Four-way frequency converter in ball mill application
August 26, 2023
Introduction In China's ceramic industry, ball mills are used in large quantities and are an indispensable and important production equipment for material crushing. The ball mill generally has large power, the system uses a simple power frequency control, requires a long grinding cycle, low grinding efficiency, easy to cause excessive grinding of the material, the power consumption of the unit product, thus becoming one of the largest power consumption equipment in the ceramic industry . At the same time, the starting current of the system is large, which has a great impact on the equipment and the power grid, resulting in a large amount of mechanical equipment maintenance. With the rapid development of frequency control technology, frequency control has been widely used in ceramic, cement, and metallurgical industries. Practice has proved that the use of ball mill frequency control energy saving effect is significant, can create very good economic benefits for the enterprise. This article takes the Quartet V560 series inverter as an example to introduce a variable frequency control application program of the ball mill.
First, process introduction Ball mill mainly consists of transmission device, cylinder device, feeding device, unloading device and electrical control device. When the equipment is running, the motor is driven by the electric control device, and then the deceleration drive of the reducer and the surrounding large wheels is used to drive the cylinder device to rotate. The materials and grinding bodies contained inside the barrel device are lifted to a certain height after being rotated to produce a certain height, and fall along the trajectory of the approximate parabola to impact and grind the other part of the material at the bottom of the barrel and generate the same. A certain axial operation causes the material to be ground and mixed evenly. The finished material is finally discharged through the unloading device for processing in the next step. The grinding process is shown in Figure 1 below.
figure 1
The power frequency control of the ball mill system has the following disadvantages in use:
1. The required grinding cycle is long, the grinding efficiency is low, the power consumption of the unit product is large, and at the same time, it is easy to cause the material to be ground up;
2. The start-up generally adopts the star-delta or auto-buck start-up, and the starting current is large, which has great impact on the equipment and the power grid;
3. Poor equipment operation stability, huge maintenance and power consumption, increased maintenance costs of the manufacturer, resulting in a serious waste of resources.
Second, the control program according to the ball mill original operating conditions existing problems and for its production processes and process characteristics, designed using the Quartet V560 series inverter system control program, as follows:
The main motor is driven by a vector-type inverter. The built-in optimized control program can automatically adjust the parameters of the motor during operation according to the real-time operating load of the ball mill so that the shaft power of the motor can be optimized. The system rotation speed can be set to an automatic adjustment mode according to the change of the milling process conditions, which can ensure the efficiency of the ball mill and effectively save the power.
The control electrical diagram is shown in Figure 2 below:
The main setting parameters
Function Code Parameter Name Factory Setting Value
2. The use of variable frequency vector control technology to drag, to meet the ball mill low-speed operation, the characteristics of a large starting torque, effective guarantee system control process;
3. The grinding time, grinding time and automatic stop function can be conveniently set by the inverter to make the operation more intelligent and user-friendly;
4. The energy-saving effect is generally up to 8% to 10%;
5. The system has perfect protection functions such as phase loss, short-circuit, over-voltage, over-current and other protection functions. At the same time, it can install the mains/energy-saving switching function to effectively ensure the stable operation of the equipment.
IV. Concluding remarks This article describes a variable frequency drive scheme for a ball mill based on the Quartet V560 frequency converter. This solution realizes a soft start of the system, effectively ensures the system control process while improving the work efficiency, has a significant energy saving effect, and effectively prolongs the system equipment. The service life of the equipment reduces the amount of equipment maintenance and has achieved good economic benefits for customers. Practice has proved that this scheme has a very broad application prospect in the ceramic industry, and it has been successfully applied to the system of frequency conversion transformation of multiple ball mills.
references:
"V560 Series High Performance Vector Inverter Manual" Shenzhen Sifang Electric Technology Co., Ltd.
First, process introduction Ball mill mainly consists of transmission device, cylinder device, feeding device, unloading device and electrical control device. When the equipment is running, the motor is driven by the electric control device, and then the deceleration drive of the reducer and the surrounding large wheels is used to drive the cylinder device to rotate. The materials and grinding bodies contained inside the barrel device are lifted to a certain height after being rotated to produce a certain height, and fall along the trajectory of the approximate parabola to impact and grind the other part of the material at the bottom of the barrel and generate the same. A certain axial operation causes the material to be ground and mixed evenly. The finished material is finally discharged through the unloading device for processing in the next step. The grinding process is shown in Figure 1 below.
figure 1
The power frequency control of the ball mill system has the following disadvantages in use:
1. The required grinding cycle is long, the grinding efficiency is low, the power consumption of the unit product is large, and at the same time, it is easy to cause the material to be ground up;
2. The start-up generally adopts the star-delta or auto-buck start-up, and the starting current is large, which has great impact on the equipment and the power grid;
3. Poor equipment operation stability, huge maintenance and power consumption, increased maintenance costs of the manufacturer, resulting in a serious waste of resources.
Second, the control program according to the ball mill original operating conditions existing problems and for its production processes and process characteristics, designed using the Quartet V560 series inverter system control program, as follows:
The main motor is driven by a vector-type inverter. The built-in optimized control program can automatically adjust the parameters of the motor during operation according to the real-time operating load of the ball mill so that the shaft power of the motor can be optimized. The system rotation speed can be set to an automatic adjustment mode according to the change of the milling process conditions, which can ensure the efficiency of the ball mill and effectively save the power.
The control electrical diagram is shown in Figure 2 below:
figure 2
The main setting parameters
Function Code Parameter Name Factory Setting Value
Function code
parameter name
Factory default
Setting value
F0.0.09
Motor type and control mode selection
0000
0000
F0.1.16
Frequency setting selection
0
9
F0.3.33
Control command 1
0
1
F1.0.03
Acceleration time 1
Factory default
According to the site setting
F1.0.04
Deceleration time 1
Factory default
According to the site setting
......
......
......
......
F2.0.00
rated power
Factory default
Motor nameplate parameters
F2.0.01
Rated voltage
Factory default
Motor nameplate parameters
F2.0.02
Rated current
Factory default
Motor nameplate parameters
F2.0.03
Rated frequency
Factory default
Motor nameplate parameters
F2.0.04
Rated speed
Factory default
Motor nameplate parameters
Third, the program features and advantages 1. Ball mill after the use of frequency control, to achieve the system's soft start. The starting current is greatly reduced, 3 to 5 times smaller than the previous power frequency control, eliminating the impact of start-up, extending the service life of the mechanical components, reducing the maintenance of the equipment and maintenance costs, but also reducing the power grid and Peripheral equipment impact; 2. The use of variable frequency vector control technology to drag, to meet the ball mill low-speed operation, the characteristics of a large starting torque, effective guarantee system control process;
3. The grinding time, grinding time and automatic stop function can be conveniently set by the inverter to make the operation more intelligent and user-friendly;
4. The energy-saving effect is generally up to 8% to 10%;
5. The system has perfect protection functions such as phase loss, short-circuit, over-voltage, over-current and other protection functions. At the same time, it can install the mains/energy-saving switching function to effectively ensure the stable operation of the equipment.
IV. Concluding remarks This article describes a variable frequency drive scheme for a ball mill based on the Quartet V560 frequency converter. This solution realizes a soft start of the system, effectively ensures the system control process while improving the work efficiency, has a significant energy saving effect, and effectively prolongs the system equipment. The service life of the equipment reduces the amount of equipment maintenance and has achieved good economic benefits for customers. Practice has proved that this scheme has a very broad application prospect in the ceramic industry, and it has been successfully applied to the system of frequency conversion transformation of multiple ball mills.
references:
"V560 Series High Performance Vector Inverter Manual" Shenzhen Sifang Electric Technology Co., Ltd.
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