CN201774496U

CN201774496U - Intelligent economizer for hydraulic press

Info

Publication number: CN201774496U
Application number: CN201020205648XU
Authority: CN
Inventors: 崔荣; 许杨波
Original assignee: Chongqing Yixienzhen Energy-Saving Electric Power Equipment Co ltd
Current assignee: Chongqing Yixienzhen Energy-Saving Electric Power Equipment Co ltd
Priority date: 2010-05-27
Filing date: 2010-05-27
Publication date: 2011-03-23
Anticipated expiration: 2020-05-27

Abstract

The utility model relates to an intelligent economizer for a hydraulic press, which comprises a power-saving output circuit formed by a circuit breaker, a frequency converter, as well as a contactor, and further comprises a PLC (programmable logic controller), and an HMI (human machine interface), wherein the PLC acquires actuating signals of an electromagnetic valve group connected with a hydraulic press pump group as input signals, codes the input signals and outputs the coded signals as multi-velocity input signals of a control end of the frequency converter; and the frequency converter adjusts output frequency to control the rotating speed of a hydraulic press pump motor through the multi-velocity input signals. The intelligent economizer has the characteristics of having high power-saving rate, soft start, power factor, harmonic treatment, dual circuit, various protective functions, simple and easy operation, and convenient site installation, improving power factor, and the like.

Description

The hydraulic press intelligent electricity-saving appliance

Technical field

The utility model relates to Hydraulic engine oil pump motor frequency conversion energy-conserving control technology, especially the hydraulic press intelligent electricity-saving appliance that combines with PLC, HMI of Hydraulic engine oil pump motor frequency conversion control technology.

Background technology

In the hydraulic press hydraulic system, when Oil pump electrical machinery ran well with 50Hz, the fuel delivery of oil pump was constant, so claim that again hydraulic oil pump is a constant displacement pump.Yet, hydraulic press is when real work, required operating pressure of hydraulic pressure executive module and flow are not unalterable, the time little when big, when the required flow of work hour, the fuel delivery of oil pump is far longer than the actual required oil mass of executive module, hydraulic oil more than needed all flows back to fuel tank through overflow valve, consumes a large amount of electric energy, causes oily temperature rise, influence the useful life of equipment, increased the repair density and the expense of equipment.Power factor (PF) was low when motor was worked under very low load condition simultaneously, and the reactive power consumption of electrical network is big.And the harmonic wave control that brings during converting operation is not thorough, and economize on electricity quantitative statistics and contrast are inaccurate, and the detection of Oil pump electrical machinery operational factor is perfect inadequately.

Summary of the invention

The purpose of this utility model provides a kind of hydraulic press intelligent electricity-saving appliance that can improve integrated power grid quality and automatic power saving rate statistical computation.

The technical scheme that adopts is so for achieving the above object, it is a kind of hydraulic press intelligent electricity-saving appliance, it is characterized in that: comprise the economize on electricity output loop that constitutes by circuit breaker, frequency converter, contactor, also comprise PLC Programmable Logic Controller, HMI man-machine interface, wherein the PLC controller is an input signal by the actuating signal of gathering the electromagnetically operated valve group that is connected with the Hydraulic engine oil pump group, the PLC controller is to the input signal output of encoding, as the multistage speed input signal of Frequency Converter Control end; Frequency converter is regulated output frequency by the multistage speed input signal and is controlled the Hydraulic engine oil pump motor speed.

The beneficial effect that the utility model hydraulic press intelligent electricity-saving appliance brings has:

1. high power saving rate

In the hydraulic press system that adopts quantitative oil pump to drag, spill losses is arranged during light running.Intelligent energy-saving electric appliance can change the frequency of Oil pump electrical machinery, regulates the Oil pump electrical machinery rotating speed, reduces spill losses, saves energy.

2. soft start

The Hydraulic engine oil pump motor adopts the starting of star triangle usually, and starting current is big.Intelligent energy-saving electric appliance can be realized soft start, and starting current is limited in 1.5 times of rated current, realizes soft start function, reduces cranking current pulse.

3. raising power factor

Load factor when the hydraulic press on the market moves is lower, and average power factor is 0.65, and reactive power is many, causes line loss.Intelligent energy-saving electric appliance makes bringing up to more than 0.95 of power factor, reduces reactive power, and the Oil pump electrical machinery of hydraulic press can reach economical operation.

4. harmonic wave control

Frequency converter is a source that produces harmonic wave and electromagnetic interference, and intelligent energy-saving electric appliance has installed reactor and filter additional, reduces harmonic wave and electromagnetic interference, and intelligent energy-saving electric appliance operation time-harmonic wave can be up to state standards, and purifies power grid quality.

5. double loop

The hydraulic press intelligent electricity-saving appliance adopts mains system and two system's controls of energy conserving system, when energy conserving system has fault, can switch to the mains system operation, does not influence ordinary production.

6. kinds of protect function

The hydraulic press intelligent electricity-saving appliance has kinds of protect functions such as overvoltage, overcurrent, overload, short circuit, phase shortage, and hydraulic press is had more complete protection.

7. operate simple and easy

The hydraulic press intelligent electricity-saving appliance adopts panel button operation and the affected control of HMI man-machine interface, and is simple to operate.

8. on-the-spot easy for installation

The hydraulic press intelligent electricity-saving appliance with hydraulic press butt joint in only need be connected one group of electricity-saving appliance power line just finish being connected of major loop with one group of load line.

Description of drawings

Fig. 1 is the economize on electricity output loop figure of the utility model embodiment 1;

Fig. 2 is the PLC control block wiring diagram of embodiment 1;

Fig. 3 is the control circuit figure of embodiment 1;

Fig. 4 is the economize on electricity output loop figure of embodiment 2;

Fig. 5 is a control flow chart of the present utility model.

Embodiment

Referring to accompanying drawing 1-3, by the order of connection, the economize on electricity output loop is made of circuit breaker Q S1, input reactance device ACL1, frequency converter input filter F1, frequency converter VF1, out put reactor ACL2, inverter output filters F2 and contactor KM2.Input and output at described economize on electricity output loop are parallel with the bypass power output circuit of being with contactor KM1.

Wherein, the main power line of frequency converter VF1 is input as R, S, T, main power source is output as U, V, W, control end S1, S2, S3, S4 are the programmable multifunctional input terminal, S1 is as the start-stop of frequency converter, and S2, S3, S4 are multistage speed input terminal, can be programmed for 8 sections speed, only used 5 sections speed in the present embodiment, the Hydraulic engine oil pump motor can nearly turn round under 5 kinds of rotating speeds.

Fragment number	Rotating speed	Frequency
			Multistage
0	Standby or starting up speed	Frequency		1
			Multistage 1		Downstream rate	Frequency	2
Multistage 2	Pressing speed	Frequency 3
			Multistage 3	Slowly return speed	Frequency	4
Multistage 4	Snap back speed	Frequency 5

Referring to Fig. 2, being allocated as follows of the input terminal of PLC controller, lead-out terminal: input terminal:

I0.0

I0.1

I0.2

I0.3

I0.4

I0.5

I0.6

I0.7

I1.0

I1.1

I1.2

I1.3

Downstream signal

Slowly write in reply number

The snap back signal

Pressurization signal

The frequency conversion fault

The control starting

Control stops

Power frequency is selected

Frequency conversion is selected

Varying frequency starting

Frequency conversion stops

Ann reset

Lead-out terminal:

Q0.0

Q0.1

Q0.2

Q0.3

Q0.4

Q0.5

Q0.6

Q0.7

Q1.0

Q1.1

Q1.2

Q1.3

Multistage speed 0

Multistage speed 1

Multistage speed 2

Varying frequency starting

Power frequency is selected

Frequency conversion is selected

Sound and light alarm

The input fan

The control indication

The energy-saving run indication

The power frequency operation indication

Energy-conservation faulty indication

For the downstream signal of input terminal, write in reply number slowly, snap back signal, pressurization signal be the actuating signal of the hydraulic press gathered of electricity-saving appliance, signal is from a pair of normally opened contact of the auxiliary relay of respective electrical magnet valve group action control in the hydraulic press control cubicle.Two ports of PLC controller, a port PORT1 is connected with the HMI man-machine interface with PPI/MPI communication, and another port PORT0 is connected with frequency converter, multi-function watt-hour meter RS485 port with the respective communication agreement.

The importation of PLC among Fig. 2: YV1-YV3 and KT1 are the actuating signal switch of electromagnetically operated valve group, SA1, SA2 be on the control cubicle startup, stop and operating loop selector switch; SB1-SB3 is respectively the energy conservation starting on the control cubicle, energy-conservation stopping and the ann reset button; Output: KA1-KA7 is a relay, is indicator light.

Referring to accompanying drawing 3, for the convenience of overhauling and safeguarding, there are illuminating lamp HD6, HD7 in electricity-saving appliance inside, maintenance lamp HD8, open power supplys such as maintenance socket.The design of radiator fan FS1, FS2 is more reasonable, and radiator fan is divided into two groups, and when frequency converter moved, one group was moved automatically, other one group of manual start-stop.When electricity-saving appliance breaks down, point out by audible-visual annunciator warning P1.

Multi-function watt-hour meter Wh is connected by promptly the economize on electricity input of output loop of instrument transformer TA1-TA3 and civil power, can test A, B, C three-phase current, voltage, active power, reactive power, apparent power, power factor, phase angle parameter real-time testing and data such as meritorious electric weight, capacity of idle power, these data are uploaded to the PLC controller by communication, and the PLC controller also reads parameters such as the running frequency, output voltage, output current of frequency converter.HMI man-machine interface and plc communication carry out data read, can monitor the test data of multi-function watt-hour meter and the parameter of frequency converter in real time, revise the parameter of frequency converter, the operation of control of conversion device.

The mode of operation of hydraulic press intelligent electricity-saving appliance has two kinds, and a kind of is by button on the electricity-saving appliance cabinet and rotary switch control; Another kind of mode of operation is by the configuration button control on the HMI, the indicator light indication ruuning situation on the electricity-saving appliance cabinet.

The calculating principle of power saving rate:

The energy-saving effect of hydraulic press joint joint electrical equipment comprises two parts, and a part is to save meritorious electric weight by the frequency control when the hydraulic press underloading; Another part is to reduce capacity of idle power by improving power factor, thereby reduces the active loss that brings because of capacity of idle power.

According to the regulation in the economical operation of GB GB/T12497-2006 threephase asynchronous, the active power of saving behind the motor reactive power compensation is calculated formula and is:

ΔP _u＝K _Q×Q _C………………………………………(1)

Δ P _u---take the active power of saving behind the reactive power compensation, unit is kilowatt (KW);

K _Q---idle economic equivalent, by following value;

Idle economic equivalent value: when motor direct-coupled generator bus or the direct-connected bus that carries out reactive power compensation, K _QGet 0.02～0.04; Connect the secondary transformation and get 0.05～0.07; Connect three transformations and get 0.08～0.10.K _QValue is decided in conjunction with practice in factory.

The power saving rate computing formula of hydraulic press intelligent electricity-saving appliance is:

K is a power saving rate; Δ P _HaveBe the active power of saving; Δ P _uBe converted to the active power of saving for the reactive power that reduces; K _QBe idle economic equivalent; P _{The city}Be the active power of hydraulic press under civil power; Q _{The city}Be the reactive power of hydraulic press under civil power; P _JointBe the active power of hydraulic press under energy conserving system; P _JointBe the reactive power of hydraulic press under energy conserving system.

When on man-machine interface, electricity-saving appliance being arranged to move under the power saving rate test pattern, be provided with testing time T hour, hydraulic press is when civil power moves or electricity-saving appliance system when operation, PLC is the meritorious electric weight and the capacity of idle power of T hour multi-function watt-hour meter of acquisition time section respectively, calculates active power and reactive power then; The formula (2) that calculates according to top power saving rate can count power saving rate automatically again, and the user only needs will be provided with parameter on man-machine interface just can finish the measurement of power saving rate volume.

Hydraulic press on market has an Oil pump electrical machinery fuel feeding or a plurality of Oil pump electrical machinery fuel feeding, the utility model just with the hydraulic press intelligent electricity-saving appliance of an Oil pump electrical machinery fuel feeding as example case study.When the major loop of the hydraulic press intelligent electricity-saving appliance that a plurality of Oil pump electrical machinery fuel feeding occur constitutes: many Oil pump electrical machineries are with regard to many economizer and civil power loop, the many one group of input and output I/O point control of control loop.The economize on electricity output loop of two motors is seen accompanying drawing 4.

The utility model also can be simplified, and can cancel filter or reactor, and the formation of economize on electricity output loop only is made of circuit breaker, frequency converter, contactor.But can not reach harmonic wave control and power factor and bring up to 0.95 with first-class characteristics.In addition, frequency converter puts into that input is connected with the input reactance device or/and the frequency conversion input filter in the described economize on electricity output loop; Frequency converter puts into that output is connected with out put reactor or/and the frequency conversion output filter in the described economize on electricity output loop.

Below be filter and reactor accessory effect:

The frequency converter input filter is used to suppress conducted interference and the radio interference that frequency converter produces, and possesses common mode and differential mode simultaneously and suppresses ability.Be used for occasion that electromagnetic environment is had relatively high expectations, when preventing frequency converter work, the interference that the frequency converter input produces electrical network and other digital devices.

Inverter output filters is mainly used in the high order harmonic component layer that reduces in the output current, suppresses the surge voltage of the outlet side of frequency converter, reduces motor by the additional torque that high-frequency harmonic causes, reduces motor noise.

The input reactance device can make rectification impedance increase effectively suppress higher harmonic current, reduce the impact of power surge to frequency converter, improve the disequilibrium of three phase mains, improve the power factor of input power supply, the wave distortion of inlet wire current approximately reduces 30%-50% like this, is not add about half of reactor harmonic current.

Because there is distributed capacitance in the cable between motor and the frequency converter, especially longer at cable distance, and when cable is thick, frequency converter modulated square wave after inversion output can produce certain overvoltage on circuit, make the motor can't operate as normal, can be by limiting being connected out put reactor between frequency converter and motor.

Technical characterstic of the present utility model is as follows:

Energy-conservation and the two circuit formation of civil power: the hydraulic press intelligent electricity-saving appliance is made up of energy-conservation and civil power double loop, when economizer has fault, can switch to the civil power loop and move, and can not influence production like this.

The order of connection of major loop: i.e. the economize on electricity output loop that constitutes by circuit breaker, frequency converter, contactor,

The division of the signals collecting of hydraulic press intelligent electricity-saving appliance and multistage speed: the hydraulic press intelligent electricity-saving appliance is gathered hydraulic press downstream signal, pressurization signal, is write in reply number slowly, the snap back signal is as input signal, and the output of encoding constitutes the input of frequency converter multistage speed to the PLC controller to input signal.

The hydraulic press intelligent electricity-saving appliance cooperates the measurement of multi-function watt-hour meter: PLC to read the data of multi-function watt-hour meter test, show by the HMI man-machine interface then, can monitor the functions such as electric current, voltage, power factor, instantaneous active power, reactive power of hydraulic press operation in real time.

Power saving rate test analysis: the method for testing of carrying out power saving rate by meritorious electric weight and capacity of idle power statistics then according to formula (2).

The control of panel button operation and the operation of HMI man-machine interface.

The good effect that the utility model result experiment obtains is as follows:

1. power saving rate reaches more than 30%;

2. improved whole power factor of electric network, brought up to more than 0.95 by original 0.4～0.75;

3. hydraulic pressure machine oil Wen Wendu and cable temperature obviously reduce;

4. reduce electric current, the electrical network load is reduced, improved the carrying load ability of transformer;

5. reduce starting current, prolonged the useful life of hydraulic press;

6. the kinds of protect function can in time be protected fault automatically, has reduced maintenance cost;

7. mains by harmonics is controlled in the national standard scope.

Claims

1. hydraulic press intelligent electricity-saving appliance, it is characterized in that: comprise the economize on electricity output loop that constitutes by circuit breaker, frequency converter, contactor, also comprise PLC Programmable Logic Controller, HMI man-machine interface, wherein the PLC controller is an input signal by the actuating signal of gathering the electromagnetically operated valve group that is connected with the Hydraulic engine oil pump group, the PLC controller is to the input signal output of encoding, as the multistage speed input signal of Frequency Converter Control end; Frequency converter is regulated output frequency by the multistage speed input signal and is controlled the Hydraulic engine oil pump motor speed.

2. hydraulic press intelligent electricity-saving appliance according to claim 1 is characterized in that: the input at described economize on electricity output loop is connected with multi-function watt-hour meter by instrument transformer.

3. hydraulic press intelligent electricity-saving appliance according to claim 1 and 2 is characterized in that: input and output at described economize on electricity output loop are parallel with the bypass civil power output circuit of being with contactor.

4. hydraulic press intelligent electricity-saving appliance according to claim 3 is characterized in that: frequency converter puts into that input is connected with the input reactance device or/and the frequency conversion input filter in the described economize on electricity output loop.

5. hydraulic press intelligent electricity-saving appliance according to claim 3 is characterized in that: frequency converter puts into that output is connected with out put reactor or/and the frequency conversion output filter in the described economize on electricity output loop.

6. hydraulic press intelligent electricity-saving appliance according to claim 2, it is characterized in that: carry out exchanges data by port and frequency converter, multi-function watt-hour meter or/and control at described PLC controller, HMI controls and exchanges data slave station PLC controller as main website.