Application of FD5000 in Cement Production Lines within the Construction Industry

1. Overview

The cement industry serves as a crucial foundational sector and a major supplier of essential raw materials for the construction industry. It plays a vital role in the development of the national economy. In recent years, with the saturation of the real estate market, the cement industry has shown some new development trends.

Amidst this wave of industry transformation, frequency converters, as key equipment in cement production lines, are essential for the production efficiency and environmental compliance of cement enterprises. A certain cement company faced issues with its high-voltage frequency converters, including aging equipment and frequent failures due to prolonged use. These problems led to increased downtime, severely disrupting normal production. Consequently, the company decided to upgrade the system, demanding new equipment with excellent performance and stability. They also required a swift implementation to minimize production losses caused by equipment stoppages.

2. Implementation Plan

Based on the customer's requirements, we employed the independently developed and manufactured FD5000-10-900G-1A series high-voltage frequency conversion system, matched with the customer's 900kW asynchronous motor. The solution details are as follows:

The FD5000 series frequency converter's unit cabinet employs a structure with 9 units connected in series per phase. The secondary windings of the phase-shifting transformer (Class H insulation) supply power to each power unit. Each power unit carries the full current, corresponding to 1/9 of the phase voltage and 1/27 of the output power. All 27 units have independent input windings, ensuring insulation between them. The secondary windings utilize an extended delta connection to achieve multiplexing and reduce input current harmonics. These 27 secondary windings are divided into three phase groups.

The secondary windings of the phase-shifting transformer divide into three groups, achieving 54-pulse rectification. This configuration lowers the harmonic content in the input current waveform, bringing the load power factor close to 1. Measurements indicate that the total harmonic distortion (THD) of the input current is less than 5%.

Stable Motor System Operation: The FD5000 series utilizes precise vector control technology, ensuring stable operation of the motor system under varying load conditions and reducing the risk of system oscillation and faults.

Intelligent Energy Consumption Management: The introduction of an intelligent energy management system enables real-time monitoring and management of the motor system's energy consumption, enhancing the intelligence of energy utilization.

Reduced Maintenance Costs: Equipped with comprehensive protection and diagnostic functions, the FD5000 series lowers the motor system's failure rate, thereby reducing maintenance and repair costs.

The FD5000 series frequency converter adopts a one-to-one automatic control method. The converter does not need to distribute power or coordinate multiple loads. It allows for complete parameter optimization tailored to the specific characteristics of the single equipment (such as motor rated power, speed requirements, load fluctuation patterns). This enables more precise automatic control and maximizes the advantages of on-demand power supply, avoiding energy waste caused by load disparities.

3. Application Advantages

• Reduced Production Losses: Through precise speed regulation and optimized operation, the system significantly improves energy utilization efficiency and noticeably lowers energy consumption.
• Coordinated System Optimization: The system features comprehensive protection with multiple built-in software protection functions. The frequency converter control system integrates perfectly with the customer's system, enabling automated control and optimized management of the production process. This enhances production efficiency and reduces labor intervention costs.
• Stable Equipment Operation: The new FD5000 series frequency converters eliminate the risk of downtime and production stoppages associated with aging equipment. They improve equipment reliability and stability, ensuring production continuity.
• Excellent Speed Regulation Performance and Control Capability: The high-voltage variable frequency speed control technology delivers high output power and causes minimal harmonic pollution to the power grid.