China's motor drive system consumes 2/3 of the total electricity, and 90% of the motors used are AC asynchronous motors. The power consumption of fans and pumps is about 35% of the national total. There are 150 million kilowatts, and the motor capacity of the rolling mill, mine hoist, mill, transportation machinery, machine tools and other production equipment is about 300 million kilowatts, and the power consumption accounts for about 30% of the national total. Fans and pumps reach about 70% of the total, installed capacity is nearly 100 million kilowatts, and annual electricity consumption is about 300 billion kilowatt-hours. They regulate the flow by gates or valves to roughly adapt to the load, and the average waste is 20%. The above electric energy is 200-300 billion yuan. It can be seen that the motor drag system has a lot of space for energy saving. The use of reliable energy-saving technologies for the energy-saving transformation of such equipment will have far-reaching significance for vigorously promoting energy conservation and emission reduction, and promoting the sustainable development of China's economy and environmental protection.
2 CB-DT series energy-saving principle, technical features and applications applied to fans and pumps
2.1 CB-DT series motor energy saving system
The CB-DT series motor energy-saving system includes a dynamic load tracking management control part and a motor drag part, wherein the dynamic load tracking management control part includes a control computer, a communication protocol conversion unit, a digital and analog interface unit, a protection unit, and system control software ( Customized), etc.; the motor drag part is the actuator mainly including the stator or rotor speed control device and the control protection mechanism.
Through the communication protocol between the above systems, multi-party communication can be realized, and real-time monitoring, control and management of the controlled system operation can be realized through comprehensive parameter collection of the system.
2.2 Energy-saving principle of CB-DT series applied to fans and pumps
Fans and pumps are commonly used in all walks of life. In actual use, the flow, pressure and temperature of fans and pumps need to be adjusted frequently. Most fans and pumps are regulated with conventional baffles or valves, allowing a large amount of energy to be spent on the baffles or valves. Fan and water pump saver adopting frequency conversion speed regulation technology can realize dynamic adjustment with the requirements of the process, greatly reduce energy consumption, improve the stability and operating efficiency of the system automatic device, and provide reliable guarantee for the economic optimization operation of the system, and guarantee The safe operation of the equipment. The mechanical characteristics of the fan and pump equipment (taking the water pump as an example) have the following three relationships: Qâˆn; Hâˆn 2; Pâˆn 3 where: Q fluid flow; n motor speed; H head; P axis power.
That is to say, the flow rate is proportional to the rotational speed, the head (pressure) is proportional to the square of the rotational speed, and the power is proportional to the rotational speed cube.
It can be seen from the above formula that as long as the rotational speed n is changed, the flow rate Q is proportionally changed, so that the purpose of adjusting the flow rate Q can be achieved, and the shaft power also changes accordingly. For example, if Q'=1/2Q, then P'=1/8P, the shaft power is only 12.5% ​​of the rated value, and the power can be saved by more than 80%.
Most fans and pumps regulate the flow and pressure when they are adjusted by baffles or valves. At this time, the input power does not change much. A large amount of energy is lost on the baffles and valves in the form of differential pressure, which not only consumes a lot of energy, but also has a large noise. And the baffle and valve are easy to wear and damage.
CB-DT series motor energy-saving system is a special power saver specially developed for fluid transportation and pressure control equipment such as fans and pumps. It adopts programmable control technology, frequency conversion speed control technology and closed-loop control technology to set pipeline parameters and setting parameters. In comparison, the output frequency of the inverter is controlled by PID operation, which fundamentally eliminates the power waste phenomenon of the “large horse-drawn carriageâ€, which is common in the selection of fans and pump equipment due to the selection or load change, and eliminates the throttling resistance of the baffle. Fans and pumps always operate at optimum conditions, saving a lot of power.
2.3 CB-DT series fan and water pump motor energy saving advantages and industry applications
CB-DT series fan and water pump motor energy replaces the wind deflector and valve adjustment, and the power saving rate is above 30%. The built-in unique energy-saving control curve is more energy-efficient than ordinary frequency conversion; the drive motor can be soft-started to reduce the starting surge current. It can adjust the rotation speed steplessly, avoiding mechanical resonance and running noise; by detecting pressure, air volume, flow rate, etc., it can form a closed loop automatic control system; pump type load special shutdown mode to prevent water hammer phenomenon; Protection can extend the service life of mechanical loads.
CB-DT series fan and water pump motor energy-saving control system is widely used in the industry, including metallurgy, coal, mining, petrochemical, electric power, water supply, building materials, light industry, etc.; at the same time in shopping malls, hotels, office buildings, urban living quarters and other buildings Various water supply, gas supply and ventilation systems are available.
3 CB-DT series air compressor power saving principle and technical characteristics
3.1 CB-DT series air compressor power saving principle
The shaft power required on the drive shaft of the air compressor has a direct relationship with the exhaust pressure and the air compressor speed. That is to say, in actual operation, since the use of compressed air changes at any time, the air compressor does not It is often operated under rated conditions, and the pressure of the air compressor exhaust pressure directly affects the actual shaft power. The higher the exhaust pressure, the greater the required shaft power.
In order to meet the requirements of the change of gas consumption, the gas in the gas storage tank must maintain a certain pressure. At present, most air compressors adopt the adjustment method of cutting to change the gas volume discharged to the gas storage tank. The relationship between the supply and demand of the air compressor air volume is the change of the exhaust pressure. When the air compressor exhaust volume meets the production gas demand, the gas storage pressure remains unchanged. If this state can be maintained, it is of course the best, but actually The gas consumption is changed at any time, and the design redundancy is large, so the air compressor exhaust volume must be greater than the gas consumption. If the air compressor is still running at a constant speed, the gas in the gas storage tank accumulates more and more. When the pressure in the tank rises to the set pressure, two methods are generally used: one is the unloading operation of the air compressor, the compressed gas is not generated, the electric motor is running at no load, and the power consumption is still 30% 60% of the full load. This part of the electricity was wasted. Another way is to stop the air compressor operation, so it seems that the electric energy wasted by the air compressor idling or venting is eliminated, but if there is no large air tank, it will bring frequent start of the motor, air pressure The starting current of the machine is about 5D7 times of the rated current, which has a greater impact on the power grid and other electrical equipment, and also shortens the service life of the air compressor.
With CB-DT energy-saving control system, the air compressor can run under the minimum pressure required for production, the input power of the motor is greatly reduced, and the pressure closed-loop control is used to achieve the dynamic matching of the air supply pressure and the speed of the air compressor. The actual input power of the motor is used for energy saving purposes. That is, the speed of the motor is controlled by the supply air pressure. How much power is required by the compressor, and how much power the motor outputs, without having to do useless work, thereby achieving good energy saving effect. On the other hand, the air compressor stops idling, and the motor does not. There is light load operation, and this part of the energy is considerable.
While saving energy, it also promotes stable supply pressure. Through the pressure regulator, the air compressor can be kept at the set pressure value, the pressure stability is high, and the pressure can be set steplessly and can be adjusted at any time. The motor realizes soft start, and the service life and maintenance cycle of the compressor will be greatly extended. The air compressor exhaust volume is controlled by the air compressor speed. The valve disc in the cylinder is no longer repeatedly opened and closed. The working conditions of the valve seat and spring are greatly improved, avoiding the rapid flow and impact of high temperature and high pressure gas. The workload is reduced.
3.2 CB-DT series air compressor power saving technology features
The energy saving of the CB-DT series air compressor power-saving control system has the following technical features: the power saving rate can reach more than 20%; realize soft start, no impact on the power grid, reduce the capacity requirement of the transformer; improve the power factor and reduce the reactive power loss Increase the active power of the grid; the supply pressure is stable and the reliability is high; the service life and maintenance cycle of the compressor will be greatly extended.
The air compressor exhaust volume is controlled by the air compressor speed. The valve disc in the cylinder is no longer repeatedly opened and closed. The working conditions of the valve seat and spring are greatly improved, avoiding the rapid flow and impact of high temperature and high pressure gas. The workload is reduced.
Easy installation and debugging; setting fault alarm and automatic switching, improving system security.
4 CB-DT series central air conditioning energy saving and intelligent fuzzy control technology principle, system and technical characteristics
4.1 CB-DT series central air conditioning energy saving principle
For central air conditioning, according to national standards, the maximum load capacity of the system is designed according to the highest temperature and maximum load working environment. As far as the system itself is concerned, there is a large reserve space, but in fact the system is very small. Work under these extreme conditions.
According to relevant statistics, the central air-conditioning equipment fluctuates at 70% of the time below 70% of the load, so the actual load can not reach full load; especially in the case of less air-conditioning demand, the host load is low.
In order to ensure a better operating state and higher operating efficiency, the host can load and unload according to the load changes within a certain range, but the matching cooling water pump and chilled water pump have been running under high load conditions. Improve the operating efficiency of central air-conditioning cooling water and chilled water system, and reduce the working time of equipment. Therefore, it is absolutely necessary to carry out energy-saving technical transformation of central air-conditioning. The central air-conditioning intelligent fuzzy control system adopts advanced computer technology, fuzzy control technology, system integration technology and variable frequency speed control technology to realize the intelligent fuzzy control of the central air-conditioning refrigerant flow system operation, scientifically solving the central air-conditioning energy supply according to the end load needs. Providing, under the premise of ensuring the comfort of air conditioning, the energy waste of the air conditioning system is minimized, and the best energy saving is achieved.
4.2 Application of Intelligent Fuzzy Control Technology
The intelligent fuzzy control system not only comprehensively controls the central air conditioning chilled water system, cooling water system, cooling tower fan and other aspects, but also uses system integration technology to interconnect the various control systems physically, logically and functionally. The information integration and resource sharing between them are centralized control and unified management on a computer platform (fuzzy controller) to realize the overall coordinated operation and comprehensive performance optimization of the central air-conditioning system. The chilled water system uses optimal output energy control, and the cooling water and cooling tower fan system uses optimal conversion efficiency control to ensure the comfort and reliability of the entire system.
4.3 CB-DT series central air conditioning energy-saving system features
1) Reliable security protection
Through comprehensive operation parameter collection, the system monitors the overall working status, and sets the low-flow protection and low-temperature protection of chilled water and cooling water, effectively ensuring the air conditioning of the chilled water and cooling water system under variable flow conditions. Safe and stable operation of the main unit evaporator and condenser.
2) Realize dynamic load following to ensure the end of service quality
The system breaks through the operation mode of the traditional central air-conditioning refrigerant system (constant flow mode or constant-source side fixed flow and load-side variable flow mode) to achieve optimal output energy control, that is, the air-conditioning mainframe refrigerant flow automatically follows the end load demand and changes synchronously ( That is to say, the flow rate is changed. Therefore, under any load condition (full load or partial load) of the air conditioning system, the service quality (comfort) at the end of the central air conditioning system can be ensured, and the maximum energy saving can be achieved.
3) Self-optimizing and adaptive intelligent fuzzy control
For complex systems with multi-parameter interactions such as central air-conditioning, it is necessary to realize all the variable flow operation of chilled water and cooling water systems. Only by making full use of the latest scientific and technological achievements, intelligent control functions can be used to perform knowledge processing and reasoning similar to human brain. Advanced control technology is only possible to succeed. Therefore, the system adopts fuzzy control technology, which makes the system have self-learning, self-optimizing and adaptive optimization control functions, which realizes the maximum energy saving under various load conditions of the central air-conditioning system, and the energy-saving of the air-conditioning water system reaches 30%-50%. .
4) Optimized the air conditioning host operating environment
The system comprehensively collects various operating parameters of the central air conditioner, and then uses advanced fuzzy control technology to dynamically optimize and control these interrelated and mutually influential operating parameters to meet the requirements of nonlinear and time-varying of the central air conditioning system, so that the air conditioning mainframe is always Operating at optimum conditions to maintain maximum heat transfer efficiency, reducing host energy consumption by 5%-10% using the CB-DT all-digital multivariable energy-saving system to keep compressor efficiency in the highest area, ensuring The operating efficiency of the air-conditioning main engine has been greatly improved, and the load rate of the main engine has been effectively reduced to avoid high energy consumption and compressor surge caused by unreasonable water system, and the life of the air-conditioning main engine has been prolonged. For the freezing and cooling pumps, since the pump runs below the rated speed for most of the time, the wear of the mechanical parts of the pump, such as the mechanical friction of the motor bearings, is reduced, and the service life of the mechanical parts is greatly extended, thus also making the central air conditioning unit The maintenance period of the equipment is prolonged, the maintenance cost of the equipment is doubled, and the comprehensive economic benefits are greatly improved.
5 Conclusion
The Zhongcang CB-DT series motor energy-saving system is reliable and stable in actual operation, and has good energy-saving effect and promotion value.
The system has been applied in energy-saving projects of Danjiangkou Aluminum Industry Co., Ltd., Guangdong Huaxing Glass Factory, Beijing Wangfujing Department Store, Shenzhen Finance Bureau and many other factories and buildings, and achieved the expected energy-saving effect.
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