English (UK) 
简体中文 Is your factory "burning money for nothing"?
Imagine: a dozens of metres long speed chain conveyor line, no goods when the idling motor, the chain clatters and runs -Isn't that like holding up a note and throwing it into a fireplace?Did you make it? Xichang vanadium plate mill's hot rolling line, 76 motors idle when the load factor is only 20%.The photoelectricity costs hundreds of thousands of dollars more a year.The more heartbreaking is that this kind of "running on empty" also makes the chain wear double. What's more, this kind of "running on empty" also doubles the wear and tear of the chain and makes it painful to change parts!
Intelligent start/stop: the best way for motors to learn to be lazy
At the heart of it all: no work? Take a break right now!
- How do you judge "no work"?
Put a few on the conveyor linePhotoelectric sensors(With automatic door induction a principle), real-time scanning there is no goods through. Once a section of 30 seconds did not detect the material, the system automatically cuts off the power supply; waiting for the goods to arrive 15 seconds in advance and then start.It's like an older driver waiting for a red light to turn off the engine and firing it up before the green light, saving fuel and not delaying things! - How much to save? Straight to the hard stuff.
reconstruction project traditional model Intelligent start/stop mode effect Motor start/stop frequency work around the clock Reduction of 701TP by more than 3T Equipment life + 2 years annual electricity consumption 450,000 degrees 270,000 degrees Power Saver 40% Chain replacement 4 times/year 1 time/year Maintenance Fee Directly Reduced by 75%
To put it bluntly, the system is a "smart switch" for the production line.When it's time to move, it's time to sleep., electricity and maintenance double kills!
Lightweighting: can "slimming down" conveyor lines also save money?
Don't underestimate the weight of the work board!Which is more tiring, when you move 10kg of bricks or 5kg of bricks? Same thing with motors!
- Material substitution is king.
- Replacing bulky steel work plates withaluminiumThe weight is directly cut down by 15%, and the motor load is reduced by 10%.
- High-end play onCarbon Fibre (CFRP)The weight is halved and the power-saving 30% starts (just a bit more expensive, so feel free to be a tycoon).
- Structural optimisation has a hidden agenda.
pass (a bill or inspection etc)topological optimisation(Simply put, the computer design skeletonised the bracket), shaving off 30% redundant material under guaranteed load bearing.It's like unloading a useless cargo box from a truck that runs light and saves fuel!
Live Action! A power plant's electricity account book that saves $150,000 a year
Let's look at a real thing: a factory making air-conditioning housings, the 80-metre-long doubling chain is split into four independently controlled segments, while the workpiece boards are put on a "diet".What's the result? Look directly at the bill.
| expenditure item | Before conversion (years) | After conversion (years) | How much do you save? |
|---|---|---|---|
| electricity | $280,000. | $168,000 | 112,000 |
| Chain replacement | $60,000 | $15,000 | 45,000 |
| Motor Repair | $30,000 | 0.8 million | 22,000 |
| add up the total | $370,000 | $191,000 | 179,000 ≈ provincial car |
The key operation is a triple axe.
- segmented intelligent control4-stage independent start/stop, avoiding "one person working and the whole family running".
- Sensor Array: Omron photoelectric eye installed at the head and tail of each section, false judgement rate <0.1%
- Weight reduction of workpiece panels: Replacement of steel plates with aluminium plates, reduction from 8kg to 5kg per piece
A three-step guide to a makeover even a beginner can handle
Step 1: Uncovering the "electricity bill assassin"
hold (a bag)clamp-on ammeterSnap the motor wires and measure the current at idle. IfExceeds rating 15%Congratulations on finding the "Electric Tiger"!
Step 2: equipment so choose not to step on the pit
| Equipment type | testimonial | Why did you choose it? |
|---|---|---|
| converter | Schneider ATV630 | With energy return, save 5% more electricity |
| transducers | Omron E3Z-D82 | Dust prevention and misjudgment, assembly line "fire eyes" |
| Lightweight panels | 6061 aluminium alloy | Strong enough, lightweight and affordable |
Step 3: Installation of lightning rods
- Don't be brutal!Older production lines are added firstSignal Conversion ModuleOtherwise the new inverter won't connect to the old PLC.
- Stay back.Retain the industrial frequency back-up line and manually top up when the intelligent system is pumping air
- Pilot first.carry on a shoulder poleCache segments with no load factor >50%Change first, quick payback (usually 6 months), bosses look at it and nod straight away
Personal view: the truth of power saving hidden in the "combination of punches"
A lot of people think that if they change to a high efficiency motor that everything will be fine -Wake up! It's been tested that replacing the motor alone saves 10% of electricity at most.becauseThe pit of idling was never filled.!
It's like if you replaced a fuel efficient engine in a truck and let it blow the throttle with no load!Real energy saving, must let the equipment "will be lazy" (intelligent start-stop) + "less weight" (lightweight), a two-pronged approach is required to blow up the 40%'s power-saving space.
By the way, remember to check every month after the changeChain sagging (don't exceed chain length of 2%)respond in singingMotor current fluctuation (within ±10%)-The data floats, 80% of the screws are loose or the bearings are stuck in the grey. Tighten it up by hand and it will last another three years!
(Data referenced from Xichang Steel Vanadium Retrofit Case Study and Multiplier Chain Energy Saving Technology White Paper)
