Application of Powtran Technology’s PI500 Series Inverters in Brick-Making Machinery
2019-07-30
In recent years, variable-frequency drive (VFD) technology has experienced rapid development and widespread application across various industries. The application of VFD technology has become increasingly mature, and its continuously improved performance and functionality provide a reliable foundation for industrial automation.
I. Principle and Characteristics of Variable-Frequency Speed Control:
As can be seen from the operating principle of an asynchronous motor, the speed formula for the drive motor is:
n0 = 60f / p
From this, we can see that the motor speed is directly proportional to the frequency; by adjusting the frequency, the motor speed can be smoothly varied. For a variable-frequency drive (VFD), the frequency can be adjusted arbitrarily within the range of 0 to 400 Hz. Consequently, the speed of the driven motor can be adjusted over any desired range. The variable-frequency speed control used in brick-making equipment leverages precisely this principle to achieve stepless speed variation. The use of VFD control in brick-making equipment has the following characteristics:
(1) Easily achieves frequency modulation requirements and meets production process demands;
(2) The motor features smooth starting, a wide speed regulation range, minimal mechanical impact, long service life, and easy maintenance.
(3) Low starting current, resulting in minimal impact on the power grid;
(4) High energy transfer efficiency, energy savings, and excellent cost-effectiveness;
(5) The motor has a low temperature rise, which is conducive to its long-term stable operation.
(6) Equipped with a variety of sophisticated protection functions, including overcurrent, overvoltage, undervoltage, and phase-loss protection, ensuring the safe operation of the motor.
(7) The inverter features a unique AVR function that ensures it can still output sufficient voltage to drive the motor even when the grid voltage is low.
II. The brick-making process is as follows:
III. Features of the PI500 Series Inverters:
Accurate motor parameter self-learning, high speed stability accuracy, wide speed regulation range, small torque ripple at low speeds with high torque output, no downtime during temporary power outages, independent air duct design for operation in 40℃ ambient temperature, next-generation energy-saving operation, three-proof coating treatment, global safety certifications CE/TÜV, built-in adaptive PID control module, user-friendly host computer software, I/O expansion capability, integrated braking unit, support for multiple communication protocols, high-protection membrane keypad, multiple installation options—including flange mounting and detachable fan—facilitating easy installation and maintenance, plus the addition of a QUICK multi-function key and keyboard lock function option.
IV. Product Application Examples:
Based on the actual conditions at the site and the customer’s requirements, we will carry out modifications to the three pieces of equipment that significantly impact the process and efficiency. The current status of these equipment is as follows:
Based on the characteristics of the load and the process conditions, we have equipped each of these devices with the corresponding variable-frequency drives as follows:
Stirring motor 1—equipped with PI500 160G3 frequency inverter
Stirring motor 2—equipped with PI500 75G3 inverter
Extruder motor—equipped with PI500 355G3 frequency inverter
V. On-site Process Characteristics and Key Points for Modification:
At the site, whether it’s the mixer motor or the extruder motor, the variable-frequency drive (VFD) first starts up and runs at 50 Hz. Then, depending on the process and production requirements, a clutch determines whether to engage the load. During on-site commissioning, due to the specific nature of the load, the VFD triggered overvoltage (ERR.05) and overcurrent (ERR.02) fault alarms when the clutch was engaged. In this situation, adjusting the internal protection settings of the VFD proved ineffective. Ultimately, after repeated parameter adjustments, performing motor parameter self-learning, and changing the VFD’s control mode, we were able to resolve the issue. For the mixer motor, after static self-learning of the motor, vector control was adopted. For the extruder motor, after comprehensive self-learning, VF control was implemented.
VI. Concluding Remarks
The PI500 series inverters feature high-precision vector control, delivering large torque at low frequencies and achieving speed regulation accuracy as high as 0.01 Hz. They offer a wide range of adjustable carrier frequencies, significantly reducing motor noise. The inverters are equipped with comprehensive protection functions, including phase-loss protection for both input and output, as well as overcurrent, overvoltage, and short-circuit protection, ensuring more stable and safer operation of the equipment. The motor speed is divided into no-load speed and clutch speed. The no-load speed is set at 15 Hz, while the clutch speed is adjusted via an external potentiometer based on the degree of screw wear. This allows the motor to operate within a frequency range of 0 to 50 Hz, extending the service life and replacement cycle of the equipment, enhancing production efficiency, and ultimately boosting overall productivity. The Powtran Technology PI500 inverter has been successfully applied to this equipment and has received high recognition from users. Powtran Technology’s inverters will continue to provide outstanding, reliable, and convenient services to an even wider range of customers.
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