I. Introduction
Screw air compressors are widely used in metallurgy, machinery manufacturing, mining, power, textile, petrochemical, textile and other industries. They are the core equipment in many process flows. Their installed capacity generally depends on the maximum amount of gas required for production and in addition Increase the remaining 10% to 20% . Due to the imbalance in the amount of gas used in the production, when the gas pressure reaches a certain value, the air compressor generally adopts two modes of unloading the no-load operation or stopping the air compressor, wherein the power consumption during unloading the no-load operation is full. 30% ~ 60% of the load , this part of the power is wasted, and stopping the air compressor operation will lead to the frequent start and stop of the motor, the impact on the power grid and other equipment is greater, and the life of the air compressor will also shorten.
According to another survey, the power consumption of various types of motors in the country accounts for about 70% of the national power generation , 80% of which are asynchronous motors, and most of the motors are in light-load operation for a long time, especially for fans and pumps. If inverters are used on such loads, the power consumption will be greatly reduced. Taking an air compressor as an example, its load characteristic is a constant torque, and its power saving rate N%=Δn↓% , ie, the power saving rate is equal to the percentage of the speed decrease. (usually about 20% , the speed can not be too low, too low will accelerate the mechanical wear)
Therefore, how to design a control scheme that is energy-saving, stable, and highly automated is the primary problem faced by air compressor operators and manufacturers. With the development of power electronics technology, variable frequency drive technology has been gradually introduced into the field of air compressors. Through a large number of application cases and actual measurements, it is verified that this solution has the advantages of stable operating pressure, small impact on the power grid, safe operation, and energy saving within a certain range.
Second, the advantages of frequency conversion screw air compressor
Technical advantages of traditional screw air compressor frequency control weaknesses and frequency control:
(1) Adding and unloading control methods to regulate the air supply seriously waste energy
The traditional control method is when the air compressor is loading: during the pressurization process from the set pressure to the unloading pressure, the electric energy is wasted, and the decompression process through the pressure reducing valve is also wasting energy; when the air compressor is unloaded : Closing the solenoid valve keeps the motor idle. This adjustment method is also a great waste of power. The power consumption during unloading is about 20% to 40% of the full load .
In the frequency conversion control mode, the variable frequency drive system controls the air pressure by controlling the motor rotation speed so that the output pressure is always maintained at the set pressure and the output pressure is kept constant, thereby avoiding the waste of electric energy caused by frequent loading and unloading.
Air compressor is a constant torque load. In terms of output power alone, the use of variable frequency speed control is far less effective than the quadratic load of fan pumps. But most of the air compressor in continuous operation for a long time, as are the needs to choose according to the maximum design displacement in the actual operation, the ratio of full accounting for the non-operating time is also very high, non-full load operation process There is a huge energy saving space.
(2) Large starting current surge
The traditional air compressor main motor adopts Y- â–³ decompression starting and the starting current is about 3 times of the rated current , which is still very large. It has a large impact on the power grid, which may easily cause grid instability and threaten the operation safety of other electrical equipment.
The inverter can make the current when the motor is started and loaded rise gently without any impact; the motor realizes soft start and stop, avoids the damage caused by the inrush current, and is beneficial to prolong the service life of the equipment.
(3) Poor gas supply pressure stability
In the production process of the product, the stability of the air pressure has a great influence on the product quality. The user has certain requirements on the pressure accuracy of the air supply. In order to avoid the lack of air pressure, the traditional air compressor has a higher pressure than the required value. However, this will result in high costs and high energy consumption. At the same time, frequent loading and unloading will also make it difficult to ensure the air pressure temperature.
The inverter can monitor the pressure of the gas in the gas supply pipeline in real time with closed loop. The PID regulator compares the current pressure with the set pressure difference to ensure that the output pressure is always maintained at the set pressure and the output pressure is kept constant to improve the production efficiency and product quality.
Third, TS 2600 screw air compressor single frequency electric control drive system introduced
TS2600 Screw Air Compressor Single Frequency Control Electric Drive System
TS 26 00 series screw air compressor single frequency conversion electric control drive system is based on the latest open drive technology platform of Sifang Electric. It is a high-performance variable frequency electric control system developed for the air compressor industry and integrates air compressor equipment. All requirements and variable frequency drive functions in control and application . The system uses a high-performance heavy-duty vector inverter unit and is equipped with an inverter air compressor control adapter card and control panel. It has the advantages of easy installation and adjustment, high integration, high system reliability, and high cost performance, and represents the field of air compressor frequency conversion drive. The leading level. 
System easy wiring reference icon
Fourth, TS 26 00 screw air compressor single frequency electric control drive system program advantages
( 1 ) Highly integrated integrated design
 The integrated electrical control components used in the air compressor industry such as air-opening, contactors, and relays eliminate the need for additional wiring and additional electrical components, reducing the cost of materials and labor during installation.
( 2 ) 120% heavy-duty long-term stable operation
For the characteristics of the air compressor industry, TS series configuration heavy-duty inverter control unit; long-term overload capacity is 120% of the rated value , more in line with the actual working conditions of the air compressor.
( 3 ) Four-stage PID setting suitable for compressor characteristics
  The three-stage process pressure and duration can be reasonably set to avoid over-pressure adjustment and rapid adjustment of air pressure in order to accurately control air pressure.
( 4 ) Oil temperature control system
 The system includes an oil temperature control system. According to the feedback temperature and the set start and stop temperature values, the start and stop of the oil cooler is controlled to keep the system oil temperature normal. When the oil temperature is abnormal, the system will automatically stop the alarm to protect the system .
( 5 ) LCD dedicated operation control panel, clock display, multi-level password protection
LCD dedicated operation control panel can directly set the relevant parameters of the inverter unit, pressure, temperature control parameters, real-time monitoring of the air compressor operating status, can record up to eight sets of fault records, to facilitate the diagnosis of air compressor operating data.
( 6 ) Easy installation, debugging and maintenance
TS cabinet eliminates the common transformer, the secondary circuit relays and other electrical equipment, and copper, cables, and other auxiliary terminals, reducing installation time, improve production efficiency and reduce the failure rate of the assembly, but also makes Commissioning time is greatly reduced.
( 7 ) Other special features:
Ø pressure, temperature and other signals through the liquid crystal interface integration set, testing;
Ø Air filter, oil filter replacement cycle, maintenance time and other independent settings;
Ø The system provides multi-level password protection to prevent illegal operations leading to system failure;
Ø Operation panel monitors all operating parameters, rich early warning and protection functions;
Ø Provide one-way independent 485 communication interface, which can be used as remote monitoring ( refer to remote monitoring scheme part ) and control use or as multiple compressor network ( TS series);
Ø With real-time clock function, it can display the current time and record the time of failure, which is convenient for maintenance and inquiry ;
Ø With automatic sleep function, it is conducive to energy saving and reduce equipment wear .
V. Conclusion
The frequency conversion screw air compressor market is continuously expanding. By 2015 , China's air compressor market capacity will exceed 30 billion yuan. Domestic variable frequency screw machines are undergoing a popularization process. Although the initial investment is large, the screw conversion machine has a high return rate. . With the increase of the government's energy conservation efforts, and improve customer awareness of energy conservation, it is foreseeable growth of high-frequency screw air compressor machine, the next huge market capacity.
In the competitive and competitive air compressor market, whether companies can effectively improve production efficiency, technology, energy conservation, and consumption reduction to reduce production costs have become an important factor in whether an enterprise can survive and develop. TS 2600 series screw air compressor single frequency conversion electronically controlled drive system has been promoted to the market, integrated design has greatly improved the production efficiency of the manufacturers, high-performance heavy-duty vector frequency conversion drive system ensures stable operation of the air compressor system It also maximizes energy savings for customers and lowers maintenance costs, and has received unanimous praise from supporting manufacturers and end users.
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