
They are used in electromechanical equipment, in the structure of which an AC electric motor with a collector is practiced. They help to reduce the wear of the mechanical part of the unit when it is turned on. Reduce the stress on the electrical components of the machine by bringing them into operation smoothly. As studies of the qualities of materials have revealed, a particularly strong development of contacting nodes is produced in the process of a sudden transition from a stationary state to rapid activity. For example, one start of an internal combustion engine in a car is equal to the wear of the piston and a group of sealing rings to 700 kilometers..
When power is applied, an abrupt transition is made from a stationary state to the rotation of a circle at a speed of 2.5-10 thousand revolutions in 60 seconds. Anyone who has used an angle grinder is well aware of the feeling that the tool “flies out of hand”. Just at this moment, most of the accidents associated with the mechanical part of the unit happen.
The rotor and stator windings are equally stressed. An alternating current electric motor with a collector starts up in a short-circuit mode, the EMF already pushes the shaft forward, but the inertia force still does not allow it to rotate. A jump in the starting electric current arises in the coils of the electric motor. Despite the fact that by design they are designed for such work, over time a moment comes (for example, with a voltage drop in the mains) when the winding insulator is not able to withstand and a short circuit occurs between the turns.
With the introduction into the electrical circuit of the instrumentation schemes for adapting a soft start and changing the frequency of rotation of the motor, all the above troubles spontaneously disappear. In addition, the issue of a sudden and significant decrease in voltage in the general power grid during the start-up of the tool is being resolved. Hence, it is clear that household electrical appliances will not be at risk of failure. And the automatic switches on the electric meter will not work and turn off the current in an apartment or house.
The soft start scheme is used in angle grinders of the middle and high price segment, the speed control unit is more and more in professional modifications of the angle grinder. Adjusting the speed makes it possible to process soft materials with an angle grinder, to carry out delicate grinding and polishing, since at high speeds the wood or paint will simply burn out. Auxiliary electrical circuit increases the cost of the toolkit, but extends the service life and the degree of safety in use.
Electronic device testing
Before connecting the block to the angle grinder, check it. Take a plug-in electrical outlet. Insert 2 wires into it, one of which connect to the board, and the other to the network cable. Connect another wire to the network board. As you can see, the regulator is connected in series in the electrical circuit. Connect a light bulb to the circuit and test the operation of the device.
Installation of the regulator in the cavity of the angle grinder housing
The electronic device, assembled separately from the angle grinder, is encased in a dielectric material since all components are energized. A portable electrical outlet with a cable is fixed to the body. The handle of the variable resistance resistor is brought out to the outside. The regulator is connected to the mains, and the tool to a portable power outlet.
For what purpose is the angle grinder low speed?
The integrated wheel speed control option will make it possible to gently process materials such as wood or plastic. At lower speeds, comfort and safety are increased. This option is most practical in radio and electrical installation, service stations and studios engaged in restoration..
In addition, among professionals who use power tools, there is a judgment that the more trivial the device is arranged, the more reliable it is. And it is advisable to take the additional service “stuffing” out of the bounds of the angle grinder. With this approach, equipment maintenance is greatly simplified. In this regard, some companies deliberately produce portable individual electrical controllers that are connected to the network cable..
How to assemble a regulator with your own hands?
A simplified and rather reliable frequency converter for an angle grinder is constructed with your own hands from available electrical parts. Below is a diagram that shows all the required components for mounting on a printed circuit board of the device of interest to us..
So, we need:
- symmetrical triode thyristor (or triac, triac) DIAC (DB3);
- resistor (resistance) R1 (its parameters should be 4.7 kΩ);
- additional triac VT136 / 138 (TRIAC);
- capacitor C1 (400 V, 0.1 μF);
- additional resistance VR1 for 500 kOhm.
A similar scheme operates according to the following method.
- The charging time of the capacitor is modified by an auxiliary resistor (it is called the trimmer). When voltage is applied to the circuit, the triacs are in the closed position, and a zero voltage value is observed at the output..
- In the process of charging the capacitor, an increase in voltage is noted on it, which leads to the opening of the DB3 triac. As a result, the voltage falls on VT136 / 138. This thyristor element also opens up, and an electric current flows through it..
- After that, the symmetrical components are closed again and remain in a similar status until the capacitor is completely recharged in the opposite direction..
- Ultimately, at the conclusion, we acquire a deterministic signal of finite energy that is complex in its configuration. Its exact range is determined by the period of performance of the functions of the circuit capacitor – auxiliary resistance – resistance R1.
Triacs are usually located on a printed circuit board. It is easy to create it from PCB (multilayer extruded plastic is used, consisting of heat-insulating fiber and foil). Individual craftsmen cut the board with a cutter. It is practiced to place the circuit elements using the hinged mounting method. Triystres are mounted only on an aluminum or copper heat exchanger. It plays the role of a good heat sink.
The test of the assembled device is carried out using an ordinary 40-60 W incandescent lamp. Connect it to the circuit and start to regulate the glow power. If the brightness changes, then you have done everything correctly. Now you can start installing the regulator in the shell of the angle grinder. This is not very easy to do, since it is necessary to ensure that the auxiliary device does not interfere with you when using the angle grinder..
You will need to calculate the installation location of the homemade control device yourself, in accordance with the design features of the angle grinder. Installation of the scheme is performed:
- in an additional box mounted on the unit body;
- into the handle of the holder;
- into a small empty niche (it is designed to cool and circulate air masses) in the rear area of the angle grinder.
The circuit itself is connected to the device by integrating it into the electric power supply channel of the angle grinder. With this, you, I suppose, will not have difficulties..
Connecting the regulator to the angle grinder
The frequency converter is connected to the instrument in series. If there is free space in the handle of the angle grinder, then this device can be placed there. The surface-mounted circuitry is glued with epoxy, which will serve as an insulator and vibration protection. Move the variable resistance resistor with a plastic handle outside to adjust the speed.
Smooth start and speed control
Smooth start-up of power tools is the main guarantee of its longevity. Remember when a light bulb burns out? Most often at the moment of switching on. Because after connecting to the electrical network, the load increases sharply. The worn-out places of the spiral do not stand up and it burns out.
The same processes take place in the angle grinder. At the moment of switching on, the current rises sharply, because the driving forces need not only to move the armature, but also quickly gain the required speed. The effect of such a hard start can be the most deplorable – a winding break.
To reduce the likelihood of tool failure due to hard starting, it is necessary to modify the angle grinder and equip it with a small built-in soft starter.
Another refinement is the rotation regulator. Everyone knows from their own practice how inconvenient it is to work with a tool that does not have a rotation adjustment. If there is no such device in an electric drill, then it is difficult to choose the rotation speed and drill feed. This will either cause the drill to jam or break..
The lathe works in a similar way, in which there is a whole set of special gears for adjusting the spindle rotation. This largely determines not only the safety of the cutter, but also the quality of material processing..
Combine two advantages – smooth start-up and shaft speed control using an electronic circuit. It is quite possible to assemble it with your own hands and install it directly into the body of the machine. With such a circuit, it will start smoothly without creating overloads in the windings and the network. And with the same scheme, it will be possible to adjust the speed in order to select the mode of operation with any material.
If you cut metal with significant thickness and hardness, then it is necessary to maintain high speed. But when processing surfaces of low-melting materials, high speed will do more harm than help the cause. It must be reduced. It is dangerous to work with stone or tiles at high speed. And here it must be slowed down.
Even when grinding the disc, the rotation speed must be proportionally changed, because the linear speed of the disc edge will decrease. You cannot do without a speed regulator when working with a diamond cut disc, because at high temperatures it collapses very quickly.
Everything suggests that if an angle grinder does not have a speed controller, then it must be made and installed in the machine..
Speed controller for angle grinder: how to reduce speed and make a smooth start
The power tool in our workshop occupies one of the main places. Each electrical device performs all functions in accordance with technical data. What else would you like? I really want the tool not to fail for a longer time or not break at all. As a person gets used to a friend – a dog, so he gets used to an instrument.
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One of the basic tools is an angle grinder, which we call an angle grinder. It is a versatile tool that can cut, grind, clean the surface, saw boards and can be adapted to many more operations..
The simple way to control the speed An Angle Grinder
How to make a speed controller with your own hands
In order not to complicate the perception of the principle of operation with complex terms, the principle operation of the circuit can be explained simply. It has a sensing element that reads the magnitude of the load. Depending on the read value, this element controls the shut-off device..
The principle of operation is similar to that of a water tap. In this case, you are the sensitive element that controls the water tap. The flow of water, depending on the need, becomes more or less. The same process occurs with the current..
It is necessary to correctly understand the moment that we will in no way be able to increase the rotation speed more than that indicated in the characteristics of the angle grinder. We can only lower the turnover. If the maximum rpm is 3000, then the range in which we can adjust the rpm will be below this value.
In its simplest form, you can use a thyristor-based regulator circuit. He will both feel and regulate. Two in one. This diagram has only five parts. It is very compact and fits easily into the case. Such a regulator will not work from zero rpm, but this is not necessary for an angle grinder.
If lower speeds are needed in the work, then it is necessary to use a different circuit on an integrated microcircuit, where a triac will be the locking element. Such a scheme will be able to regulate the speed from almost zero to the desired value..
And in that, and in the other scheme, the main load falls on the shut-off element. It must be rated for voltages up to 600 V and for currents up to 12 A. If your grinder is more powerful than 1 kW, then the locking element must withstand a load of up to 20 A.
All the details of the circuit on the thyristor can be placed on a printed circuit board or simply surface-mounted. According to the second option, the parts are soldered onto a printed circuit board. The printed circuit board can be manufactured in different ways. It can be etched out of foil-clad PCB, you can even cut it with a cutter, but it will turn out very roughly. In principle, she can be asked to make a familiar radio amateur for a very modest remuneration..
When the finished board is ready, you need to choose a convenient place in the angle grinder case to install it. It is desirable to install it so that it is convenient to use, and so that it does not interfere with the work process.
Before installing the circuit in the car, you need to check it. To do this, instead of an angle grinder, an ordinary incandescent lamp must be connected to the output. A copy with a power of 60 – 40 W at 220 V will do. The efficiency will be obvious by the change in the glow of the light bulb.
Now it remains to mount the device in the selected place and make a test run of the angle grinder. It will stop breaking out of your hands during start-up, and the speed will be smoothly adjusted by rotating the regulator.