Comparison

Currently, most enterprises adopt frequency conversion speed regulation methods for their fans and pumps. In view of the problems that occur in the production and operation of the variable frequency governor, especially the uncertainty of the failure of the variable frequency equipment, it brings hidden dangers to the production of the enterprise, which directly affects the continuity, stability and reliability of the production operation. Enterprises have brought great economic losses, which are usually caused by downtime when electrical equipment fails. The use of a high-power adjustable speed magnetic coupling speed-regulating scheme to replace the current frequency-converter speed-regulating scheme (that is, changing the indirect control to direct control form) can obtain the incomparable absolute advantage of using the frequency-converter speed-regulating scheme.

As a breakthrough new technology, the adjustable speed magnetic coupling is a new product specially developed for centrifugal load transmission/speed regulation energy saving of fans and pumps. The magnetic transmission technology uses the magnetic force to drive the load to work and realizes the non-contact torque transmission between the motor and the load. The active rotor driven by the motor rotates at high speed, and cuts the magnetic field lines in the magnetic field generated by the driven rotor, thereby generating an induced magnetic field. Through the interaction force between the magnetic fields, the load is driven to work, and the transmission of torque is realized between the active rotor and the driven rotor. The smaller the gap, the greater the torque transmitted by the magnetic transmission, and the higher the load speed; the larger the air gap, the smaller the torque transmitted by the magnetic transmission, and the lower the load speed. By adjusting the size of the air gap, the stepless speed regulation of the load can be realized. As a revolutionary energy-saving device across the era, the adjustable speed magnetic coupling has been widely favored by industrial customers with the gradual improvement of technology and the vigorous promotion of the market. Under the background of promoting energy-saving and environmental protection in the whole society, the adjustable speed magnetic coupling has gradually gained a firm foothold in the competition with frequency conversion energy saving due to its unique performance characteristics and wider application fields and is developing at a greater speed.

We made a comparison with four aspects that customers care most about:

The reliability of the system

Adjustable speed magnetic coupling

The adjustable speed magnetic coupling is a purely mechanical product with stable performance, without any requirements for the power supply, and will not cause high-order harmonic pollution to the power grid during use (the harm caused by the pollution of high-order harmonics to the power grid is well known, and it is no longer here. repeat). Because there is no electricity, there is no electromagnetic interference problem.

High voltage drive

Although the current technology of the high voltage drive has passed the test, as a highly complex electronic device, the unpredictability and uncertainty of the fault in its operation are obvious to all. First of all, the requirements for the environment are very harsh. The special room should be sealed and dustproof. In summer, there should be an air conditioner to maintain the temperature required for the normal operation of the equipment. The investment in auxiliary facilities is large. Secondly, there are certain requirements for the power supply, and the electronic equipment is susceptible to electromagnetic interference, which will cause the unreliable operation of the inverter equipment. At the same time, when the inverter is running, it will also produce high-order harmonic pollution to the power system, destroy the quality of the power grid, and even affect the stable operation of electronic equipment in severe cases, requiring users to use other equipment (filters) to eliminate. In addition, due to the use of high voltage drives, the shaft connection between the motor and the load is a contact type, which does not have the advantage of reducing damage to bearings and seals.

Stability of long-term operation

Adjustable speed magnetic coupling

The adjustable speed magnetic coupling has a simple mechanical structure. Once installed and put into use, it is basically not disturbed and affected by the use environment, and its operation is stable and reliable. Because there is no electricity, there is no electromagnetic interference problem. When the adjustable speed magnetic coupling is used, the shaft connection between the motor and the load is non-contact, so the vibration of the load will not be transmitted to the motor; it is precisely because the shaft connection is non-contact, it brings two aspects. benefit:

First, the “centering” requirement during installation is low;

Second, in the long-term operation, there will be no damage to the bearing and seal caused by the direct shaft connection, so as to ensure the use of the equipment. 

According to the usage of other enterprises (in the United States, the longest continuous use time has reached six years, and the theoretical life is 30 years), the adjustable speed magnetic coupling has shown excellent long-term operation stability. As pure mechanical equipment, its possible operating failures are predictable, and users will not be caught off guard due to sudden failures.

High voltage drive

The core of the inverter is a complex electronic device. After the installation is completed and put into operation, it is susceptible to the interference and influence of the use environment, and it is difficult to ensure its stable and reliable operation. According to the survey of the usage of most enterprises, the high voltage drive will fail once a year on average during the use process, and the long-term operation stability is very poor. As a complex electronic device, its operation failure is unpredictable, and it will bring unexpected accidents to users due to sudden failures.

Initial installation and future maintainability

Adjustable speed magnetic coupling

The structure is simple, the shaft connection between the motor and the load is non-contact, the requirement for alignment accuracy is low, and the installation and debugging are fast. Because it is purely mechanical equipment, there is no complicated electronic equipment; after simple training, the maintenance personnel or electrical personnel of the power plant will quickly determine the cause of the failure and quickly solve the failure by themselves, without having to ask someone from a professional company to repair it. Its service life can reach 30 years.

High voltage drive

The high voltage drive is a complex electronic device. Once an electrical fault occurs (recurrent and unpredictable), it will be difficult for the maintenance personnel or electrical personnel of the power plant to quickly determine the cause of the fault and involve the replacement of spare parts, so it is impossible to quickly solve the fault by themselves , can only be repaired by the inverter manufacturer or a professional company, and it is difficult to guarantee quick repair without affecting production. The service life of the inverter is only 7 to 10 years at the longest.

Economic analysis

Adjustable speed magnetic coupling

Initial investment

The initial investment of the adjustable speed magnetic coupling is roughly the same as that of the high voltage drive at present;

Maintenance fee

Since the adjustable speed magnetic coupling is basically maintenance-free, the maintenance cost is almost zero;

Economic losses caused by failures

Although adjustable speed magnetic couplings and high voltage drives are both energy-saving devices, the adjustable speed magnetic coupling is a real benefit for users to see the energy-saving benefits, because its mean time between failures (MTBF) is higher than The high voltage drive is much longer, so the load reduction power generation caused by a fault will not completely exhaust the energy-saving benefits brought by energy saving.

Repair and spare parts cost

Because the adjustable speed magnetic coupling is basically maintenance-free, the cost of repairing spare parts is almost zero.

High voltage drive

initial investment

The initial investment of the high voltage drive is comparable to that of the permanent magnet coupler;

maintenance fee

On average, there is one failure every year, and the cost of each maintenance, replacement and labor is expensive. And because of the uncertainty of its failure, the loss caused to production is also greater.

Economic loss due to failure

Although the high voltage drive is also an energy-saving device, the high voltage drive cannot actually let users see the benefits brought by energy saving, because its mean time between failures (MTBF) is too short, and the average time is reduced due to one fault every year. Losses such as load power generation and increased fuel consumption will completely exhaust the economic benefits brought by energy saving (it is very likely that additional costs will be added).

Repair and spare parts cost

In order to ensure that the production is not affected in the event of a sudden failure of the inverter, the spare parts of the inverter are usually prepared, which results in the occupation of funds, and due to the uncertainty of the failure, it often happens that some spare parts are not used all the year round. Due to the certain timeliness of electronic components, expired spare parts can only be scrapped, resulting in a waste of funds.

It can be seen from the previous analysis that the permanent magnet coupler has a much superior economy than the high voltage drive in terms of immediate economic benefits and long-term economic returns.

Conclusion

Whether in terms of economic benefits or safety and stability of production, the use of the speed-regulating adjustable speed magnetic coupling speed-regulating scheme has the unparalleled absolute advantage of the high-voltage high voltage drive’s speed-regulating scheme, and is the best application choice for enterprises.

The magnetic drive produced by osenc magnet can maximize the benefits by combining with the actual operating conditions of the motor and the load. Usually the service cycle and use environment of the inverter will be limited. The reason is that the inverter composed of countless components is directly affected by the normal use of each component. When any component is due to aging, breakdown, and its own quality When there is a problem, there will be endless inspection and replacement, and it will also bring countless times of abnormal shutdown and production reduction and high maintenance costs. The inverter is a delicate device with very strict requirements on the environment. It needs to be in an independent space with constant temperature, constant humidity and no dust to operate normally. For example, hundreds of power modules and rows of control cabinets require a large house of tens of square meters, 24-hour constant temperature treatment and 24-hour meticulous care. The magnetic speed governor can completely solve these problems. It only needs a little installation space, the structure is simple, the installation and maintenance are convenient, and it can also adapt to harsh environments and voltages. Most importantly, under the premise of equivalent energy saving effect, as a pure mechanical device, the simple mechanical connection does not require huge space support at all. It is precisely because it is a pure mechanical device with a service life of 25 years. Compared with the high voltage drive, it is undoubtedly the first choice for energy-saving technological transformation of fans and pump equipment.

Choice means benefit and responsibility. The right choice brings higher benefits and avoids unnecessary responsibilities. Osenc has a strong R&D team, and has developed more high-efficiency and energy-saving permanent magnet speed regulation products for different types of industrial customers and complex working conditions. With a strong sense of social responsibility, Osenc is committed to making correct efforts to choose.