Optimisation of Plating Pump Motors
Background of the Pump Industry
The main products of the pump industry include various types of centrifugal pumps, mixed flow pumps, axial flow pumps, vortex pumps, rotary displacement pumps, reciprocating displacement pumps and water ring vacuum pumps, etc. The existing pumps are equipped with motors that are mainly three-phase asynchronous motors. Existing pumps are equipped with motors, mainly three-phase asynchronous motors, which have a narrow economic operating range and consume large amounts of energy, and most of them implement energy efficiency standards below IE3.
Electroplating Pumps Have the Following Requirements for Motors.
Corrosion resistance
Plating solution usually contains corrosive media such as strong acids, alkalis or salts, which may contact the motor through the pump body or seal leakage. The motor housing material needs to be corrosion resistant, such as stainless steel, engineering plastics or special coatings.
High protection class (IP rating)
Electroplating workshop environment is humid, may spray liquids or the presence of corrosive gases. The motors need to be resistant to moisture and chemical gases. The protection class should be at least IP55 (protection against dust and water jets), IP65 (complete protection against dust and high pressure water jets) is recommended.
High temperature resistance
The plating bath may be high temperature (e.g. heating of the bath or temperature rise due to prolonged operation). Motor insulation class F or H, high temperature resistance. Motor heat dissipation design should be optimised, such as installing heat sinks or forced air cooling.
High efficiency and energy saving
Plating pumps need to run continuously for a long time, high energy consumption will increase the cost. The motors need to comply with IE4 or higher energy efficiency standards. It can be equipped with frequency converter (VFD) to achieve flow regulation and reduce energy consumption.
Overload and jamming resistance
The plating solution may cause the pump body to be clogged due to impurities or crystals, leading to generator overload. The motor should have overload protection function (such as thermal relay, overcurrent protection). The blocking torque should be high enough to avoid frequent tripping.
Low vibration and noise
The environment of electroplating workshop requires high stability of equipment operation. Motor rotor should be calibrated for dynamic balance. Adopt low noise bearing (such as NSK, SKF brand) and vibration damping design.
Explosion-proof requirement
If there are flammable gases or volatile solvents in the electroplating workshop, explosion-proof motors are required.
Reliability and Long Life
High maintenance cost for plating line downtime. Key components (e.g. bearings, windings) should be designed for long life.
Ease of Installation and Maintenance
Compact structure, adapt to the space limitations around the plating tank. Provide convenient oil filling port and inspection port for daily maintenance.
Introduction to Working Conditions
1) Load Characteristics:
Water pump motor is square torque. That is, the flow rate is proportional to the rotational speed, the torque or water pressure is proportional to the rotational speed, and the shaft power is proportional to the rotational speed. Low-speed load torque is small, the output power is small, high-speed load torque is large, the output power is large; according to the requirements of the actual working conditions, 3000rpm motors are generally used in the head slightly high, the flow is not large. If the flow rate is large and the head is small, you can choose 1500rpm motor. If the flow is large and the head is small, choose 1000rpm motor. When choosing 1000rpm motor, the power can be reduced by one level according to the shaft power.
2) Starting characteristics:
The working characteristics of the pump are relatively small starting torque, relatively small starting frequency, relatively long continuous running time and so on.
3) Power configuration:
Stock market in the water pump common selection and design margins, low efficiency. Commonly used power configuration using industrial frequency direct drive or three-phase asynchronous motor + inverter programme, low motor energy efficiency, high efficiency range is narrow, often run in the inefficient range, the overall power economy is poor.
Hiatran Electrical Retrofit Solutions
Original solution: asynchronous motor YE3-132M-4-7.5kW-1465rpm
Retrofit solution: High-efficiency motor + drive
Motor model: HCM5-132M-7.5-1500-T4-FRS-B3
Drive model HCD-G6-T47P5G
