Industrial Frequency Converters Boost Belt Conveyor Efficiency and Sustainability

2024-08-07

In modern industrial production, belt conveyors are indispensable in coal mining transportation. With the continuous advancement of high-yield and high-efficiency coal mining operations, more and more large-scale belt conveyors are being designed and put into use. While these devices have improved transportation efficiency, they have also exposed some issues, such as motor overload and high impact loads. To address these challenges, the application of industrial frequency converters has become crucial in enhancing the performance of belt conveyors and promoting energy efficiency and environmental protection.

Energy-Saving Applications of Industrial Frequency Converters in Belt Conveyors

Belt conveyors must withstand significant impact loads during startup and operation. Traditional hydraulic couplers, while capable of soft starting, come with problems such as excessive startup currents, grid voltage fluctuations, and high maintenance difficulty. The introduction of industrial frequency converters offers an effective solution to these problems.

Industrial frequency converters enable precise control of the motor's startup and operation process, ensuring smooth starting torque. This smooth startup not only reduces the impact on the power grid but also prevents motor overload issues. Industrial frequency converters can automatically adjust the output frequency and torque based on actual load changes, thereby reducing startup current and minimizing severe voltage fluctuations in the power grid. Additionally, the use of frequency converters significantly improves the overall transmission efficiency of the system, with an efficiency increase of 5% to 10% compared to traditional hydraulic coupler transmission.

Soft Start and Operation Control of Industrial Frequency Converters

In the actual operation of belt conveyors, industrial frequency converters can precisely control the acceleration during startup, avoiding equipment slippage or overheating caused by too rapid a start. For belt conveyors with large inclinations, industrial frequency converters can effectively control startup acceleration, preventing material slippage or rolling, thus ensuring the smooth operation of the conveyor.

The industrial frequency converter system is composed of a PLC, frequency converter, current transformer, current transmitter, nuclear scale, belt speed sensor, and motor speed sensor. The detection unit is responsible for collecting data such as motor current, belt speed, motor speed, and traffic signals. The control unit makes judgments and decisions through the PLC, while the execution unit adjusts the motor's operating state based on the frequency control signals from the PLC. This automated control not only enhances the operational efficiency of the belt conveyor but also reduces the equipment's failure rate.

Energy-Efficient and Eco-Friendly Advantages of Industrial Frequency Converters

Using industrial frequency converters to upgrade belt conveyors not only enables soft starting and stopping but also delivers significant energy savings. Industrial frequency converters implement energy feedback functions within the system, further reducing energy consumption. Meanwhile, the system maintains a power factor above 0.9 throughout, greatly conserving reactive power. Compared to hydraulic couplers, the application of industrial frequency converters lowers equipment maintenance and repair costs, reduces environmental pollution, and enhances the overall eco-friendly performance of the equipment.

In conclusion, the application of industrial frequency converters provides belt conveyors with a comprehensive energy-efficient and eco-friendly upgrade solution. Through precise control and optimized operational management, industrial frequency converters not only improve the working efficiency of belt conveyors but also significantly reduce energy consumption and maintenance costs. In the future, with ongoing technological advancements, industrial frequency converters will continue to play a vital role in energy efficiency and environmental protection, bringing more benefits to industrial production.