IE5 High Efficiency Motor Solution —— Rubber Mixing Mill
Background
Rubber mixing mill is a key equipment for rubber mixing and plasticizing, which is widely used in tire manufacturing, industrial rubber products, plastic processing and other fields. With the continuous development of the global rubber industry, especially the growth in demand for tires and high-performance rubber products, the rubber mixing mill market has shown a trend of steady expansion. Market demand mainly comes from Asia, North America and Europe, among which China, the United States and Germany are the main consumer markets. With the increasingly stringent environmental regulations, rubber mixing mills are developing in the direction of more energy-saving, environmental protection and intelligence. The application of automatic control technology and high-efficiency motors makes the equipment play an increasingly important role in improving production efficiency and reducing energy consumption. In addition, the market demand for high-performance rubber materials continues to increase, which has promoted the technological progress of rubber mixing mills in processing complex formulas and higher-quality rubber.
Equipment Introduction
Rubber mixing mill is a kind of equipment that mixes and plasticizes rubber raw materials with other additives (such as carbon black, chemical additives, etc.) through mechanical pressure and temperature control. It usually consists of two pairs of parallel rollers, called "rollers" or "drums", which rotate relative to each other at different speeds. The raw materials are stretched, squeezed and turned between the rollers to achieve uniform mixing. The gap and speed difference between the rollers can be adjusted to control the uniformity of mixing and the temperature of the materials. The plasticization process of rubber can be completed by heating, pressurizing and controlling the gap between the rollers, and finally a rubber mixture that meets the requirements is obtained.
Due to the harsh working environment, especially under high temperature and high pressure working conditions, the service life of ordinary asynchronous motors is greatly shortened, and permanent magnet motors are prone to demagnetization at high temperatures. These are all problems that may occur in the motors of rubber mixing mills.
Many rubber mixing mills do not fully consider energy efficiency issues when designing, resulting in a large amount of energy waste during the mixing process. Especially in the case of long-term continuous operation, the energy consumption of the equipment is high, which puts pressure on production costs. With the increasingly stringent energy-saving and environmental protection regulations, improving the energy efficiency of equipment has become a development trend.
Working Conditions
① Load characteristics:
The mixing mill has constant torque load characteristics. However, at different stages of rubber mixing, the load changes are relatively large, and the load torque fluctuates greatly during the rubber mixing process. It is necessary to be able to respond quickly to load mutations. There is a rubber start-up situation, so overload start-up and large starting torque are required.
② Operating environment:
The ambient temperature is relatively high and the oil pollution on site is relatively large.
③ Power configuration:
Traditional mills are generally equipped with three-phase asynchronous motors, some old-style JR series winding asynchronous motors, and a large part of them are equipped with DC motors + DC speed regulators. The commonly used power configuration is a three-phase asynchronous motor + inverter solution, the motor has low energy efficiency, a narrow high-efficiency range, often runs in low-efficiency areas, and the comprehensive electricity economy is poor.
Haichuan Electric Optimizes and Upgrades Rubber Mill Motor Scheme
During the operation of the rubber mill, the motor is the core component that provides power, which directly affects the operating efficiency, energy consumption and production stability of the equipment. Traditional asynchronous motors (such as IE2 class motors) usually have problems such as low energy efficiency, large load fluctuations, and frequent maintenance during operation. These factors lead to energy waste and increased long-term operating costs. Therefore, by optimizing and upgrading to Haichuan Motor's HCM5 series magnetically assisted synchronous reluctance motors, the performance of the rubber mill can be effectively improved, operating costs reduced, and energy utilization efficiency improved.
Advantages of upgrading to HCM5 motor:
Improve energy efficiency and reduce energy consumption:
The HCM5 motor adopts advanced magnetic-assisted synchronous reluctance technology to achieve efficient operation under different load conditions, especially in rubber mill applications with large load fluctuations. The HCM5 motor can automatically adjust the speed and power output according to the real-time load. , keep the system running in the optimal energy efficiency range, significantly reduce energy consumption, and help enterprises reduce power costs.
Wide load adjustment range:
The HCM5 motor can cope with the load changes of the rubber open mill under different working conditions, especially the low load and high load fluctuations that often occur during the mixing process. By optimizing the speed control of the motor, the equipment can be kept in a high-efficiency operating range, and energy waste caused by overload or low load can be effectively avoided even if the load changes significantly.
Reduce mechanical wear and maintenance costs:
Traditional asynchronous motors usually cause high heat loss and mechanical wear due to operating in an inefficient range. The HCM5 motor has higher operating efficiency and lower heat loss, which reduces the pressure on the motor and other transmission components, thereby reducing the failure rate of the equipment, extending the service life of the motor and mechanical components, and reducing the cost of maintenance and replacement of parts. frequency.
Improve system control accuracy:
The HCM5 motor is equipped with an intelligent frequency conversion control system, which can automatically adjust the motor speed according to the actual load of the rubber mill to achieve precise torque and speed control, thereby ensuring rubber quality consistency and production stability during the mixing process.
Higher reliability and stability:
Compared with traditional IE2 asynchronous motors, HCM5 motors have higher operating stability and longer service life. Its reluctance characteristics allow the motor to run more smoothly under different loads and speeds, reducing downtime caused by equipment instability.
By upgrading the traditional IE2 asynchronous motor to the Haichuan Electric HCM5 series magnetically assisted synchronous reluctance motor, the rubber mill can significantly improve energy efficiency, reduce energy consumption, improve production stability and product quality, reduce maintenance costs, and help Meet more stringent environmental standards. This upgrade solution can not only meet the current market demand for high-efficiency equipment, but also help companies maintain technical advantages and economic benefits in fierce market competition.