logo
products
SOLUTION DETAILS
Home > Cases >
Application of Frequency Inverters in Air Compressors
Events
Contact Us
86--13829778525
Contact Now

Application of Frequency Inverters in Air Compressors

2025-08-08

Latest company case about Application of Frequency Inverters in Air Compressors

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:

  1. Pressure Detection: Pressure sensors monitor system pressure in real time.
  2. Signal Feedback: Pressure signals are transmitted to the frequency inverter.
  3. Frequency Adjustment: The inverter modulates the motor's power supply frequency based on pressure signals, altering rotational speed.
  4. 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.