The XYO technology shows significant improvements in angle grinder performance during independent studies. Perpetual Industries wants to work with innovative power tool manufacturers to optimize and implement the XYO balancer in their product.
Contact us to see how your product can beat the competition using XYO
The XYO balancer reduces vibration by compensating for variable mass imbalance during the operation of an angle grinder. Tests show that the XYO balancer has a significant impact on the performance of an angle grinder.
Benefits of reduced vibrations include:
Vibration Decreased by 51%
Power tools have been known to induce the risk of vibration-related diseases. An acute disease that is caused by regular exposure to hand-arm vibration (HAV) is known as white finger or Raynaud’s disease. There are also other vibration-related diseases such as: permanent and painful numbness and tingling in the hands and arms, painful joints and muscle weakening, damage to bones in the hands and arms.
Vibration issues have been an important topic in the power tool sector ever since the EU guideline 2002/44/EC, where the employer can be held liable for vibration-induced injuries. Depending on the vibration value associated with a power tool the daily usage has limited as shown by Figure 2.
According the EU guidelines, shown in Figure 2, a power tool can be used continuously if the vibration level is at 2.5 m/s2-rms or less, while a power tool with a vibration level of 5.0 m/s2-rms will be limited to 8 hours of usage per day.
Some factors that contribute to angle grinder vibration include:
The main cause of vibration in an angle grinder is due to the changing mass imbalance of the grinding disk during operation (Figure 3).
Manufacturers have introduced anti-vibration handles and gloves to reduce the exposure to vibration but they do not cure the problem, and most workers do not like the reduced precision that is associated when these methods are employed.
The XYO balancer can compensate for dynamic or static unbalanced forces during operation. As a result, the XYO balancer-equipped angle grinder will continue to provide consistent performance even when the mass imbalance varies as the grinding disk wears during use.
The objective of the testing was to quantify the advantages of using the XYO balancer with angle grinders, like the one shown in Figure 4. The capabilities and limitations of angle grinders were also to be tested to determine the minimum achievable vibration for the Rockwell angle grinder being tested.
The prototype XYO balancer was installed on the spindle, replacing the backing flange (Figure 6).
Vibration levels were measured with and without a prototype XYO balancer installed.Tri-axial accelerometers placed on the support hand and body of the angle grinder (Figure 7) were used to record data.
Different acceleration levels were applied to the disk
spin speed in order to optimize performance of the
110 mm, 115 mm and 125 mm disk with no mass imbalance were also tested without the XYO balancer to determine the gyroscopic effects of the rotating disk; this provides a true baseline for calculating the vibration reduction with XYO.
See the “Appendix” for additional details of the testing procedures.
The rotational motion of the grinding disk can effect vibration of the angle grinder. Slight misalignment at the spindle and slack in the gearing can amplify gyroscopic effects further and make it challenging to reduce vibrations. The following disks with no mass imbalance were tested on the RK4751 angle grinder to measure gyroscopic effects on vibration:
Figure 8 shows the minimum achievable vibration (baseline) with no mass imbalance of the disk. Vibration levels start at 1.11 m/s2-rms with no disk applied to the angle grinder, and increased up to 2.12 m/s2-rms with a 125mm balanced disk. The data shows a direct correlation between the vibration intensity and diameter of the disk being tested. The increasing trend in the vibration level with the disk diameter is attributed to:
Note: The balanced disks used for this test were similar to the ISO disks shown
in Figure 5, except they did not have a hole to create a mass imbalance.
An angle grinder running with prototype XYO balancer was tested against a stock model. The results are shown in Figures 9 and summarized in Table 1.
The prototype XYO balancer facilitates up to a 36% reduction at the support handle, and a 39% reduction along the angle grinder body.
Table 1. Vibration reduction with a prototype XYO balancer; results are compared to the baseline vibration.
Initial testing with the XYO balancer showed improvement in the vibration; however, we wanted to produce a greater reduction to get closer to the baseline values. An optimized speed profile was developed to adjust the disk acceleration. Further testing demonstrated the benefits as shown in Figure 10, and Table 2.
There is a remarkable improvement in the angle grinder performance with an optimized speed profile;
a 49% reduction was observed at the support handle and a 51% reduction on the body with the prototype
Table 2. Vibration reduction with a prototype XYO balancer and an optimized disk speed profile; results are compared to the baseline vibration
The XYO balancer can have a significant impact on vibration of angle grinders. A prototype XYO balancer was tested with the RK4751 angle grinder.
The XYO balancer produced the highest vibration reduction using an optimized speed profile, up to 51%. This is a significant achievement in the advancement of angle grinder technology; however, analysis of the various tests indicate that the XYO balancer can reduce vibrations much further with the following design enhancements:
We are confident that the outlined changes coupled with the XYO balancer can have a lasting impact on the future of angle grinder designs. The XYO balancer can provide the following benefits:
Perpetual Industries wants to work with a capable and innovative angle grinder manufacturer to optimize and implement the XYO technology and provide a strong competitive advantage in the market.