Patent Product ----- Open Mixer Intelligent Control Device
Zero-load zero-energy era
First, the existing open mill operating status:
0 The open mill work is sent to the open mill after unloading the rubber in the final mixer of the mixer. After two to three passes on the open mill, it is transferred to the next open mill. In the next open mill, After three times, the film is cooled down to the cold line for later use. There is a cycle when the mixer is sent to the open mill. This cycle has
Certain uncertainties have changed with different rubber processes. Sometimes the time is 4 minutes, sometimes 3 minutes, and the uncertainty is large.
0 The semi-finished product is placed on an open mill and scrutinized. Based on the experience, it is judged that the degree of smelting is sent to the next open mill for sizing. This time of sizing and sizing is determined by judging the degree of smelting by hand.
Second, program demonstration
The traditional mixing process adopts a squirrel-cage three-phase asynchronous motor with a motor power of 250KW, which is typically used in an open-blanketing machine, and adopts two working modes of star-delta step-down starting or auto-coupling step-down starting. As we all know, due to the large power of the open mill motor, no step-down start is performed, and the impact on the power grid is even greater.
The impact is also greater, but also consumes energy! Therefore, now many tire rubber enterprises in the operation of the traditional open electric control part of the upgrade can be upgraded, the new procurement of open mill equipment can be directly used to support, so as to achieve equipment technology upgrades, energy saving effect.
Shiyi Electric developed CYK-I open mill integrated intelligent control special device, has three patents to master the core technology, equipment has been launched in January 2016 has been in Jinyu, Yongsheng, Hengfeng, peace, Shuangwang, etc. More than a dozen tire manufacturing companies have carried out equipment transformation or new equipment directly supporting the use of the various operating indicators of the effect of recognition and praise. Based on the CYK-I type operation data, we have developed a CYK-III open mill integrated intelligent control special device on the basis of the CYK-I type. The indicators have been further improved.
Case: The CYK-III open mill integrated intelligent control special device for on-site operation of the Shenyang Peace Tire Plant is converted into the following data:
We use a 280kW winding motor-driven open mill as an example. Typical operating conditions are 3 points.
The bell is 1 cycle, 2 minutes loaded with rubber, 1 minute idling conditions, calculated as follows:
If the inverter is driven by a variable frequency drive and constant torque operation, the speed of the motor is reduced to a suitable condition with no idling. The inverter drive speed is thus the best value:
N variable = effective revolutions / duty cycle = 2N/3 = 2/3N rpm
The open mill is a typical constant torque load process. According to the theory of motor speed regulation, the speed and power of the motor are known.
The current relationship is as follows:
Motor power: P=1.732è›è®¥èªosφ Motor torque: T=9549è°®/n;
Torque=9550*output power/output speed
P = T*n/9550 Power = Force * Speed ​​ie P = F*V
Therefore, under constant torque conditions, the motor power consumption is proportional to the motor output speed.
Specific plan: 50Hz load operation, idling adopts frequency conversion mode, 280KW open mill as an example, the actual test load rate is approximately 60%:
Q frequency conversion 50Hz load =280kw*0.6*0.92 *(2/60) h=5.2kwh
When Q frequency conversion is unloaded, 0 Hz, the main drive motor does not consume energy
Q frequency conversion period = Q frequency conversion 50Hz load + Q frequency conversion 0Hz no load =5.2kwh
We calculate the energy consumed by the open mill in a working cycle under the power frequency conditions as follows:
Energy consumption with load cycle Q load =280KW*0.6*(2/60)h=5.6kwh
Power consumption for no-load time Q Empty load =280KW*0.6*0.25*(1/60)h=0.7kwh
Therefore, the power consumption during the 3-minute work cycle Q cycle = Q load + Q no load = 6.3 kwh
In summary, the power saving rate after the variable frequency drive is changed
R = 1 - Variable Frequency Drive Cycle Power / Power Frequency Drive Cycle Power
=1-5.2kwh/6.3kwh= 0.175≈17.5%
We calculate 8 hours for each class of open mill.
Energy consumption per class before transformation: Q Energy consumption before reconstruction=6.3kwh*20*8h=1008kwh
Energy consumption per class after transformation: Q Energy consumption after transformation=5.2kwh*20*8h= 832kwh
Under this working condition:
Each class (8 hours) saves energy = 1008kwh-832kwh = 176kwh. Through the calculation of the above scheme, if everyone uses our company's open mill integration program, each class (8 hours) can save 176 degrees of energy, Its energy saving rate is approximately 17.5%.
Third, the use of "opening machine integrated intelligent control device" advantages:
1. Reduce idling energy consumption and achieve zero energy consumption in no-load condition to achieve energy saving and consumption reduction.
2. The DC bus support capacitor of the special device can play a role of reactive power exchange, which greatly improves the input power factor of the equipment without having to purchase another power factor compensation device.
3. It realizes the soft start of the motor, eliminates the impact of power frequency startup on the equipment and the power grid, avoids possible trip failures to other electrical equipment, and extends the shaft, gears, reducer, lubrication system, and cooling components. The useful life of mechanical parts enables better safe operation.
4. To achieve stepless speed regulation function According to the actual production needs, it is convenient to set the positive and negative rotation of the roller, the speed and the acceleration and deceleration time, making the operation of the equipment more convenient and convenient.
5. Various detection and protection functions such as undervoltage, overvoltage, input phase loss, output phase loss, overcurrent detection, overload detection, etc., to ensure long-term stable and safe operation of the device.
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