Guangdong Zhufeng Electric Co., Ltd. Cases

I. Application Scenarios and Technical Implementation 1. Freezing Water Circulation System Principle: The frequency converter regulates the speed of the chilled pump based on the return water temperature to adjust the flow rate and achieve indoor temperature stability. Technical Details: Flow Rate and Speed Relationship: The flow rate (Q) is proportional to the first power of the speed (n), and the shaft power (P) is proportional to the third power of the speed. For example, when the flow rate is reduced to 80%, the shaft power is reduced to 51.2%. Control Strategy: PID control is adopted, combined with return water temperature feedback, to dynamically adjust the pump speed and avoid freezing of the evaporator, ensuring system safety. Case: A certain type of frequency converter is applied in the HVAC water circulation system to achieve stable outlet temperature of chilled water, with an energy - saving effect of 20% - 40%. 2. Cooling Water Circulation System Principle: Taking the temperature difference between inlet and outlet water as the control basis, the speed of the cooling pump is adjusted to optimize the cooling efficiency. Technical Details: Temperature Difference Control: When the temperature difference is large, the pump speed is increased; when the temperature difference is small, the pump speed is decreased to keep the condenser working efficiently. Protection Requirements: The cooling tower environment is humid and dusty, so the frequency converter needs to have an IP55 protection level to prevent the entry of water vapor and dust. Case: A certain industry - leading product drives the cooling tower fan in a commercial building, achieving 30% energy savings through constant temperature difference control and integrating intelligent modules for remote monitoring. 3. Cooling Tower Fan Control Principle: Adjust the fan speed according to seasonal changes and cooperate with the cooling pump to achieve the best energy - saving effect. Technical Details: Smooth Start - Stop: The frequency converter reduces mechanical shock and extends the fan life. For example, a certain type of frequency converter is applied in the cooling tower fan, and a lower - limit frequency is set to avoid damage to the gearbox. Energy - saving Effect: When the fan runs at a low speed, the amount of drift water is reduced, the water source is saved, and the noise is reduced. Case: The frequency converter controls the cooling tower fan in the building of a certain transmission company, achieving 50% energy savings and realizing automatic management through the BMS system. 4. Ventilation System Principle: In scenes such as subways and industrial plants, the frequency converter drives the fan system to adapt to complex environments (such as high temperature, high humidity, and high dust). Technical Details: Protection Level: The subway ventilation system needs an IP55 or higher protection level to ensure stable operation of the equipment in harsh environments. Intelligent Control: Integrated PLC monitoring is used to adjust the air volume in real - time. For example, a certain type of frequency converter supports multi - pump variable frequency start in the subway project, reducing the pressure impact on the pipe network. Case: A certain city subway project adopts a frequency converter, and through the functions of condensation and frost protection, the reliability of the ventilation system is ensured. II. Energy - saving Effect and Data Support 1. Significant Energy Savings Theoretical Basis: The shaft power is inversely proportional to the third power of the speed. When the flow rate is reduced by 20%, the shaft power is reduced by 51.2%. Actual Cases: A Certain Transmission Company Building: After using the frequency converter, the HVAC system saves about 50% of energy, and the annual electricity cost savings are significant. A University Hospital: The frequency converter saves 800,000 kilowatt - hours of energy annually, reduces 750 tons of carbon dioxide emissions, and the COP is increased to 3.6 (heat pump) and 5 (cooling machine). A Certain Type of Frequency Converter: It saves 20% - 40% of energy in the HVAC system and avoids the energy consumption of full - speed operation through dynamic speed regulation. 2. Extended Equipment Life Soft Start: The frequency converter reduces the starting current impact of the motor and extends the life of pumps and fans. For example, the maintenance cost of equipment in a certain project is reduced by 30% due to smooth starting. Mechanical Protection: The cooling tower fan sets a lower - limit frequency through the frequency converter to avoid damage to the gearbox due to low - speed operation. 3. Environmental Adaptability IP55 Protection Level: In HVAC environments with a lot of dust and moisture (such as food processing plants and coal mines), the frequency converter needs to reach an IP55 level to prevent the entry of dust and water vapor and ensure stable operation. Case: A certain type of IP55 frequency converter is applied in high - requirement occasions such as military units and weapon manufacturing, adapting to harsh industrial environments. III. Intelligent Integration and System Integration 1. Integration with Building Automation System (BAS) Communication Protocols: The frequency converter supports protocols such as Modbus and Profibus, and can be seamlessly connected with BAS to realize remote monitoring and parameter adjustment. Case: A certain type of frequency converter uses an intelligent connection module, and mobile devices can be used for quick commissioning and monitoring, improving the intelligence level of the system. 2. Data Monitoring and Analysis Real - time Data: The PLC monitoring system records equipment efficiency, such as the number of cooling machine operations and automatic load adjustment, to ensure the optimal state. Fault Warning: The frequency converter stores fault information, such as flexible handling when signals are missing, reducing downtime. 3. Energy Management Dynamic Adjustment: Automatically switch the operating mode according to the season and time period. For example, switch to the energy - saving state at night and on weekends, and keep running at a low speed to maintain temperature and humidity. Case: The BMS system of a certain building automatically adjusts the frequency converter parameters in winter and summer to meet the demand and save energy at the same time.   Conclusion The frequency converter realizes the following core advantages in the HVAC system through precise speed regulation, intelligent control, and efficient energy management: Significant Energy Savings: The shaft power decreases according to the third power of the speed, and the case shows that the energy - saving effect is 20% - 50%. Extended Equipment Life: Soft start and mechanical protection reduce maintenance costs. Intelligent Integration: It is seamlessly connected with the BAS system to realize remote monitoring and automatic management.

Variable Frequency Drives (VFDs) play a critical role in optimizing the performance of Electric Submersible Pumps (ESPs) in oilfield production. By adjusting the power supply frequency, VFDs enable stepless speed regulation of submersible motors, dynamically matching the pump’s discharge capacity to the well’s fluid supply. This adaptive control ensures efficient production, particularly in wells with varying fluid properties such as viscosity and gas content. Technical Principles and Benefits Energy Efficiency: VFDs reduce energy consumption by optimizing motor转速 (speed) to avoid overloading, thereby improving system efficiency. Dynamic Adaptation: Real-time frequency adjustments allow ESPs to maintain stable operation under fluctuating well conditions, enhancing reliability. Extended Equipment Lifespan: By mitigating mechanical stress and reducing abrupt starts/stops, VFDs prolong the service life of motors and pumps. Industry Applications and Challenges Offshore Platform Case: In Penglai 19-3 offshore oilfields, Rockwell Automation’s PowerFlex 7000 medium-voltage VFDs have been deployed to drive ESPs. These systems achieve significant energy savings and stable operation, though challenges like high-order harmonics (which increase copper and iron losses) and end overvoltage (due to long cable transmission) require mitigation through passive filters or motor design optimization. Harmonic Management: VFD-induced harmonics necessitate advanced filtering or adjustments in motor parameters (e.g., slot leakage reactance) to protect insulation systems. ConclusionThe integration of VFDs with ESPs represents a advanced solution in oilfield artificial lift systems, balancing energy efficiency, operational stability, and equipment durability. Continuous advancements in VFD technology, such as multi-level inverters and harmonic suppression, further enhance their applicability in complex well environments. This description synthesizes technical terminology, industry practices, and case studies to provide a comprehensive English overview of VFD applications in ESP systems.

Variable Frequency Drives (VFDs), also known as Adjustable Speed Drives (ASDs), are critical in optimizing the performance of fans and pumps across industrial, commercial, and municipal sectors. By adjusting motor speed to match real-time demand, VFDs significantly reduce energy consumption, enhance system reliability, and enable precise control. Key Applications and Benefits 1. Energy Efficiency and Cost Savings Principle: VFDs leverage the Affinity Laws for pumps and fans, where power consumption is proportional to the cube of motor speed (P∝n3). Even minor speed reductions yield substantial energy savings. Example: Reducing fan speed by 20% lowers power consumption by 50%. Case Studies: HVAC Systems: VFDs achieve 20–50% energy savings in air handling units by adjusting airflow to match occupancy or temperature needs. Water Treatment: A wastewater pumping station in Scotland doubled efficiency after installing VFDs, saving $80,000 in electricity costs over 20 years. Industrial Pumps: A paperboard mill reduced pump duty to 60% under normal conditions, with a 16-month payback period. 2. Enhanced System Control and Reliability Precision Flow Control: In HVAC systems, VFDs enable ±0.5°C temperature accuracy and eliminate pressure swings caused by traditional damper/valve control. Steel plants use VFDs to stabilize轧机 cooling systems, improving product quality. Extended Equipment Lifespan: Soft starting reduces mechanical stress, cutting motor/bearing wear by up to 50%. Municipal sewage pumps using VFDs avoid overflows and extend service intervals. 3. Industrial and Municipal Use Cases Mining and Metallurgy: VFDs optimize energy use in crushers and ball mills, with ton-level electricity savings in cement production. Agriculture: Irrigation systems achieve 20–50% water savings through precise flow control. Data Centers: Retrofitting CRAC units with VFDs reduces fan energy use by 30–70% while maintaining thermal stability. 4. Emerging Trends and Innovations Smart Integration: VFDs paired with IoT sensors and AI algorithms enable predictive maintenance and dynamic energy management (e.g., demand response). Material Advances: Wide-bandgap semiconductors (e.g., SiC) enhance VFD efficiency to >99%, reducing heat loss and footprint. Renewable Synergy: In wind turbines, VFDs stabilize grid integration by managing variable output, while in solar inverters, they optimize DC-to-AC conversion. Technical Advantages Reduced Operating Costs: Energy savings often offset VFD costs within 1–3 years. Compliance: Meets IEEE 519 harmonic standards and supports ISO 50001 energy management. Scalability: Suitable for retrofits and new installations across motor sizes (1 kW to multi-MW). VFDs are transformative in fans and pumps, delivering unparalleled energy efficiency, operational flexibility, and sustainability. As industries prioritize decarbonization, VFD adoption will accelerate, driven by advancements in smart controls and semiconductor technology. From reducing municipal energy bills to optimizing industrial processes, VFDs remain a cornerstone of modern motor control systems.

I. Technical Principles and Core Advantages 1.1 Operating Principles Frequency inverters regulate motor speed to control the air discharge volume of air compressors, achieving constant-pressure output. The core workflow includes: Pressure Detection: Pressure sensors monitor system pressure in real time. Signal Feedback: Pressure signals are transmitted to the frequency inverter. Frequency Adjustment: The inverter modulates the motor's power supply frequency based on pressure signals, altering rotational speed. Discharge Volume Adjustment: Changes in motor speed lead to variations in compressor discharge volume, enabling precise pressure control. 1.2 Core Advantages (1) Energy Conservation Elimination of No-Load Losses: Traditional air compressors operate at full speed even under low demand, while inverters reduce speed to minimize wasted energy. Pressure Band Loss Reduction: Conventional units frequently load/unload within pressure limits, whereas inverters stabilize pressure to reduce energy waste. Soft Start Reduces Impact: Startup current is only 1.5–2 times the rated current (vs. 6–8 times for traditional units), significantly lowering grid shock and energy consumption. Energy Savings Rate: 30–40% energy savings under 60–80% load conditions. For example, a 55kW air compressor saves 130,000–170,000 kWh annually, equivalent to reducing 40–50 tons of standard coal consumption. (2) Equipment Protection and Lifespan Extension Reduced Mechanical Wear: Lower motor loads at partial loads extend the lifespan of bearings and other components. Stable Pressure: Minimizes pipeline leaks and equipment failures. (3) Intelligent Control Integrated PLC and HMI: Enables remote monitoring, data visualization, fault alerts, and self-diagnostics. Communication Protocol Support: Compatible with Modbus and other protocols for seamless integration with upper-level systems. II. Selection Guidelines 2.1 Load Matching Reciprocating Air Compressors (Impact Load): Select inverters with 150% instantaneous overload capacity. Screw Air Compressors (Constant Torque Load): Prioritize low-frequency torque output. 2.2 Power Calculation Formula: Inverter rated power = (Air compressor motor power × 1.1) / 0.92. Electrical Parameters: Grounding resistance < 4Ω, three-phase imbalance < 2%. 2.3 Compatibility and Testing Communication Protocols: Ensure protocol compatibility (e.g., Modbus) between inverters and PLCs. Conduct 72-hour joint debugging, including emergency stops and soft starts. EMI Filter: Mandatory installation at power input to mitigate electromagnetic interference. 2.4 Environmental Adaptability High-Altitude Areas: Output capacity decreases by 6–8% per 1,000m elevation. Use enhanced-cooling inverters. Explosion-Proof Environments: Require ATEX or IECEx certification. III. Typical Application Cases 3.1 Zhejiang Xinfuling Electric Co., Ltd. Solution: H130 dedicated inverter with Pulete controller driving a permanent magnet synchronous air compressor. Advantages: Compact design with 100% transmission efficiency. Motor volume 1/3 of conventional units, facilitating installation. Superior energy efficiency, even at low speeds. 3.2 Shaanxi Mining Company Retrofit Background: Original 132kW fixed-speed air compressor had high startup current and severe pressure fluctuations. Results: Reduced startup current and stabilized pressure. Loading current dropped from 220A to 130A; unloading current from 90A to 50A. 3.3 Pharmaceutical and Electronics Industries Pharmaceuticals: Precise control of gas flow, pressure, and temperature ensures packaging quality. Electronics: Stable high-purity gas output meets semiconductor manufacturing demands. IV. Conclusion Frequency inverters optimize air compressor performance through intelligent speed regulation, delivering energy savings, pressure stabilization, extended equipment lifespan, and intelligent management. Selection requires careful consideration of load type, power matching, environmental adaptability, and compatibility. Case studies validate their significant industrial benefits. With global carbon reduction initiatives, inverter-driven air compressors are poised to become the mainstream choice for industrial energy efficiency.

Overview Mine hoist is an important equipment in the production process of coal mines and non-ferrous metal mines. The safe and reliable operation of the hoist is directly related to the production status and economic benefits of the enterprise. This kind of dragging system requires frequent forward and reverse motor starting, deceleration and braking, which is a typical frictional load, i.e. constant torque characteristic load. Previously, mainly within the gear winch (mechanical drag), hydraulic winch (hydraulic drag) and AC asynchronous motor rotor series resistance speed control winch (electrical drag) and other types of dominant. The power of the inclined shaft hoist is provided by the wire-wound motor, which uses the rotor series resistance speed regulation. The mechanical structure of the inclined shaft hoist is schematically shown in the following figure.   At present, most small and medium-sized mines use inclined shaft winch to hoist, and the traditional inclined shaft hoist generally adopts AC winding type motor series resistance speed control system, and the resistance is controlled by AC contactor- thyristor. This control system is easy to oxidize the main contacts of the AC contactor and cause equipment failure due to the frequent action of the AC contactor during the speed regulation process and the long operation time of the equipment. In addition, the speed control performance of the hoist in the deceleration and crawling stage is poor, often resulting in inaccurate stopping position. The frequent starting, speed regulation and braking of the hoist generates considerable power consumption in the rotor external circuit of the series resistor. This AC winding motor series resistance speed control system is a step speed control, speed control of the smoothness is poor; low speed mechanical characteristics of the soft, static difference rate is large; resistance on the consumption of the differential power, energy saving is poor; starting process and speed shifting process current impact is large; high speed operation vibration, safety is poor. Therefore, the original system in the safety and reliability, speed regulation, energy saving, operation, maintenance and other aspects have different degrees of defects. Since the inverter winch, so that the equipment level of the slope winch has changed qualitatively. At present, the frequency conversion winch has become the dominant product in the market, and its main features are as follows. Compact structure, small size, easy to move, used in underground mines can save a lot of development costs. ZF series frequency conversion winch is based on the full digital frequency conversion speed control, vector control technology as the core, so that the asynchronous motor speed performance can be comparable to the DC motor. The performance of low frequency torque, smooth speed regulation, wide range of speed regulation, high precision, energy saving, etc. Adopting double PLC control system, the control performance and safety performance of the inclined shaft winch is more perfect. Simple operation, safe and stable operation, low failure rate, and basically maintenance-free. Frequency conversion system composition In order to overcome the shortcomings of the traditional AC winding motor series resistance speed control system, the use of frequency conversion speed control technology to transform the hoist, you can achieve the full frequency (0 ~ 50Hz) range of constant torque control. The treatment of regenerative energy, can be used inexpensive energy braking program or energy-saving more significant feed-back braking program. And in the design process of the hydraulic mechanical braking, secondary brake valve and inverter braking to be integrated.  Inverter winch electric control system for single or double drum winding winches driven by AC asynchronous motors (wire-wound or squirrel-cage type). Can be used with the newly installed winches, but also suitable for the technical transformation of the old winch electrical control system. Frequency conversion winch electric control system can be simply divided into: frequency conversion speed control system (frequency converter + brake unit + brake resistor box); PLC control system driver's desk. The composition of the winch mechanical system is shown in Figure: System Features Two-wire system:The PLC control system consists of two main PLC systems.PLC1 is used as the main control system and PLC2 as the monitoring system. Each PLC system is equipped with its own independent position detection element (shaft encoder). During normal operation, the two PLC systems are put into operation at the same time to realize the "two-wire system" control and protection of the winch. In order to ensure that the two PLC systems can work synchronously, the position and speed signals of the two PLC systems are compared in real time within PLC1, and once the deviation is too large, an alarm will be immediately generated. The two PLC systems exchange data mainly in the form of communication Emergency mode: If one PLC fails or its position detection element fails, the single PLC can continue to work in the "Emergency 1" or "Emergency 2" mode. Winch in the emergency mode of work, due to the protection is not missing, but no "two-wire system". However, in order to ensure the safety and reliability of the winch operation, the operating speed is reduced to half speed. If two sets of position detection elements fail, the winch can only run at a speed of no more than 0.5m/s. Dual speed sources: The actual speed in the control system comes from two different speed sources, the inverter and the shaft encoder, and the actual speed involved in the control and overspeed protection is taken from the maximum value of both. Position control: PLC automatically generates the speed giving v(s) with travel as the independent variable, and the speed giving after the equal speed section implements the double giving of v(t) and v(s), and the travel giving v(s) is the main one in both. Semi-automatic operation mode: different from the traditional sense of semi-automatic operation mode, is the use of the driver's console "speed selector switch" to control the winch running speed and work gate opening and closing at the same time, especially for the operation of the inclined shaft winch. The working process of the hoist  After the hoist is transformed by frequency conversion, the working process of the system does not change much. When pushing the handle forward and backward, it can drive the encoder to rotate and send the pulse number to the PLC high-speed counting terminal, which can steplessly adjust the speed of the inverter within a certain range. It can also give "handle zero", "forward" and "reverse" contacts. No matter the motor is forward or reverse, the coal is dragged from the mine to the ground, the motor works in forward and reverse electric state, only when the fully loaded trailer is close to the mouth of the shaft, it needs to decelerate and brake, the hoist working timing diagram is shown in the figure below.

A layer of film is attached to the inside of disposable paper cups, instant noodle bowls or melon seed bags, etc. This is the effect of laminating machine processing. The laminating machine is a plastic machinery equipment that uses polyethylene and polypropylene as raw materials to coat plastic film on paper, BOPP, BOPET and other substrates by using extrusion laminating process to improve the tensile strength, air tightness and moisture resistance of the substrates. The equipment is widely used for lamination; release paper, mouth cup paper, paper bowl paper, melon bag paper, cleaning bag paper, trademark paper, non-woven fabric, gauze, aluminum foil and other substrates. The controller gives each inverter line speed signal to synchronize the whole machine; it controls the logical action of each part of the machine. Unwinding is center curl mode, using ZF3000 series high performance vector frequency converter to control output frequency in 'main + auxiliary' way, the main frequency is calculated using controller given line speed and roll diameter, the auxiliary frequency is controlled by closed loop of tension pendulum. The extruder speed is synchronized with the whole machine to maintain the same film quality attached on the same area of material. The cooling wheel runs at open-loop speed. The winding is a sleeve-cylinder winding method, using ZF3000 series high performance vector frequency converter to control the output frequency in the way of 'main + auxiliary', the main frequency is the controller given line speed signal, and the auxiliary frequency is controlled through the closed loop of tension pendulum. The difference with the unwinding is that the ZF3000 used for winding does not have a roll diameter calculation function. Unwinding is a duplex operation with a 'pre-drive' function that automatically calculates the frequency of the 'ready axis' according to the given line speed and roll diameter to synchronize the reel change. Control program features High line speed automatic disc change, automatic disc change fluctuation is small, high speed accuracy, system can be emergency stop in many places, high safety, line speed accuracy 0.1M/min, low frequency force 0Hz150%, film coating speed and line speed matching, film thickness to meet the end customer requirements

In textile industry, there are many varieties of equipment and complex structures, and many textile machines need speed regulation from the process. In the textile machinery, the constant line speed regulation of the fabric has experienced several forms of speed regulation, such as pure mechanical differential mechanism speed regulation, hydraulic motor speed regulation, wound rotor asynchronous motor and DC motor. In recent years, with the continuous improvement of the level of mechatronics of textile machinery, in order to improve production efficiency, improve product quality and reduce energy consumption, inverter as a way to improve the process and energy-saving transmission since the early 1990s batch into the textile industry, has been rapid growth. With the market for textiles has expanded, but competition has become more intense, for which manufacturers are committed to new equipment research and development to improve product competitiveness. The demand for inverters in the textile industry is growing and the requirements are increasing. It is the duty and mission of us to actively understand the textile industry, thoroughly study the demand of textile machinery for inverter, and provide the textile industry with applicable inverter products and solutions for inverter speed control transmission. Textile machinery classification Chemical fiber machinery, cotton textile machinery, knitting machinery, nonwoven machinery, printing, dyeing and finishing machinery Requirements of textile machinery for inverter Spinning machinery is responsible for removing, loosening and drawing cotton, wool, linen, silk and chemical fiber materials into uniform and flexible yarn. The starting process requires a smooth, inverter start frequency setting as low as possible. The braking process is required to be fast and smooth. Programmable multi-segment speed output. The multi-motor cascade operation requires speed synchronization. In order to wind the yarn evenly on the spindle, the frequency swing is required, i.e. the triangle wave frequency output for textile. with self-adjusting leveling control system, for high speed or high performance parallel machine requires vector closed loop control frequency converter or servo drive system. Weaving machines are responsible for processing fiber yarns into cloth, threads or knitted products. Winding, warping and sizing are the preparatory processes before weaving. Single spindle winders, knitting machines and warping machines require automatic stopping for faults and fixed length (or when the shaft is full). winding, drawing-in and twisting machines require frequency converters with oscillating frequency function. smooth start and fast braking. Sizing machine requires large speed range, constant tension and multi-motor synchronous speed control. Dyeing and finishing machinery is cloth and yarn after processing equipment. According to the process requirements can be divided into refining and bleaching, dyeing, printing, finishing and other processes, in each process, according to the different requirements of the processing fabric, and a number of unit operations. Among them, refining and bleaching include blank preparation - burning - desizing - cooking and refining - bleaching - mercerizing - heat setting and other processes. Intermittent dyeing machine requires wide range of speed regulation, tension winding control, fast forward and reverse rotation. Printing machine requires wide range of speed regulation, smooth and fast starting and braking, and high accuracy of flower positioning (positioning drive mostly adopts servo system). Washing machine load inertia, requiring frequency converter fast braking. Finishing line of multi-motor drive requires high speed synchronization accuracy, tension control. Some occasions require the inverter to take a common DC bus scheme to save the braking resistor as well as energy loss. Chemical fiber machinery includes spinning machine, post-treatment line, elastic yarn machine, nonwoven production line, etc. Power range: 0.75-280kW, with public rectifiers up to 800kW. Requirement for a common DC busbar solution. spinning machines are driven by permanent magnet synchronous machines to ensure high precision synchronization of speed at each drive point. the draft motor is required to keep the tension of the chemical fiber yarn constant both when running and stopping, and the frequency converter should have zero servo function and tension winding control function. the upper and lower double-roller separately driven hot rolling mill requires load balancing control function. ZFENG converter solution Our ZF900 series high-performance vector converter, has a wide range of applications in the textile industry, the following discussion of the Zhufeng converter solutions according to the speed control transmission characteristics of textile machinery respectively. Require reliable operation in the dusty and humid working environment of textile and dyeing workshop All Everest inverters have been improved in structural design, the air duct of module radiator is isolated from the control board, and the control board and devices are implemented with special dustproof and moisture-proof measures, so the reliability is greatly improved. Require reliable operation under the condition of poor quality of grid side For China's power grid voltage fluctuation, Everest inverter has the feature of wide voltage working range, which can work normally in the voltage range of 304V-456V; when there is instantaneous power failure in the power grid, Everest inverter has the function of "instantaneous stop and no stop", which can use the load inertia energy to keep the inverter running for a period of time. The equipment of steel cleaning and dyeing line is multi-motor cascade operation, which requires speed synchronization. ZF3000 has various ways of speed cascade synchronization, analog input and output, (ZF900) pulse input and output and field bus communication. The frequency setting has rich arithmetic and auxiliary quantity compensation function, which can meet the choice of different users and different usage requirements. Most of the textile equipments such as carding, roving and spinning require smooth starting and fast braking. Everest inverter has S-shaped acceleration and deceleration curve function, ZF900 series can run at low frequency to below 0.5Hz and still provide rated torque, which can ensure smooth start of machinery; energy braking and DC braking through braking resistor can easily realize fast and smooth braking. Spinning machinery requires multi-speed operation Everest inverter has built-in 16 preset frequencies to be given, which can be switched through external terminal control. Roving, spinning, rotor spinning and winding machines require swing frequency output in order to wind the yarn evenly on the spindle The center frequency and the shape of the triangle wave can be set individually, and it can also be used with the internal PLC function or the closed loop control function. Zhufeng converter solution features Textile industry is booming and the speed of technological progress and renewal of spinning machine equipment will become faster and faster. As a supporting part of spinning machine equipment, frequency converter will play an increasingly important role in improving the performance of spinning machine, improving textile technology and saving energy. It can make the ordinary asynchronous motor realize stepless speed regulation. Low starting current, reduce the capacity of power supply equipment. Starting smoothly, eliminating the impact of machinery, protecting mechanical equipment. The motor has a protective function, reducing the maintenance cost of the motor. 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Solutions for the plastics industry Plastics industry is the pillar of the national economy. Plastic machinery industry and plastic manufacturing industry to provide processing equipment, in recent years, China's plastic machinery industry is developing rapidly, its development rate and the main economic indicators created in the machinery industry, 194 industries ranked among the top. Plastic machinery annual manufacturing capacity of about 200,000 units (sets), a full range of categories. Although China's rapid development of plastic machinery, production of more varieties, basically to supply domestic plastic raw materials processing about plastic products processing, molding the general technical equipment required, individual products also into the world's forefront, but compared with developed countries in the industry, China's plastic machinery there is a big gap, mainly in the variety of less, high energy consumption, low level of control, unstable performance and other aspects. Plastic machinery classification Plastic extrusion machine Plastic injection molding machine Plastic film machine Film blowing machine Plastic film bag making machine Plastic laminating machine Plastic machinery requirements for inverters Plastic Extruders Extruder is the production equipment for manufacturing plastic sheet, film, various shaped pipes, etc. Plastic is plasticized into a uniform melt through the extruder, and under the action of the pressure established in plasticization, the head is continuously extruded through the screw at a fixed temperature, a fixed quantity and a low pressure. between the speed of the screw and the driving power, which is a constant torque load control. constant screw speed without sudden changes in the extrusion process. Constant pressure, when the demand pressure is reached, the speed control switches to pressure control. No shock when switching, and pressure PID control is realized after receiving the pressure signal. For high speed or high performance need vector closed loop control. Injection Molding Machine Injection molding machine is also known as injection molding machine or injection machine. It is the main molding equipment for making plastic products of various shapes from thermoplastic or thermosetting materials using plastic molding molds. The injection molding machine can heat the plastic and apply high pressure to the molten plastic to make it shoot out and fill the mold cavity. Make the quantitative pump into an energy-saving variable pump, so that the hydraulic system of the injection molding machine matches the power required for the operation of the whole machine, without high pressure throttling overflow energy loss. High efficiency and energy saving. Blister Machine Suction molding machine (also called thermoforming machine) is a machine that heats and plasticizes PVC, PE, PP, PET, HIPS and other thermoplastic rolls into various shapes of advanced packaging and boxes, frames and other products. After adding frequency converter, it can reduce power consumption, improve transmission efficiency, smooth speed and high precision. ZFENG Inverter Solutions ZFENG Electric's high performance, multi-functional, inverter ZF series is widely used in the plastic machinery industry. The following is the solution of EM series in plastic machinery industry. Application of Zhufeng ZF900 inverter on plastic extruder Before retrofitting: Sliding differential motor speed control After renovation: adopting frequency converter for speed regulation Everest ZF900 inverter integrated cabinet on injection molding machine ZF3000 is a high-performance vector inverter, which automatically adjusts the speed of oil pump motor to control the oil pump supply according to the current working status of the injection molding machine, ensuring that the oil supply of the oil pump is consistent with the hydraulic load of the injection molding machine in each working stage, and the oil pump motor has the least energy consumption in a complete injection working cycle, eliminating the overflow phenomenon and ensuring that the processing quality and efficiency of the injection molding machine are not affected in any way. Everest inverter solution features Extruder Saving power at 25%~60% and improving power factor. Change the quantitative pump into an energy-saving variable pump, so that the hydraulic system of the injection molding machine matches the power required for the operation of the whole machine, without high pressure throttling overflow energy loss. High reliability. Retain the original control method and oil circuit, find fault timely alarm, with overvoltage, undervoltage, overcurrent, overload, overheating and short circuit to ground and other protection, but also effective protection of the oil pump motor. Frequency conversion soft start, no inrush current, smooth starting . Reducing the vibration of the unlocking membrane and noise. Industrial/inverter switching . Simple operation, synchronous operation with the injection molding machine, without any adjustment. Injection molding machine Easy to install, no need to make changes to the injection molding machine, retaining the original control method and oil circuit. Saving electricity at 20%~60%, improving power factor. Free switching of industrial/inverter operation mode, even if the inverter is faulty, switching industrial frequency operation, does not affect normal production. Fault automatic reset function, to ensure continuous production. So that the quantitative pump into an energy-saving variable pump, so that the hydraulic system of the injection molding machine and the power required for the operation of the whole machine to match, no high-pressure throttling overflow energy loss. High reliability. The alarm is found in time, with over-voltage, under-voltage, over-current, overload, overheating and short-circuit to ground protection, but also effective protection of the oil pump motor. Frequency conversion soft start, no inrush current, smooth starting . Reduce the vibration of the unlocking membrane, reduce noise and extend the life of the machine. Simple operation, synchronous operation with the injection molding machine, without any adjustment. Operators do not need training, does not affect the production and processing efficiency. .gtr-container { font-family: Arial, sans-serif; color: #333333; font-size: 14px !important; line-height: 1.6; max-width: 1000px; margin: 0 auto; } .gtr-heading { font-weight: bold; color: #1a5276; margin: 20px 0 10px 0; font-size: 18px !important; } .gtr-subheading { font-weight: bold; color: #2874a6; margin: 15px 0 8px 0; font-size: 16px !important; } .gtr-paragraph { margin-bottom: 15px; } .gtr-list { margin: 10px 0 15px 20px; padding-left: 15px; } .gtr-list li { margin-bottom: 8px; } .gtr-image-container { margin: 20px 0; text-align: center; } .gtr-image-caption { font-style: italic; margin-top: 5px; font-size: 13px !important; } .gtr-feature-box { background-color: #f8f9f9; border-left: 4px solid #3498db; padding: 15px; margin: 20px 0; } .gtr-feature-title { font-weight: bold; margin-bottom: 10px; color: #2874a6; }

Overview Mine hoist is an important equipment in the production process of coal mines and non-ferrous metal mines. The safe and reliable operation of the hoist is directly related to the production status and economic benefits of the enterprise. This kind of dragging system requires frequent forward and reverse motor starting, deceleration and braking, which is a typical frictional load, i.e. constant torque characteristic load. Previously, mainly within the gear winch (mechanical drag), hydraulic winch (hydraulic drag) and AC asynchronous motor rotor series resistance speed control winch (electrical drag) and other types of dominant. The power of the inclined shaft hoist is provided by the wire-wound motor, which uses the rotor series resistance speed regulation. The mechanical structure of the inclined shaft hoist is schematically shown in the following figure. At present, most small and medium-sized mines use inclined shaft winch to hoist, and the traditional inclined shaft hoist generally adopts AC winding type motor series resistance speed control system, and the resistance is controlled by AC contactor- thyristor. This control system is easy to oxidize the main contacts of the AC contactor and cause equipment failure due to the frequent action of the AC contactor during the speed regulation process and the long operation time of the equipment. In addition, the speed control performance of the hoist in the deceleration and crawling stage is poor, often resulting in inaccurate stopping position. The frequent starting, speed regulation and braking of the hoist generates considerable power consumption in the rotor external circuit of the series resistor. This AC winding motor series resistance speed control system is a step speed control, speed control of the smoothness is poor; low speed mechanical characteristics of the soft, static difference rate is large; resistance on the consumption of the differential power, energy saving is poor; starting process and speed shifting process current impact is large; high speed operation vibration, safety is poor. Therefore, the original system in the safety and reliability, speed regulation, energy saving, operation, maintenance and other aspects have different degrees of defects. Since the inverter winch, so that the equipment level of the slope winch has changed qualitatively. At present, the frequency conversion winch has become the dominant product in the market, and its main features are as follows. Compact structure, small size, easy to move, used in underground mines can save a lot of development costs. ZF series frequency conversion winch is based on full digital frequency conversion speed control and vector control technology as the core, so that the speed control performance of asynchronous motor can be comparable to that of DC motor. The performance of low frequency torque, smooth speed regulation, wide range of speed regulation, high precision, energy saving, etc. Double PLC control system is adopted to improve the control performance and safety performance of the inclined shaft winch. Simple operation, safe and stable operation, low failure rate, and basically maintenance-free. Inverter system composition To overcome the shortcomings of the traditional AC winding motor series resistance speed control system, the use of frequency conversion speed control technology to transform the hoist, you can achieve the full frequency (0 ~ 50 Hz) range of constant torque control. The treatment of regenerative energy, can be used inexpensive energy braking program or energy-saving more significant feed-back braking program. And in the design process of the hydraulic mechanical braking, secondary brake valve and inverter braking to be integrated. Inverter winch electric control system for single or double drum winding winches driven by AC asynchronous motors (wire-wound or squirrel-cage type). Can be used with the newly installed winches, but also suitable for the technical transformation of the old winch electrical control system. Frequency conversion winch electric control system can be simply divided into: frequency conversion speed control system (frequency converter + brake unit + brake resistor box); PLC control system driver's desk. Winch mechanical system composition as shown in Figure. System features Two-wire system: The PLC control system consists of two main PLC systems, PLC1 as the main control system and PLC2 as the monitoring system. Each PLC system has its own independent position detection element (shaft encoder). During normal operation, the two PLC systems are put into operation at the same time to realize the "two-wire system" control and protection of the winch. In order to ensure that the two PLC systems can work synchronously, the position and speed signals of the two PLC systems are compared in real time within PLC1, and once the deviation is too large, an alarm will be immediately generated. The two PLC systems mainly exchange data in the way of communication. Emergency mode: If one PLC fails or its position detection element fails, the single PLC can continue to work in the "Emergency 1" or "Emergency 2" mode. Winch in the emergency mode of work, due to the protection is not missing, but no "two-wire system". However, in order to ensure the safety and reliability of the winch operation, the operating speed is reduced to half speed. If two sets of position detection elements fail, the winch can only run at a speed of no more than 0.5m / s. Dual speed sources: The actual speed in the control system comes from two different speed sources, the inverter and the shaft encoder, and the actual speed involved in the control and overspeed protection is taken from the maximum value of both. Position control: PLC automatically generates the speed given by the stroke as the independent variable v(s), and the speed given by the equal speed section after the implementation of v(t) and v(s) double giving, in both of which v(s) is mainly given by the stroke. Semi-automatic operation mode: Different from the traditional semi-automatic operation mode, it uses the "speed selector switch" on the driver's console to control the running speed of the winch and the opening and closing of the working gate at the same time, which is especially suitable for the operation of the inclined shaft winch. Lifter working process After the hoist is transformed by frequency conversion, the working process of the system does not change much. When pushing the handle forward and backward, it can drive the encoder to rotate and send the pulse number to the PLC high-speed counting terminal, which can steplessly adjust the speed of the inverter within a certain range. It can also give "handle zero", "forward" and "reverse" contacts. No matter the motor is forward or reverse, the coal is dragged from the mine to the ground, the motor works in forward and reverse electric state, only when the fully loaded trailer is close to the mouth of the shaft, it needs to decelerate and brake, the hoist working timing diagram is shown in the figure below. .gtr-container { font-family: Arial, sans-serif; color: #333333; line-height: 1.6; max-width: 1000px; margin: 0 auto; padding: 20px; } .gtr-heading { font-size: 18px !important; font-weight: bold; color: #2c3e50; margin: 25px 0 15px 0; padding-bottom: 5px; border-bottom: 2px solid #3498db; } .gtr-text { font-size: 14px !important; margin-bottom: 15px; } .gtr-list { font-size: 14px !important; margin-left: 20px; padding-left: 15px; } .gtr-list li { margin-bottom: 8px; } .gtr-image { max-width: 100%; height: auto; margin: 20px 0; border: 1px solid #ddd; box-shadow: 0 2px 4px rgba(0,0,0,0.1); } .gtr-image-container { text-align: center; margin: 25px 0; } .gtr-image-caption { font-size: 12px !important; color: #666; margin-top: 5px; font-style: italic; }

Ball mill power saving principle Wet ball mill (ceramic enterprises) is selected and configured according to the diameter of the drum and the process requirements and production volume It contains motor (primary power) reducer, hydraulic coupling, auxiliary motor, brake coil, pulley, drum, etc.. The original control for running at a constant speed, only through experience and test to determine what products need to do how much time, that is, when the ball, while the starting force distance is very large and difficult to start. And after a large number of trials and data summary of our company, for the ball mill developed ACI ball mill economizer, production of various power section of the series of products DLT-QM11 control cabinet and Q11 controller. Working process: The ball mill is based on media movement, and the grinding process of material particles occurs between media and media and between media and liner plate. The media movement is divided into throwing down (adapted to coarse grinding), lagging (adapted to fine grinding) and centrifugal (lost grinding effect). According to the above three types of motion and force, in order to improve the efficiency of ball mill, the ball mill economizer adopts vector control calculation to decompose the force longitudinally and laterally, make it a scalar quantity in the rotating axis and control it, and at the same time use fuzzy theory to track and sample the ball mill, so as to adjust the output torque and speed. It makes it achieve the best grinding effect with the most economical power. The following figure shows. Save electricity through four areas The soft start function of the economizer can reduce the starting current by 4-7 times. The power factor of the economizer can reach above 0.99, while the power factor of the original motor is below 0.88. Because different products require different speeds, and because power is proportional to the square of speed, we can set different control speeds at different times, and customers are free to set or choose (through a microcomputer processor to achieve). The economizer can automatically track the best running current of the motor in real time, so as to adjust the corresponding output voltage and torque to reach the best economic running point. According to the above four points, the comprehensive power saving effect can reach more than 10%-35%, the average can reach about 15%, the effect is very significant. It is different from the general frequency converter, soft starter and power factor compensator, it is an organic combination of the three, a perfect combination of overcoming starting difficulties and effective energy saving, and is the preferred energy-saving product for modern ceramic enterprises. Functions and features of ball mill economizer ACI ball mill special power saver has unique dynamic power saving function, and the power saving rate reaches 10%~35%. After the installation of ACI ball mill special economizer, the ball mill start becomes real soft start, the starting impact force of the ball mill is greatly reduced, and the life of the belt and gear of the ball mill is greatly improved. After using this machine, since both the starting impact current and working current of ball mill are reduced, it will not cause the fluctuation of grid voltage and decrease of grid voltage, which eliminates the fault phenomenon such as tripping of other electric equipment caused by this. ACI ball mill special power saver has perfect protection functions of overload, overcurrent, short circuit and grounding. It is easy to set the ball mill time and automatic stop time, and it is also easy to choose the grinding time. Low investment and high return, all investment can be recovered within 5-12 months by saving electricity cost. Our ACI ball mill special economizer is a special ball mill special economizer developed and produced on the basis of frequency conversion with special improvement and software enhancement, which is different from the general inverter. After the installation of ACI ball mill special economizer in ceramic factory, the ball mill can start easily and the starting current can be controlled below the rated current (for example: 100 tons ball does not exceed 500A, 60 tons ball does not exceed 400A, 40 tons ball mill starting current does not exceed 300A), so the starting performance of the equipment is very good, which greatly reduces the starting current of ball mill, the impact of power grid and mechanical equipment. It also improves the efficiency of transformer capacity use by more than 20%, in the same transformer capacity, it can increase the number of ball mills and increase the equipment without increasing the transformer capacity, saving a lot of money, in addition, it can also improve the ball mill belt, bearing, gear life of the reducer, etc., reducing the cost of maintenance. When starting, it will not cause fluctuation of power grid and decrease of power grid voltage, which eliminates the tripping of other power equipment and undervoltage fault caused by it. It is especially suitable for the use of generators and ball mills in low power grid. The need for energy-saving renovation of ball mill Factories that use ball mill equipment generally have long working hours and consume a lot of electricity, with annual electricity expenses reaching millions, causing a heavy cost burden to the factory. The electricity consumption of ball mill accounts for 40-60% of the total electricity consumption of the workshop, therefore, in order to effectively bring down the cost expenditure, we must first solve the problem of electricity consumption of ball mill. And the existing ball mill equipment and its working method mainly have the following problems: The existing starting and control methods of ball mills are not power-saving, such as through the transformation can save a lot of electricity costs. The impact force of the ball mill is not large when starting with the existing starting method, which will easily cause damage to the ball mill bearings and gears of the wave box and result in large maintenance costs. When starting the ball mill with the existing starting method, the impact current is very large (usually 7-8 times of the rated current), which will cause voltage fluctuations in the power grid and reduce the power grid voltage, thus causing other power equipment to trip and malfunction, which will inevitably affect normal production. Therefore, it is extremely necessary to carry out power saving transformation for ball mill equipment. After the transformation, not only can significantly reduce the cost of electricity, maintenance costs, reduce costs, and by reducing the line loss and line heating, can extend the service life of the ball mill, reduce noise pollution, while improving the safety factor of the workshop production line. .gtr-container { font-family: Arial, sans-serif; font-size: 14px !important; line-height: 1.6; color: #333; max-width: 100%; margin: 0 auto; padding: 15px; } .gtr-heading { font-size: 18px !important; font-weight: bold; color: #1a5276; margin: 20px 0 10px 0; padding-bottom: 5px; border-bottom: 1px solid #ddd; } .gtr-subheading { font-size: 16px !important; font-weight: bold; color: #2874a6; margin: 15px 0 8px 0; } .gtr-paragraph { margin-bottom: 15px !important; } .gtr-list { margin: 10px 0 15px 20px !important; padding-left: 15px; } .gtr-list li { margin-bottom: 8px !important; } .gtr-image { max-width: 100%; height: auto; margin: 15px 0; border: 1px solid #ddd; display: block; } .gtr-highlight { background-color: #f8f9fa; padding: 15px; border-left: 4px solid #3498db; margin: 15px 0; }

Variable Frequency Drive (VFD) is a power electronic device used to control the speed and torque of AC motors. It achieves precise adjustment of the motor's operating speed by changing the frequency and voltage of the power input to the motor. Frequency converters are widely used in industrial automation, building control, energy management, and other fields, and are an indispensable core component in modern motor drive systems. I. Working Principle of a VFD A VFD primarily consists of four parts: a rectifier, a DC bus, an inverter, and a controller: Rectifier: Converts incoming AC power to DC power. DC Bus: Filters and stores the rectified DC power, providing a stable DC voltage. Inverter: Converts the DC power back to AC power with adjustable frequency and voltage, supplying it to the motor. Controller: Adjusts the output frequency and voltage of the inverter based on control signals to achieve precise motor control. Core Principle: According to the motor speed formula n=p120f​×(1−s) (where n is speed, f is power supply frequency, p is the number of pole pairs, and s is slip), a VFD changes the power supply frequency f to alter the motor speed. II. Main Functions of a VFD Speed Control: Enables stepless speed regulation of the motor to meet varying speed requirements under different operating conditions. Energy Savings: Adjusts motor speed based on load demand, avoiding inefficient "over-specification" and reducing energy consumption. Soft Start Function: Limits inrush current, reducing shock to the power grid and mechanical equipment, and extending equipment lifespan. Protection Functions: Includes overload, overvoltage, undervoltage, overcurrent, and short-circuit protection to enhance system reliability. Improved Process Quality: Enhances product quality in industries requiring precise speed control, such as textiles, papermaking, and printing. III. Applications of VFDs Industrial Automation: Used for speed control of conveyors, fans, pumps, compressors, and other equipment. Building Control: Applied in energy-efficient control of HVAC systems, water supply and drainage systems, elevators, etc. Energy Management: Used for power regulation and optimization in renewable energy systems like wind and solar power. Transportation: Applied in motor drive control for electric vehicles and rail transit. Machine Manufacturing: Used in CNC machines, injection molding machines, packaging machinery, etc., to achieve precise speed and torque control. IV. Advantages of VFDs Significant Energy Savings: Particularly effective in reducing energy consumption for fan and pump loads through speed regulation. Extended Equipment Lifespan: Soft start and speed regulation functions reduce mechanical shock and wear. Easy Operation: Modern VFDs feature user-friendly interfaces and communication ports for convenient parameter setting and remote monitoring. Strong Adaptability: Suitable for various types and power ratings of motors, meeting diverse application needs. V. Classification of VFDs By Input Power: Single-Phase Input VFD: Suitable for low-power motors, with single-phase AC input. Three-Phase Input VFD: Suitable for medium to high-power motors, with three-phase AC input. By Output Voltage: Constant Torque VFD: Output voltage is proportional to frequency, suitable for constant torque loads. Constant Power VFD: Output voltage remains constant at high frequencies, suitable for constant power loads. By Control Method: V/F Control VFD: Regulates motor speed by adjusting the ratio of voltage to frequency, with a simple structure and low cost. Vector Control VFD: Based on the motor's mathematical model, achieves decoupled control of torque and flux, with good dynamic performance. Direct Torque Control VFD: Directly controls motor torque and flux, with fast response and high control accuracy. VI. Selection and Usage Considerations for VFDs Selection Criteria: Power Matching: The rated power of the VFD should slightly exceed that of the motor. Voltage Rating: The output voltage of the VFD should match the motor's rated voltage. Control Method: Choose an appropriate control method based on load characteristics. Environmental Requirements: Consider the installation environment of the VFD, such as temperature, humidity, and altitude. Usage Considerations: Proper Grounding: Ensure reliable grounding of the VFD to prevent leakage and interference. Cooling Measures: The VFD generates heat during operation, requiring good ventilation and cooling. Electromagnetic Compatibility: The VFD may generate electromagnetic interference, requiring shielding and filtering measures. Maintenance: Regularly inspect the VFD's operating status, clean dust, and check for loose connections. If you want to learn more about frequency converters, please feel free to contact us at any time.

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