Abstract: In industrial and mining enterprises, a large number of fans, pumps and compressors are used. These machines are mainly driven by alternating current motors. Practical applications have proved that the use of intelligent process pump energy saving devices can achieve unexpected results. In particular, Reduce production costs, improve economic efficiency today. This paper introduces the application of intelligent process pump energy-saving device in heavy-duty pump control device and its energy-saving effect. First, an overview In industrial and mining enterprises to use a large number of fans, pumps, mixers, compressors, these machines are generally driven by AC motors. Most of these motors do not work at rated power, and often only have 50% to 70% of rated power or even less (20% to 70%). However, most of the motors are running at constant speed and flow or pressure regulation is carried out by using baffles, valves or venting backflow, thus a large amount of electric energy is lost in vain. Fans and pumps with larger power will lose more electric energy. For pumps and fans, the parameters to express their characteristics are: flow (air volume) Q, lift (pressure) H, power P and so on. When the rotation speed changes from n1 to n2, the relationship between Q, H and P is as follows: Q2 = Q1 (n2 / n1) H2 = H1 (n2 / n1) 2 P2 = P1 (n2 / n1) In proportion, the lift is proportional to the square of the speed, and the shaft power is proportional to the cube of the speed. Such as the pump flow or fan air volume adjustment, just adjust the motor speed can be achieved, while at the same time will greatly reduce the power consumption of the motor, saving energy. According to the basic principles of electrical engineering, the motor speed n by the following formula: Where: n --- motor speed f1 --- power supply frequency S --- slip P --- motor pole pairs so To change the motor speed, simply change the frequency of the power supply or change the motor pole number or slip can change the motor speed. Second, intelligent flow pump energy-saving device features introduced 1. Overview 1.1 System Overview System Components and Procedures: Field Data Acquisition = "A / D Conversion =" IPC Data Processing = "Communication Module Remote Transmission =" Power Device Control = "Pump Motor Variable Speed ​​Operation. 1.2 Acquisition part of the acquisition point is the key to the signal acquisition module in the analog front-end dual-output channel safety barrier installation, the flow, the valve opening signal from the original DCS system to take safe, through the analog acquisition module will be converted data Give artificial control machine to carry on operation processing. 1.2 Operation Processing Part The operation processing part is mainly processed by Advantech's high-performance IPC. It provides high-speed processing performance and reliable open network communication capability to meet the requirements of real-time and remote control of industrial and mining closed-loop control system. The processing part adopts the fuzzy PID closed-loop operation, adopts the mathematical function formula to carry on complicated logic operation, according to the function relation between speed and pressure and flow rate, accurately and real-time response to the system demand flow, the energy-saving effect is more obvious and the stability is stronger. 1.3 The output part of the IPC processing operation of the pump motor frequency data, through the remote communication RS-485 network, into the power distribution room. And then through the communication isolation module will be isolated from the signal into the master control unit, real-time traffic corresponding to the corresponding dynamic 1.4 Energy-saving control mode Original DCS system, the flow needs to change, the original DCS system automatically or manually to follow the automatic valve changes , Thus the valve opening signal as a reference value in energy-saving control, energy-saving control added a new pump speed variable. In the meet the pressure and head conditions, the valve opening in accordance with a certain ratio than the original increase, and then the original valve opening signal as a reference value for flow control that the pipe flow measured by the flow sensor pipe flow into Standard current signal, the main control unit used to control the pump speed, change the pump flow, thus changing the pipeline flow. LBP series of high-performance smart energy-saving devices to absorb the current field of digital control and power electronics in the field of advanced technology, and built-in bypass unit using the cell structure, energy-saving devices at any time switch to the original system failure, the device operating reliability Amplitude increased. In addition, many new functions of the device provide more solutions for applications. For example, the overall size of the device is the same as that of the original system, the long-life power capacitor, the Chinese WINDOWS interface, the industry standard communication function and the remote control function, Power grid automatically re-run after the coincidence, easy maintenance and so on. 1.5 Electrical Structure The system consists of control loop and frequency adjustment device, according to the needs of different occasions, can be equipped with input switch. The system also has a flexible measurement control configuration, thus simplifying the measurement control circuit structure. 2. Features 2.1 The main features 2.1.1 operating circuit If the main control unit alarm occurs during operation, the system will automatically bypass the unit into the original system operation, the system can be uninterrupted operation; the other can also be based on the need for artificial Switch to standby circuit operation. Unit by-pass, the system automatically records the cause of the alarm, corresponding to the alarm menu to help troubleshoot the solution, according to the record to find the corresponding fault point, troubleshooting. Unit to automatically bypass the unit in the following fault conditions: Output short-circuit unit Over-voltage unit Over-current unit temperature is too high Unit program flow error Unit power failure 2.1.2 Failure The main control unit can be replaced online ---- High reliability The LBP series high performance intelligent device adopts the main circuit and the backup circuit to allow the online replacement of the faulty unit during the operation. The operator continues to run after the fault unit is shunted by the unique mechanical bypass mechanism under the prompt of the master status, The unit can be serviced online, the unit automatically bypasses the main control unit and the unit can be changed online to increase the reliability of the unit. 2.1.3 The use of high-performance long-life capacitor, the capacitor life of up to 10 years, cost-effective LBP1000 series of high-performance smart devices with high-performance long-life capacitors, capacitor life of up to 10 years, cost-effective, ordinary capacitor general service life In 5 years, the power capacitor is an important device in the frequency conversion device. The cost of replacing the capacitor and the engineering cost are also quite high. The use of high performance long-life capacitor not only improves system reliability and efficiency but also has the best economy. 2.1.4 Dedicated Radiator For the special occasions that require high operational stability, our large heat sink with high conductivity dissipates heat and greatly reduces the heat dissipation effect, greatly improves the heat dissipation efficiency, reduces the temperature rise of the IGBT body, Improve the device overload capacity, reduce device damage and improve device reliability. 2.1.5 Acquisition, communication signal disconnection detection LBP series of high-performance intelligent device can have online detection disconnection function, when the detected signal acquisition, communication signal is disconnected automatically alarm, automatically switch to a fixed frequency operation to ensure that the system Safe and stable operation. 2.1.6 Perfect protection limits The unit itself has the following protection: Output short-circuit protection Input voltage phase loss protection Output over-current protection input and output Over-voltage protection unit temperature is too high Protection and protection Limit function: motor protection, including overload, lack of Phase, temperature and other main control unit protection. Including overload, regenerative energy, fans and other main control provided by the protection functions to the user open, the protection parameters can be set online 2.1.7 to adapt to fluctuations in the input voltage Strong & nb
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