The Application of FD300 high-performance low voltage drive in Open Mill
Rubber, a highly elastic polymer material, is widely used in both industrial and daily life fields. For instance, vehicle tires, insulated cables, and children's toys are all made from it. However, in the face of the severe global energy shortage, the rubber industry, as a high-energy-consuming sector, is now confronted with an urgent energy consumption issue.
1. Item information
A certain tire company in Shandong is a rubber company that integrates tire manufacturing, sales and related products. The company's annual production capacity reaches 3 million sets of all-steel heavy-duty tires and 80,000 sets of all-steel, cross-ply engineering tires. It also produces over 12,000 all-steel and cross-ply giant tires and 600,000 industrial vehicle tires. The annual output value is as high as over 6 billion yuan. According to different usage environments, they classify and manufacture various high-quality tires with features such as long-distance wear resistance, mining-specific types, and medium-short distance carrying capacity. These tires have received wide acclaim from users in both domestic and international markets.
2. Customer Pain Point
The rubber compounding equipment plays a crucial role in the production process of the tire industry. Since tire enterprises are energy-intensive enterprises, 40% to 60% of their energy consumption is spent in the rubber compounding workshop. Therefore, reducing the electricity consumption in the tire industry mainly lies in the rubber compounding equipment. The open mill mainly relies on two rotating rollers that are in opposite directions to exert compression and shearing effects on the rubber. Through multiple kneading processes and the chemical reactions that occur during the kneading process, the large molecular chains inside the rubber are broken, allowing the various components in the formula to be evenly mixed, thus meeting the requirements of rubber compounding.
The open mill has a constant torque load characteristic. At different stages of rubber mixing, the load varies greatly. Therefore, it is necessary to respond quickly to the equipment operation conditions caused by sudden load changes. Meanwhile, due to the high on-site temperature and heavy oil contamination, it has brought certain challenges to production.
3. The on-site operation effect of the FD300 series high-performance frequency converter
The original production line of the owner unit used a 245kw asynchronous motor. However, due to its low energy efficiency (0.85), the overall electricity economy was poor. In response to the national call for energy conservation and emission reduction, after recommendation, they have now replaced it with an FGI FD300 series high-performance frequency inverter. Using the rotor field-oriented vector control method to control the motor for large torque, high precision, and wide-range speed regulation, it has the characteristics of being resistant to high temperature, humidity corrosion, not prone to demagnetization, high reliability, and powerful functions.
After use, the overall efficiency was increased to around 0.95. Meanwhile, the rated output current of the FD300 series high-performance frequency inverter was 590A. During the production process, the peak current reached 1100A, but the equipment did not stop running due to overcurrent. We hope that this successful variable frequency transformation of the open-molding machine can minimize energy consumption, improve economic benefits and production efficiency, ensure the safe operation of the opening-molding equipment, and fully demonstrate the important position of variable frequency speed regulation technology in industrial production.
