TCL Group Precision Metal Product Center Power Saving Project Case I. Project Background
In March 2005, Guangzhou Baowa Electronic Technology Co., Ltd. was informed of the energy-saving demand information of a precision metal product center under the TCL Group. The company's monthly electricity consumption is over 300,000-400,000 degrees, the average electricity price is 0.9 yuan / kWh, and the monthly electricity bill is as high as more than 300,000 yuan, of which lighting and power load account for the largest proportion of total electricity consumption. Huge power consumption constitutes one of the company's major operating costs. Saving electricity has become a non-negligible problem for the company to reduce its operating costs and enhance its competitiveness.
Energy conservation is China's basic national policy. Guangdong, as one of China's major economic provinces, is in short supply of energy. The implementation of energy-saving projects by the company is of great significance. Guangzhou Baowa Electronic Technology Co., Ltd. attached great importance to this cooperation project and set up a service team with a sophisticated business to guarantee the smooth implementation of the project.
2. The Project Implementation Department has carefully planned the implementation plan, determined the general principles of “integrity, service, and responsibilityâ€, and carried out project management on the basis of national technical specifications and quality standards. The inspection and testing, technical solutions, project quotation, and product quality The implementation of elements such as transportation, protection, technical training, technical disclosure, document filing, etc. has resulted in elaborate and easy-to-manage solutions. In terms of safety management and civilized construction, we will vigorously implement standardized management, implement a certificate-based employment system, adhere to the principle of prevention, conduct effective communication and coordination with user units, create a favorable construction environment, and achieve civilized construction and accident-free safety production. aims.
In response to the inspection and testing requirements put forward by the company’s project leader, Guangzhou Baowa Electronic Technology Co., Ltd. dispatched senior engineers to inspect the power system and office lighting system of the hardware machinery factory. The workshop has a total of more than 50 presses. The working time is 16 hours per day, and the press power rating ranges from 2.5KW to 22KW. Taking a stamping machine as an example, the phase voltage of the motor during operation is 224V, the current is 8.84A, the average active power is 2.33KW, the load is 50% of the time, 50% of the time is no-load, and there is ample space for power saving.
According to the data recorded on-site, after technical selection, it was determined that 19 sets of Dr. Paul's DP series motor smart energy savers can be installed; the lighting system uses 2 sets of Dr. Paula DL series lighting smart energy saver. It is expected that the power system And the lighting system will save more than 15% and more than 20% respectively.
Power production equipment Under normal circumstances, when the motor is running for a long time, the light load is more than the full load time, resulting in a certain amount of wasted energy. Paula Dr. DP series motor smart energy saver adopts international advanced chip technology and adopts intelligent microprocessor control to automatically reduce the voltage of the motor to the minimum requirement under light load conditions, while keeping the rotation speed constant and reducing the stator of the motor. Excitation current makes the loss of the power supply line, copper loss of the motor winding significantly reduced, the iron loss of the motor is reduced, avoiding the electrical energy waste of the motor and improving the efficiency. If the load increases, the voltage can be automatically increased in one hundredth of a second through the thyristor to prevent the motor from stalling, so that the output power of the motor can exactly match the real-time load, thereby reducing the copper loss and iron loss, improving the motor starting performance, and achieving savings. The purpose of electrical energy. At the same time, the motor can be continuously and smoothly started, eliminating the mechanical shock caused by the large starting current generated by the conventional starting method, effectively reducing the wear of the bearing and the belt, and greatly reducing the mechanical stress of the transmission mechanism, thereby prolonging the service life of the equipment. . Its technical features include:
1. Stepless start-up of non-contact program, ie soft start, soft stop, step-down startup of the program, which not only improves the impact of the motor on the power grid, but also reduces the large mechanical impact force that the motor starts itself. The motor starts to increase the speed, automatically increases the starting voltage, and accelerates the start of the motor. The advantages of starting performance of fans, pumps, and motors with load startup are significant. Compared with Y-â–³ starter and auto-coupling depressurization starter, its biggest advantage: it is suitable for frequent start, suitable for heavy-duty start, smooth start-up speed, no noise, no vibration, no spark, a wide range of applications.
2. Use dedicated energy-saving control software to achieve energy-saving operation. With the change of the motor load rate, the motor automatically adapts to adjust the input voltage of the motor, so that the power factor of the motor is increased accordingly, and the power loss during the operation of the motor is also reduced. For motors that are often at light loads and are frequently loaded, energy efficiency is significant.
3, the motor can run in an energy-saving manner under load conditions. Operating at 60% load, the average energy saving is 15%. If the system is used for a long time, the investment can be recovered in about 1 year.
4, full-featured protection system. The motor control system is provided with protection against voltage loss, overcurrent, phase failure, and short circuit.
5, the use of the latest microcomputer digital control technology, so that complicated control circuit integration, simplification. It not only improves the system's operating reliability, but also greatly reduces the maintenance workload. At the same time, it can reduce the shutdown rate of the transmission system and improve the overall production efficiency. Running without contact eliminates the effects of poor contact in the system. Reliable work, strong anti-interference ability, reliable operation, convenient maintenance and service life of 10 years.
In view of the above technical advantages, "Dr. Paula" is particularly suitable for power-saving control of motor equipment operating with varying loads.
Third, the implementation of effects Since the "Professor Paula" in the company's operation for three months, its electricity system is stable, significant power-saving effect, using a stamping machine as an example: after installation, the current dropped to 4.91A, the average The active power was reduced to 1.89KW. After comparison and recording of 168 hours before and after installation, the average power saving rate of the power system measured was 18.9%, and the lighting system was 20%. The effect fully met the project's system power saving rate of 5%. Claim.
The built-in soft-start function of “Dr. Paula†eliminates the mechanical shock and high starting current generated by the original start-up method, saves investment in auxiliary equipment, significantly reduces the operating temperature of the motor, and reduces noise. Without changing the rotation speed and without affecting the efficiency, the motor energy is saved. The benefits of power saving greatly reduce equipment maintenance and repair costs and production costs, and enhance the market competitiveness of the product.
According to the results of this test, it is expected that after the company implements energy-saving projects, it will save more than 50,000 yuan in electricity bills per month and over 600,000 yuan each year. The investment return period is about 10 months, and the economic benefits are considerable. The social benefits are also substantial. Very significant. The project party is very satisfied with this result. Subsequent on-site inspections, technical support, customer satisfaction surveys and a series of related after-sales services are also one of the important factors that make the project owners feel satisfied.