Energy-saving Transformation Plan for Spinning Frame
Spinning machine is the main machine of spinning, and it is also the last process of spinning process, and it is the machine that consumes more energy in spinning production. At present, ring spinning machine has become the main equipment for spinning, spinning machine 24 hours continuous production, damage and aging fast, stock market in many equipment electrical system has entered the end-of-life period, the proportion will increase year by year. With the aging of the motor its energy consumption will also increase, improve efficiency and energy saving is the urgent need of many cotton spinning enterprises, in order to reduce production costs.
Equipment Introduction
Spinning machine, spinning process of spinning semi-products of roving or strips by drafting, flicking, winding into spun yarn tube yarn spinning machine. Spinning machinery is responsible for removing, opening, drafting, twisting and winding cotton, wool, linen, silk and chemical fibre raw materials into uniform and flexible yarn.
The main basis for measuring the production quality of spinning machine
1, spindle and spindle speed
Spinning machine production level - spinning machine is the main spinning machine, yarn production, quality is a comprehensive reflection of the merits of the spinning process. Spinning machine production unit is the spindle, often per thousand spindle hour output (kg) to measure the production level of spinning machine. Spinning mill production scale is to have the total number of spindles to express the spinning machine.
2、Breakage rate
The yarn spun on each spindle will be broken due to various reasons, and the breakage rate is often expressed by the number of breakages occurring in 1,000 spindle hours. The level of breakage rate affects the labour productivity, equipment productivity, yarn quality and workshop dust content. Generally, small yarns have the most breakage (50%), medium yarns have the least (20%), and large yarns have the second highest (30%).
3、Rolling and loading yarn
Spinning machine production process spinning full of a volume load (tube yarn) to stop production, to be dropped on the tube yarn replaced by an empty tube before you can continue to spin. Therefore, the size of the rolls affects the labour productivity, equipment productivity, but also affects the energy consumption.
Introduction to Working Conditions
①Load characteristic: the load of spinning machine in spinning different yarns is not the same, and the spindle drive system of spinning machine accounts for a larger proportion of the load.
②Running environment: textile industry, cotton flower, cotton wool, environmental humidity, motor installation space is small, poor heat dissipation effect, the motor needs to be in the high temperature and high humidity environment to continue to run.
③Starting and stopping characteristics: when the spinning machine starts, it starts with the transmission system of the whole equipment, therefore, it needs the motor to have good starting ability with load, and it is required to start fast and smooth, brake fast and linear, and it cannot be reversed, etc.
④Power configuration: the traditional spinning machine starts with the transmission system of the whole equipment. Power configuration: The traditional spinning machine adopts two-speed motor, which has low production efficiency, large reactive power loss and unstable spinning tension. Commonly used power configuration for three-phase asynchronous motor + inverter programme, using belt drive, low transmission efficiency, low motor energy efficiency, high efficiency range is narrow, often run in the inefficient region, the overall power economy is poor.
Hiatran Electric Solution
Taking the main drive motor and belt drive mechanism of the spinning machine as the object of energy-saving renovation, the original belt drive is cancelled and replaced by a direct drive structure. Improve the transmission efficiency. Adopt HCM5 series super-efficient magnet-assisted synchronous reluctance motor as the main drive motor, which has the features of low energy consumption, wide high-efficiency interval, small volume, reliable and economic. DT6 series driver is chosen as the motor drive control device, with good control performance and through-the-wall fanless design, reliable and durable. Using the ventilation device of the original equipment to dissipate heat, it has good heat dissipation effect and effectively avoids the risk of over-temperature blowing up due to the blockage of cotton wool.
①Hiatran Motor Product Features:
High energy efficiency:
No rotor loss, high efficiency, wide high-efficiency interval, good overall operating economy.
High power factor:
Ferrite magnetic material as auxiliary excitation, low reactive power, high power factor.
High reliability:
Resistant to high temperature and humidity corrosion, not easy to demagnetise, high reliability.
High economy:
With reluctance torque as the main torque source, the motor does not have rare earth permanent magnet materials, high grade silicon steel sheet and other expensive raw materials, the drive adopts the drive inverter hardware architecture, a cost-effective IE5 energy-efficient motor drive solutions, good economy.
②Hiatran Drive Product Features
HCD-DT6 series through-the-wall drive is a textile-specific high-performance current vector frequency converter drive, adopting high-performance vector control technology, with good dynamic characteristics, super overload capacity, communication bus function, etc., the combination of powerful functions, stable performance. Adopting special through-wall mounting and fanless design to provide robust and durable protection for the product, it can meet the needs of harsh environments such as multi-lint, high dust, heavy pollution, etc. It is suitable for spinning machines and roving machines in the textile industry, as well as for other highly polluting industries such as machine tools, ceramics and glass.
Input voltage: 3PH 380V±10% 50/60Hz
Power range: 15-22kW
Installation form: through-the-wall installation
1. Through-the-wall installation design, improve the protection ability, and effectively avoid the secondary pollution of cotton wool, oil, dust, etc. on the frequency converter.
2. Fanless natural air-cooled heat dissipation design, using the cooling system of the equipment, effectively preventing the accumulation of fibres and cotton wool on the heat sink, to solve the problem of fan failure and overheating.
3. The whole series of metal shell, large size heat sink design, can be in the 50 ℃ high temperature environment for long-term reliable operation.
4. Instantaneous stop and non-stop function, using the power generation energy during parking brake to make the frequency converter decelerate smoothly, realising synchronous and proportional parking of multiple motors, effectively reducing the risk of yarn breakage caused by power failure and abnormal parking.
Application Effects
After replacing the Hiatran motor solution, the energy saving rate can reach 14.5% when comparing the power consumption of 1000m of wire sand production.
