CN210265360U - Fluid control equipment energy-saving appliance - Google Patents

Fluid control equipment energy-saving appliance Download PDF

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CN210265360U
CN210265360U CN201920186676.2U CN201920186676U CN210265360U CN 210265360 U CN210265360 U CN 210265360U CN 201920186676 U CN201920186676 U CN 201920186676U CN 210265360 U CN210265360 U CN 210265360U
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fluid control
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韩西昌
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Chongqing Changxian Science And Technology Co ltd
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Chongqing Changxian Science And Technology Co ltd
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Abstract

The utility model relates to an energy saver of fluid control equipment, which comprises a terminal sensor, a man-machine interaction terminal, an energy-saving program controller and an execution unit; the terminal sensor is connected with the fluid control equipment, is used for acquiring the operation data of the fluid control equipment in real time, and respectively sends the operation data acquired in real time to the human-computer interaction terminal and the energy-saving program controller through the switch, wherein the operation data comprises pressure data, servo motor rotating speed data, oil temperature and servo motor temperature rise data; the man-machine interaction terminal displays the real-time collected operation data on a visual interface in a graphic mode and sends the energy-saving operation data to the energy-saving program controller; the energy-saving program controller receives the real-time collected operation data and the energy-saving operation data through the switch, analyzes and sends an energy-saving signal to the execution unit; the execution unit comprises a servo driver and a servo motor; the servo driver receives the energy-saving signal and controls the servo motor to execute; the servo motor is connected with a hydraulic pump of the fluid control device.

Description

Fluid control equipment energy-saving appliance
Technical Field
The utility model relates to an energy-saving appliance specifically is a fluid control equipment energy-saving appliance.
Background
The power source of the fluid control equipment such as a hub low-pressure casting machine is arranged in a hydraulic pump station. In the whole production period, the oil pump is always in a full-speed working state, and the energy consumption is high. In actual work, the flow and pressure required by different process sections are different, and in order to realize the control of the flow and the pressure, the hub casting machine is realized by controlling the overflow valve. The process meets the requirements, but brings great energy waste, and the long-term high-speed operation of the equipment also reduces the service life of the equipment, increases the maintenance cost of the equipment and reduces the use efficiency of the equipment.
Most of energy-saving devices in the market at present sample flow and pressure signals, and achieve the purpose of energy saving by processing and controlling the rotating speed of a motor. Such an economizer cannot collect data in real time; the motor can be controlled only according to a preset program and cannot be adjusted according to actual conditions; the power saver is easily damaged due to lack of system protection measures.
Disclosure of Invention
In view of the above problems, an object of the present invention is to provide an energy saver for fluid control equipment, which is characterized by comprising a terminal sensor, a human-computer interaction terminal, an energy-saving program controller and an execution unit;
the terminal sensor is connected with the fluid control equipment and used for acquiring operation data of the fluid control equipment in real time and respectively sending the operation data to the human-computer interaction terminal and the energy-saving program controller through the switch, wherein the operation data acquired in real time are pressure data, servo motor rotating speed data, oil temperature and temperature rise data of the servo motor;
the human-computer interaction terminal receives the running data acquired by the terminal sensor in real time through the switch and displays the running data on a visual interface in a graphic mode; sending preset energy-saving operation data to an energy-saving program controller, wherein the energy-saving operation data is the optimal operation data of the fluid control equipment in each process section;
the energy-saving program controller receives the running data acquired by the tail end sensor in real time and the energy-saving running data through the switch, analyzes and sends an energy-saving signal to the execution unit, wherein the energy-saving signal is an energy-saving speed signal and an energy-saving pressure signal;
the execution unit comprises a servo driver and a servo motor; the servo driver receives the energy-saving signal and controls the servo motor to execute; the servo motor is connected with a hydraulic pump of the fluid control device.
The real-time collected operation data and the energy-saving operation data are transmitted to an energy-saving program controller in an Ethernet physical transmission mode; the switch is an 8-port Ethernet switch with the speed of 1000M, the energy-saving program controller and the servo driver adopt a connection mode of an RS485 interface, and a standard MODBUS protocol is used for communication to transmit data so as to realize real-time synchronous transmission of the data. The human-computer interaction terminal can adjust the energy-saving operation data according to corresponding processes.
The terminal sensor comprises a pressure sensor, a temperature sensor, a rotary encoder and a terminal communication module; the rotary encoder is connected with the servo motor and used for collecting motor rotating speed data.
The energy-saving program controller also receives execution unit data, wherein the execution unit data is system protection data formed by an execution loop formed by the servo driver and an external execution unit. The external execution unit and the servo driver form an execution loop of a fuse, a circuit breaker, a surge protector, a reactor, a filter, a resistor and a contactor.
The servo motor is connected with the heat dissipation equipment. The heat dissipation device may be a heat dissipation fan.
The servo driver is connected with the servo motor through a cable; the cable is provided with a magnetic ring.
The fluid control device economizer may be used on a fluid control device, such as an oil hydraulic device, e.g., a casting machine.
The utility model discloses following beneficial effect has:
1. the collected operation data, the energy-saving operation data and the execution unit data are transmitted to the energy-saving program controller in an Ethernet physical transmission mode, the energy-saving program controller and the servo driver adopt an RS485 interface connection mode, and data are transmitted by a standard MODBUS protocol for communication so as to realize real-time synchronous transmission of data and completely solve the problem that each process section is not lagged after energy is saved. The optimal energy-saving effect is achieved while the pressure and the flow in production are met, and the actually measured energy-saving rate is 65%;
2. the servo driver has multiple protection functions, so that the maintenance frequency of the equipment is reduced, and the service life of the equipment is prolonged;
3. the control panel of the original equipment is used for controlling, so that energy conservation and protection are realized under the condition that the operation of the original equipment is not influenced;
4. the man-machine interaction terminal forms reliable man-machine conversation, so that the corresponding process can be adjusted in time. Meanwhile, corresponding data are published to a remote client in a WEB mode, so that a reliable information platform is provided for management; meanwhile, the man-machine interaction terminal can receive and display the alarm prompt of system protection, so that managers can process more quickly and effectively protect the energy saver;
5. the energy-saving program controller can automatically adjust output according to the real-time running condition of the field process, thereby realizing optimized energy conservation;
6. the servo motor can be used for more accurately controlling the rotation of the motor, so that accurate positioning is realized;
7. the servo motor is provided with an independent heat dissipation fan, and particularly under the condition of low speed and large torque force, the heat dissipation of the motor is needed;
8. the servo driver is connected with the servo motor through a cable, and a magnetic ring is sleeved on the cable for harmonic treatment, so that interference to the sensor and other control systems in operation is prevented.
Drawings
The structure of the present invention can be further illustrated by the following non-limiting examples given in the figures.
FIG. 1 is a communication connection diagram of an economizer for a fluid control device;
FIG. 2 is a diagram of execution unit connections;
FIG. 3 is a control connection for a servo driver;
fig. 4 shows an access portion of the fluid control device and an external wiring portion of the programmable controller.
Detailed Description
The following description of the present invention will be further described with reference to the accompanying drawings, and the embodiments of the present invention are only used for illustrating the present invention and not for limiting the present invention, and various replacements and modifications can be made according to the common technical knowledge and the conventional means in the field without departing from the technical idea of the present invention, and all should be included in the scope of the present invention.
As shown in fig. 1, the economizer of the fluid control device is characterized by comprising an end sensor 1, a human-computer interaction terminal 2, an energy-saving program controller 3 and an execution unit.
The original fluid control device, such as a control system of a casting machine, adopts Siemens S7-300(CPU is 315), has an Ethernet communication interface, the Ethernet site address of the system is 192.168.0.1, the touch screen (IP address: 192.168.0.2) of a man-machine interaction terminal 2 is connected through an Ethernet switch with 8 ports at the speed of 1000M, meanwhile, the PLC (S7-200 SMART of Siemens, IP address is 192.168.0.3) of an energy-saving program controller 3 is connected through the switch, and the energy-saving program controller 3 and a servo driver 4 adopt a connection mode of RS485 interface, and the communication carries out data transmission by using a standard MODBUS protocol.
The terminal sensor 1 is connected with the fluid control equipment and used for acquiring the running data of the fluid control equipment in real time and sending the running data to the human-computer interaction terminal 2 and the energy-saving program controller 3 respectively through the switch, wherein the running data acquired in real time are pressure data, rotating speed data of the servo motor 5, oil temperature and temperature rise data of the servo motor 5.
The tail end sensor 1 comprises a pressure sensor, a temperature sensor, a rotary encoder and a terminal communication module; the pressure sensor is used for acquiring system pressure data of the fluid control equipment, and the temperature sensor is used for acquiring oil temperature and temperature rise data of the servo motor 5; the rotary encoder is connected with the servo motor 5 and used for acquiring the rotating speed data of the servo motor 5; the pressure sensor, the temperature sensor and the rotary encoder respectively send the real-time collected operation data to the human-computer interaction terminal 2 and the energy-saving program controller 3 through the terminal communication module and the switch.
The human-computer interaction terminal 2 receives the operation data acquired by the tail end sensor 1 in real time through the switch and displays the operation data on a visual interface in a graphic mode; and sending preset energy-saving operation data to an energy-saving program controller 3, wherein the energy-saving operation data is the optimal operation data of the fluid control equipment in each process section. The human-computer interaction terminal 2 can adjust the energy-saving operation data according to a corresponding process.
The human-computer interaction terminal 2 can also receive an alarm prompt of system protection sent by the energy-saving program controller 3 and display the alarm prompt on a visual interface to remind a manager.
The energy-saving program controller 3 receives the running data acquired by the terminal sensor in real time and the energy-saving running data through a switch, analyzes and sends an energy-saving signal to an execution unit, wherein the energy-saving signal is an energy-saving speed signal and an energy-saving pressure signal; the energy-saving program controller 3 comprises an input module, a programmable controller and an output module; the input module receives the operation data collected by the terminal sensor 1 and the energy-saving operation data of each process section sent by the human-computer interaction terminal 2 through a switch and sends the operation data and the energy-saving operation data to the programmable controller; and the programmable controller receives the data sent by the input module, analyzes and sends the energy-saving signal to the execution unit.
The processing procedure of the programmable controller is realized by adopting a common technical means, which is not the invention point of the utility model.
The real-time collected operation data and the energy-saving operation data are transmitted to an energy-saving program controller 3 in an Ethernet physical transmission mode; the switch is an 8-port Ethernet switch with the speed of 1000M, the energy-saving program controller 3 and the servo driver 4 adopt a connection mode of an RS485 interface, and a standard MODBUS protocol is used for communication to transmit data so as to realize real-time synchronous transmission of the data. The input module adopts an RJ45 interface to receive data of the end sensor 1 and the man-machine interaction terminal 2.
The execution unit comprises a servo driver 4 and a servo motor 5; the servo driver 4 receives the energy-saving signal and controls the servo motor 5 to execute; the servo motor 5 is connected to a hydraulic pump of the fluid control apparatus.
The energy-saving program controller 3 also receives execution unit data, wherein the execution unit data is system protection data formed by the servo driver 4 and an external execution unit forming an execution loop.
The external execution unit and the servo driver 4 form an execution loop of a fuse protector, a circuit breaker, a surge protector, an electric reactor, a filter, a resistor and a contactor, so that the servo driver 4 has multiple protection functions, such as overcurrent, overvoltage, short circuit, phase failure, ground, three-phase balance protection, stall and the like, thereby forming a perfect protection function, and additionally, various interlocks of the original control and energy saver and various protections of program software form a set of complete protection system, and alarm prompt can be performed from the man-machine exchange terminal 2 in a voice and text mode from the disconnection of a control circuit, the damage of components, the pressure, the flow and the given abnormal change of proportion. And an audible and visual alarm is also arranged on the energy saver. When the alarm level reaches a serious level, the energy saver automatically locks and stops. The system is required to be put into operation after fault removal is confirmed through a human-computer interface of the HMI or a reset button on the energy saver is operated.
The servo driver 4 is connected with the servo motor 5 through a cable; the cable is provided with a magnetic ring. The servo motor 5 is connected with a heat dissipation device.
As shown in fig. 2, the execution unit mainly consists of a circuit breaker, a contactor, a servo driver 4, a servo motor 5 and a gear pump. And connecting a main power line at the upper end of the servo driver 4 with the lower end of an alternating current contactor of the original fluid control equipment, and performing start-stop control in the original control mode. Servo motor 5 is connected to servo driver 4 lower extreme, and the cable of connecting needs to do harmonic processing, need cover 3 magnetic rings promptly on the cable and carry out harmonic processing, prevents to the interference of in service to sensor and other control system. In order to better dissipate heat, especially under the condition of low speed and large torque, the servo motor 5 needs to dissipate heat of the motor, so that a set of independent heat dissipation fans is connected.
As shown in fig. 3, F1 and COM are flow data inputs, and analog signals with 0-10V dc voltage are transmitted to AI2 and GND of servo driver 4 (AI2 is signal positive input, and GND is signal negative input); p2 and GND are analog signal inputs of the pressure sensor, and the input range is 0-10V direct current analog signals. The AI3 and GND input interfaces of the servo drive 4 are accessed. Through the control of flow and pressure, the speed control of the servo motor 5 is finally converted, and the pressure and the flow of the casting machine are met, and meanwhile, the maximum energy-saving effect is achieved. DI1 is a digital input terminal DI1 for access to the drive given the enable of the servo drive 4; DI4 is the alarm reset of servo driver 4, and is connected to digital input terminal DI4 of the driver; d03 is the alarm output of the servo driver 4 for alarm protection and system fault inquiry. +24V and GND are the control power supply inputs of the driver.
The terminals L1, L2 and L3 of the servo driver 4 are connected with three-phase 380V alternating current power input ends to provide power supply power for the system. U (red), V (yellow) and W (blue) are used as three-phase power supply outputs and are connected to the servo motor 5.
The specific working mode is as follows: the operation data of the original fluid control equipment, such as a casting machine, the energy-saving operation data preset by a man-machine interaction terminal and the data of the servo driver 4 are all transmitted to the energy-saving program controller 3 at the speed of 1000M, the servo driver 4 is driven through automatic program control (energy-saving software special for our party), the real-time synchronous transmission of the data is realized, the optimal energy-saving effect is achieved, and the actually measured power saving rate is 65%.
The electricity-saving principle is as follows: the essence of energy saving is to save the margin. One is the plant static rich and the other is the plant dynamic rich. The static margin is the difference between the device configuration power and the actual required power. The dynamic margin is the difference between the maximum power required by the device and the actual running dynamic load. The intelligent communication data acquisition technology, the synchronous data processing technology, the PLC control technology, the motor parameter self-testing technology, the servo control technology, the pressure flow double closed-loop technology, the man-machine conversation technology and the power-saving control program are comprehensively applied. Dynamic prediction, advanced adjustment and synchronous optimization are realized, and finally the supply pressure and flow of the oil pressure station are regulated.
The utility model discloses a process is actually exactly a load cycle change's process, and this process has very big margin (the process is: side forms compound die → under the top mould → die cavity injection liquid aluminum alloy → pressurize → cooling → side forms open → top mould on → get the piece → side forms compound die), and this process cycle is 5-6 minutes, and the time of action cycle is 1-2 minutes, also is the load biggest. The rest process sections have small load and long time, and the operation of the oil pump is mostly in an overflow state.
In order to guarantee that the original process is not changed, the main point of the utility model is that the response time of the requirement system must be calculated in milliseconds, wherein the pressure energy when the pressure maintaining is ensured to be consistent with the original pressure energy which can ensure that each action of the casting machine can meet the original action speed. Therefore, the utility model discloses from the collection of data to central processing unit's procedure processing, the output of procedure has all proposed the requirement to the speed. In data acquisition, the utility model discloses a physical transmission mode of ethernet carries out real-time collection to the various data (pressure, flow, process data, the electric current of equipment, torsion, rotational speed, temperature etc.) of original casting machine, through human-computer interaction terminal 2, wholly transmits the parameter of each technology section for energy-conserving program controller 3 with the mode of prescription, and the energy-conserving control program that energy-conserving program controller 3 bore combines human-computer interface's data and the operational data of original casting machine to carry out the control of pressure and flow. The pressure and the flow in production are met, and meanwhile, the energy conservation is maximized.
The energy saving of the electricity saver is divided into two aspects, namely saving the electric energy of an oil pump station and saving the management and maintenance of the equipment. The judgment of the electric energy saving is determined by installing an active watt-hour meter at the power input end of the energy saver, and the comparison form of the saving can be compared in two ways: one is a comparison by a combination of operating time and production volume to compare the amount of electricity used per unit number of pieces produced, and the other is a comparison by comparison conditions of the two operating modes (original operating mode and energy saving operating mode) at the same time and the same number of pieces.
The calculation formula for the two comparisons is:
Figure DEST_PATH_GDA0002354076250000051
Figure DEST_PATH_GDA0002354076250000052
as shown in fig. 4, the connection portion with the original fluid control device mainly includes signal inputs of various operation buttons of the original casting machine (opening and closing of the left side dies 1 and 2, opening and closing of the right side dies 1 and 2, up and down of the upper die, advancing and retracting of the thimble), and inputs and outputs of the programmable controller include the following table:
Figure DEST_PATH_GDA0002354076250000053
i0.0 is the alarm stop reset input and is composed of a mushroom self-locking button on a control panel of the casting machine. I0.1 is the running signal of the original casting machine, an auxiliary contact of an oil pump alternating current contactor connected into the original casting machine is connected into one end of the contact through an input power supply signal carried by a programmable controller, and the other end of the auxiliary contact is connected into I0.1 of a PLC (programmable logic controller) to control the start and stop of an energy-saving system. I0.2 is the alarm output signal of the servo driver, which is a passive signal converted by KA10 of the intermediate relay to detect the fault output of the execution unit and the protection of the energy-saving system. I0.3-I1.0, which is the operation input of various actions of six operation platforms of the casting machine. Taking I0.3 as an example, the input is carried out by opening and closing the side die of the No. 1 operation table and advancing and exiting the thimble; the upper and lower signals of the bedplate are integrated and finally output an action signal I0.3 in parallel, so that various action conditions of the field No. 1 operation platform are responded. I0.4 to I1.0 are operation signals of 5 operation stations.
In the output part of the programmable controller, Q0.0 is reset output, is connected with an intermediate relay KA1 of AC220V through an output point of the programmable controller, and transmits 4 paths of signals through the intermediate relay, wherein one path of signals is used for resetting the servo driver 4, and the other path of signals is used for releasing a self-locking alarm device of a system control system. Q0.1 is an operation enabling output, an AC220V signal is output through a physical output point Q0.1 of the PLC, the signal is connected with an intermediate relay KA2, one path of the signal is connected with DI1 (enabling access point of the driver) of the servo driver, and the other path of the signal is used for energy-saving starting operation. Q0.2 is a starting signal of a motor cooling fan, and the signal drives an alternating current contactor KM1 through an intermediate relay KA 3. Q0.3 is a backup contact and is connected by KA 4.

Claims (9)

1. The fluid control equipment energy saver is characterized by comprising a terminal sensor (1), a human-computer interaction terminal (2), an energy-saving program controller (3) and an execution unit;
the terminal sensor (1) is connected with the fluid control equipment and used for acquiring operation data of the fluid control equipment in real time and respectively sending the operation data to the man-machine interaction terminal (2) and the energy-saving program controller (3) through the switch, wherein the operation data acquired in real time are pressure data, rotating speed data of the servo motor (5), oil temperature and temperature rise data of the servo motor (5);
the human-computer interaction terminal (2) receives the running data acquired by the tail end sensor (1) in real time through the switch and displays the running data on a visual interface in a graphic mode; sending preset energy-saving operation data to an energy-saving program controller (3), wherein the energy-saving operation data are the optimal operation data of the fluid control equipment in each process section;
the energy-saving program controller (3) receives the running data acquired by the tail end sensor (1) in real time and the energy-saving running data through a switch, and sends an energy-saving signal to an execution unit, wherein the energy-saving signal is an energy-saving speed and pressure signal;
the execution unit comprises a servo driver (4) and a servo motor (5); the servo driver (4) receives the energy-saving signal and controls the servo motor (5) to execute; the servo motor (5) is connected with a hydraulic pump of the fluid control equipment.
2. The economizer of fluid control equipment according to claim 1, wherein the real-time collected operation data and the energy-saving operation data are transmitted to the energy-saving program controller by physical transmission of ethernet; the switch is an 8-port Ethernet switch with the speed of 1000M, the energy-saving program controller and the servo driver adopt a connection mode of an RS485 interface, and a standard MODBUS protocol is used for communication to transmit data so as to realize real-time synchronous transmission of the data.
3. The economizer of fluid control equipment according to claim 1, characterized in that the end sensor (1) comprises a pressure sensor, a temperature sensor, a rotary encoder, a terminal communication module; the pressure sensor is used for acquiring system pressure data of the fluid control equipment, and the temperature sensor is used for acquiring temperature rise data of oil temperature and the servo motor (5); the rotary encoder is connected with the servo motor (5) and used for acquiring the rotating speed data of the servo motor (5); the pressure sensor, the temperature sensor and the rotary encoder respectively send the real-time collected operation data to the man-machine interaction terminal (2) and the energy-saving program controller (3) through the terminal communication module and the switch.
4. The economizer of fluid control devices according to claim 1, characterized in that the human-machine interaction terminal (2) is capable of adjusting the economizer operating data according to the respective process.
5. The fluid control device economizer of claim 1 wherein the energy saving program controller (3) comprises an input module, a programmable controller, an output module; the input module receives the operation data collected by the end sensor (1) and the energy-saving operation data of each process section sent by the human-computer interaction terminal (2) through a switch and sends the operation data to the programmable controller; and the programmable controller receives the data sent by the input module and sends the energy-saving signal to the execution unit.
6. The economizer of claim 1 or 5, wherein the economizer controller (3) also receives execution unit data, wherein the execution unit data is system protection data formed by the servo driver (4) and an external execution unit forming an execution loop.
7. The fluid control device economizer as claimed in claim 6, characterized in that the external execution unit and the servo driver (4) constitute an execution loop of a fuse, a circuit breaker, a surge protector, a reactor, a filter, a resistor, a contactor.
8. The economizer of fluid control devices according to claim 1, characterized in that the servo motor (5) is connected to a heat sink.
9. The economizer of claim 1, wherein the servo drive (4) is connected to the servo motor (5) by a cable; the cable is provided with a magnetic ring.
CN201920186676.2U 2019-02-02 2019-02-02 Fluid control equipment energy-saving appliance Active CN210265360U (en)

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Application Number Priority Date Filing Date Title
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