1. Foreword
For a long time, the wall, ground, bricks, and chemical plants generally use ball mills to grind ceramic raw materials. It generally uses simple frequency control, which can easily cause excessive grinding of materials, requiring a long grinding cycle, low grinding efficiency, and unit product performance. Larger power consumption, large load start-up current when the motor power frequency is started will have a great impact on the equipment and the power grid, the production and maintenance of mechanical equipment is also large, and the amount of power loss is quite alarming, which will inevitably bring to the manufacturer. A lot of unnecessary troubles and serious waste of resources, so with the social and economic development and the expansion of production scale, the disadvantages of the direct industrial control ball mill have been exposed, and seriously hindered the rapid development of industrial enterprises. This prompted people to develop a smooth, high grinding efficiency, high output, low energy consumption of the ball mill - variable frequency control ball mill.
2. The main structure
The ceramic cement industrial ball mill mainly consists of a transmission device, a cylinder device, a charging device, a unloading device, and an Electrical control device.
3, transmission
The ceramic cement industrial ball mill has a large load and consumes a large amount of power. Therefore, the ceramic cement industrial ball mill usually uses 1 to 2 sets of high-power motors to drive a hardened cylinder gear reducer through a fluid coupling and then a pair of gears. Or pulleys and other driving cylinder rotation, so as to achieve the role of abrasive materials. 3 Working principle: The ball mill consists of the feeding part, the discharging part, the turning part, the transmission part (reducer, small transmission gear, motor, electric control) and other major parts. The ceramic cement industry has a horizontally placed cylinder body. The cylinder body is divided into 3 to 4 grinding chambers by a partition plate (circular plate drilled with many small round holes). Each grinding chamber is equipped with a certain shape and size of grinding. When the body rotates, the material and the grinding body are lifted by the barrel to a certain height under the action of friction force and centrifugal force, and then fall under the action of gravity along the approximate parabolic track to impact and grind the other part of the bottom of the barrel. , And produce a certain amount of axial movement to promote the material grinding and mixing.
4, the basic electrical control device
The ceramic cement industrial ball mill belongs to low-speed heavy-duty equipment, and has a large load and a large starting torque. Therefore, the ceramic cement industrial ball mill is usually started by an additional starter motor impact start or soft start device, and has a large impact on the power grid, and the operation is completed after the start is completed. The required torque is reduced, so there is a lot of room for saving energy.
5, transformation program:
According to the problems existing in the original working conditions and combined with the production process requirements, the modified ball mill system should meet the following requirements.
(1) The transformed equipment must have sufficient starting torque to meet the requirements for large ball load, and ensure that the equipment runs smoothly under variable frequency operation to ensure that the motor has constant power characteristics.
(2) The use of frequency control system to transform the original ball mill drive system to meet the normal operation of the ball mill at low speed, to ensure the normal process control technology, so that the life of the ball mill and motor to extend and reduce maintenance.
(3) The retrofitted equipment can realize automatic control, manual/mains frequency and fault self-switching functions, and can overcome the large inertia caused by the ball mill to raise the recovery voltage and effectively ensure the normal operation of the equipment.
6, inverter selection
Based on the above principles, Emerson's heavy-duty series inverters were selected to enable the system to meet the above conditions.
(1) Emerson's frequency converter uses flux vector PWM control technology right to use low speed load capability = up to 200% rated torque output. Built-in PLC program control function, a variety of controls, operating methods, complete protection.
(2) Emerson's frequency converters have high frequency accuracy, the figures are set to +0.01%, and the simulations set to +0.2% can make the operation smooth to meet the design requirements.
(3) Emerson Corporation's over-voltage converter, over-current stall into prohibited function, the right to use frequency inverter in the acceleration and deceleration process over-voltage or over-current frequency is maintained until the release of over-voltage, over-current automatically Acceleration and deceleration control.
7, the superiority of the equipment after the transformation
(1) The use of frequency control technology to transform the ball mill's drive system to meet the ball mill low-speed operation, the characteristics of a large starting torque, to achieve a continuous adjustment of the ball mill operating speed. There is no inrush current when starting the motor, enough starting power, perfect protection function. It ensures the quality of process control and saves maintenance costs.
(2) According to the requirements of the work, after changing the gear ratio to A, the inverter will run at a given frequency set to B (below 50HZ) and the operating voltage will be C (380V) and the operating current will be D (less than 180A) after the transformation. The system consumes an average of E degrees per year (C*D* daily working hours*365). Before the system transformation, the power frequency is 50HZ, the operating current is 180A, the operating voltage is 380V, and the average annual power consumption is F (90* working time per day*365) degrees. The electricity saving rate is (1-E/F)%.
(3) When the inverter of Emerson Corporation runs the automatic energy-saving function, the inverter can automatically adjust the operating frequency and output voltage according to the required torque of the load, so as to achieve the requirement of saving electric energy. When the frequency converter's automatic energy-saving function is running, its energy-saving rate is 5%----15%
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