English (UK) 
简体中文 Why does the workshop electricity bill break the meter every month? Your home's multiplier chain may be secretly burning money!
Dry twenty years of factory operation and maintenance, seen too many companies spend a lot of money on new equipment, but ignored those 24 hours buzzing old times the speed chain - no load when soaring at full speed, chain friction sparks, motor hot like a soldering iron ... ... These invisible tigers of electricity, a minute to swallow up 30% of your profits! Today we will nag to understand, from a few hundred dollars of inverter to intelligent control, how to step by step to cut down the electricity bill.
First, frequency conversion: to the motor with "intelligent throttle"
Q: Why does an idling motor cost electricity? It's like a truck with the throttle down!
The old motor will run at full power as soon as it is switched on, regardless of whether you have goods or not. Frequency converter is to give the motor with a smart brain, so that it should be fast fast, the slow slow slow.
Three Steps to Practice::
- Pick the right inverterVector inverters are recommended for workstations with large load fluctuations (e.g. assembly line gaps), such as ABB ACS880, which is a big brand, more expensive but more costly.
- Velocity profile: No-load speed down to 30%-50%, acceleration time set ≥ 10 seconds - don't mind that little deceleration time, the motor inrush current can drop 60%!
- evaluate the results and see what happens (idiom); to judge by the results::
Suzhou electronic factory measured: no-load speed from 15m/min down to 10m/min.Gaining 12,000 kWh of electricity a year for nothingThe motor life has been extended by 40%.
Second, the transmission system to reduce the burden: and friction loss "fight"
Q: What does chain friction have to do with the electricity bill?
Friction = burning moneyThe friction coefficient is 0.1 per litre! Friction coefficient of 0.1 per litre, energy consumption directly up 12%. old steel chain dragging the rusty guide rail, living like an old ox pulling a broken cart.
Save Money 3-Pack::
- Self-lubricating chainCoefficient of friction has dropped dramatically from 0.15 to 0.03, and it saves you from climbing the ladder to grease it every month!
- Polymer guide: Replacement of engineering plastics rails reduces resistance by 30% and saves lubrication costs by 40%.
- Workplace boards slimmed downReplace the iron plate with hollow aluminium alloy and cut the weight in half.
Zhejiang auto parts factory personally tested: three strokes used togetherMonthly Electricity Bill Reduction 18%The noise level in the workshop was reduced from 75 dB to 62 dB - the workers' ears were cleared!
Third, intelligent control: special "idle ghost"
Q: Why does the equipment not stop when there is no work on the production line?
The 30%'s factory doubler chains are all idling and consuming power! The photocells are not fitted properly, the PLC control is not zoned, and the electricity bill is just going down the drain.
Root and Branch Programme::
- act as a guideKey stations with high-precision photoelectric sensors (±1mm error) to keep an eye on the material in real time.
- manifold: Use PLC to cut the production line into small sections, and automatically stop the section with no work.
- energy recovery: Regenerative braking unit in the lift section, braking energy to electrical energy
Shanghai electronics factory relies on this trickRecovery of 23,000 kWh of electricity per yearThat's $14,000 for nothing.
Fourth, avoid the pit guide: do not let the transformation into a "car"
Q: Why do others save 40%, but I only save 10% after the change?
Step on one of these three minefields and it's all over:
- bite off more than one can chew::
do sth. firstInverter + Intelligent Start/Stop(power saving 25%+), get energy recovery when you're back in the money
→ Phased transformation over one-stepPayback is six months early. - Equipment fights::
New inverter connected to old PLC?First, 48 hours with a signal simulator.Don't wait for production to stop and cry. - security hole::
Retention of the industrial frequency emergency circuitSwitching speed <0.5 sec, no fear of line breakdown even in power failure.
Personal opinion: the matter of saving electricity must be "key details".
After working on so many projects, I've noticed a pattern.Companies that are willing to spend time on sensors and commissioning save at least 30% more electricityFor example, in Guangdong that home power plant. For example, Guangdong that home power plant, photoelectric sensors adjusted for three days to find the right position, the result of idle time froze down 80%.
And ah.Don't look down on petty cash.! A self-lubricating chain is expensive at $50 a year, but it saves enough electricity to buy ten chains. Electricity costs only rise these days, now each degree of electricity to gouge down 10 cents, five years later may be to gouge down 30 cents - I say, energy-saving transformation is a sure-fire deal!
(Note: case data from industrial measurement, the actual effect varies depending on the production line conditions, it is recommended to find a professional factory to do a physical examination of energy consumption before doing so)
