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Electronics in Corded Tools

Wamsutta

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Amarillo, Texas
Electronics would be stuff like constant speed control under load, variable speed, and soft start. Would that make an issue with reliability?

I've never had any power tools with those features. It seems like if that electronic box was to go out, it would take the whole tool down with it.
 
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Wamsutta

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I seems like all the variable speed grinders on the market also have electronic speed control and soft start. I'm pretty sure my variable speed Dremel doesn't have any electronics in it. I guess the manufacturers have forgotten how to make a tool variable speed without electronics.
 

dr_clyde

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Holland, MI
It’s not that they forgot, it’s just the old way sucked. Modern electronics are so much better than what we had 30 years ago it’s laughable anyone would want to use those old tools.

I have several variable speed Metabo tools and they’ve never had a problem. Had some of them pushing 15 years now, used heavily in industrial environments.

Power tools are not intended to be a lifetime purchase. They do wear out with enough use. Anything with a motor will eventually wear out. I replaced the original motor on my 1949 Marvel tilt frame saw a few years ago.
 
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neophyte

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The electronic modules were usually the first part to fail on older tools with the safety or variable speed modules.
On European made tools, those electric modules were also fairly expensive, and could easily cost $100+ just for the replacement part.
Some manufacturers however made the same tool both with and without the fancy electronic module, so if a module failed, it was sometimes possible to just rewire the tool as a fixed speed tool.
Router speed controllers, made for routers such as the Porter Cable 690, which was made for decades without variable speed, could allow speed adjustment on fixed rpm tools, and the variable speed controllers weren’t that expensive at maybe $30+/-.
If ghe speed box failed it was far cheaper to just buy a new one than to repair a tool with a broken internal electrical module.
The boxes weren’t as convenient as the internal modules, but were originally intended for routers that might be used in router tables.

It’s possible the current electrical modules are more reliable, and a bit more affordable, but problems seem to still show up, particularly on “brushless tools” were the electronics are fundamental to the motor operation.
These brushless tools also may have more complex tool switches, judging by cordless tools, and the switch is one of the other main components that can fail.
On older tools, switch types were usually somewhat standardized, so replacements could be found in case a switch failed.
I’m not sure how well that is going to work on some of the newer tools.
Admittedly this is speculation based on problems I’ve heard of and reviews I’ve read, so 🤷‍♂️.
 
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Wamsutta

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Just for kicks I looked up the price of an electronic control unit for a Metabo WEV 10-125 grinder. It's about $53 plus whatever the shipping cost would be. The unit comes with the variable speed dial built in.

Metabo 343083560.jpegMetabo WEV 10-125.jpeg
 
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