Solution of MICNO KE300A Open Loop Vector Control VFD In Air Compressor System

What is Air Compressors And Air Compressor Applications

Air compressor is a kind of equipment that uses a motor to compress air in the compressing chamber and brings the compressed air to a certain pressure. As a basic industrial equipment, the air compressor has been widely used in almost all industrial fields such as metallurgy, machine manufacturing, mine, electric power, textile, petrochemical, light textile, etc.

The Challenge: The Air Compressor Consumes Lots of Energies

The electric energy consumption of air compressors accounts for 15% of all large scale industrial equipment (fan, pump, boiler, air compressor, etc.). Most air compressors have obvious inherent technical weaknesses due to their structure and principle.

When the output pressure exceeds a certain value, it automatically opens the relief valve and idles the asynchronous motor, which cause a waste of energy.
Moreover, the asynchronous motor are always being start and stop frequently. This will affect the service life of the motor.
The air compressor has a high starting current in power frequency mode. This has a high impact on the power grid and causes serious wear of the motor shaft and erquires a higher maintenance of equipment.
Becasue of the harsh working conditions, loud noises, and low automation level, the adjustment of output pressure is realized by manually regulating the valve opening. This way has the disadvantages of low regulation speed, large fluctuation, low stability and low accuracy.

What Benefits Can AC Inverter Drive Bring To Air Compressor System?

Electric frequency converter system is consist of an low voltage inverter, a pressure sensor and other peripheral devices.

KE300A open loop vector control VFD adopts sensorless vector control technology to meet the requirement of high torque when low frequency;

The electric frequency converter system adopts PID control, the whole control processes are as follow:

Air requirement up↑
Pipe air compress down ↓
The difference between pressure setting value and pressure feedback value up↑
PID output up↑
Inverter output frequency up↑
Air compressor motor speed up↑
Supply air flow up ↑
Pipe air compress is stable.

0~10V (or 4~20mA) signal is provided, pressure sensor is used as PID given to input AI from KE300Aanalog input;

Start and stop signal is given by central control system, KE300A vector control inverter can provide analog output signal via AO, then connect to the central control system to monitor pressure fluctuation. Meantime, fault warming signal can be provided by reactor;

You can configurate power frequency by-pass to ensure the continuity of production.

This diagram shows how Micno low voltage inverter is used in an air compressor.

Advantages of Micno Low Voltage Inverter Solution

Active Power Electricity Saving

when air compressor speed reduces, active power electricity saving is more obvious. (The meaning of active power electricity saving is saving energy & lower production cost);

Stable High Load Start

Low frequency response of KE300A inverter vector control is good, plus big power margin, can totally meet torque requirement when low frequency. So it is definitely suitable for "high load start";

Prolong Mechanical Life

Lower air compressor speed, reduce air compressor wear, can prolong the service life of air compressor. Meanwhile, the leakage of air compressor oil way is greatly reduced, relieve the pressure of environmental pollution;

Lower Oil Temperature Increase

Lower oil temperature increase is a good solution for the shortage of air compressor working pressure decreases under high temperature environment;

Reduce Noise

Can prove the working environment obviously to provide a good solution for managing the environment noise pollution in professional health governance;

Excellent Soft Start And Soft Stop Functions

The start & stop time of KE300A inverter can be adjusted randomly (0~10min), means that acceleration when start & deceleration when stop can be adjusted randomly, meanwhile, you can match with S curve ACC/DEC time to start smoothly, which can minimum the impact of air compressor caused by start & stop, this can hardly achieved by other drive devices.

If you want to make your own energy efficient air compressor solutions, Welcome to contact Micno VFD and Inverter, we are a reputable variable speed drive manufacturer in the world. We are definitely a reliable variable speed drive variable supplier partner.

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