Intensive frequency digging transformation method for upgrading and updating of frequency converter

Abstract

The invention relates to the technical field of frequency digging transformation, in particular to an intensive frequency digging transformation method for upgrading and updating of a frequency converter, which comprises the following steps of: removing kernel components of an old frequency converter, including a rectification unit and an inversion unit; a basic framework structure and a communication programmed control system of original equipment are reserved; installing a new high-performance frequency converter kernel component, and accessing an original PLC system through a DP bus protocol; pLC program control software and a communication protocol are updated and upgraded, and the compatibility of a new system and an original system is ensured. The reserved original equipment comprises a control cabinet box body, a bus copper plate, a PLC system and a driving motor peripheral, an electric driving system is integrated and replaced, so that leap-type improvement in performance and great reduction in research and development cost are achieved, and the control cabinet is suitable for being applied to integration of various systems and various projects. Vector control and servo control can be achieved in an optimized mode, and single-machine and multi-machine transmission work of complex tasks can be met.

Description

Technical Field

[0001] The invention relates to the technical field of frequency-removal modification, and in particular to an intensive frequency-removal modification method for upgrading a frequency converter. Background Art

[0002] In modern industrial production, inverters for drive systems of large mechanical and electrical equipment play a vital role. These inverters not only control the speed and torque of the motor, but also improve the efficiency and reliability of the system by optimizing the use of electricity. However, with the development of technology, the original complete drive system inverters have gradually shown problems such as insufficient performance, high energy consumption, and high maintenance costs, and need to be replaced.

[0003] At present, the most common replacement solution is to replace the whole machine. For example, Siemens 6SE70 series MASTERDRIVE products usually adopt the method of replacing the whole machine during the performance improvement and technical transformation process. Although this method can completely solve the problems of old equipment, it also brings a series of new challenges:

[0004] Reconstruction of basic framework facilities: The installation space and method of the original equipment are often not suitable for the requirements of the new equipment, and the basic framework facilities need to be dismantled and rebuilt, which not only increases the difficulty of construction, but also significantly increases the cost of transformation.

[0005] Mismatch of communication program control system: There may be mismatch between the network program control communication of the new inverter system and the original electric control system, which requires redesigning and changing the configuration mode, or even replacing the new generation PLC program control system, which further increases the technical difficulty and economic burden.

[0006] Production interruption and economic losses: During the machine replacement process, the equipment needs to be shut down for a long time, resulting in production interruption and causing additional economic losses to the company.

[0007] Although the whole machine replacement solution is necessary in some cases, it has the following limitations in practical applications:

[0008] High cost: Replacing the entire machine requires the purchase of new equipment, as well as a lot of civil engineering and installation work, resulting in a high overall cost.

[0009] Long cycle: From equipment procurement to installation and commissioning, the entire process takes a long time, affecting the normal production and operation of the enterprise.

[0010] Waste of resources: Some of the original equipment and facilities still have certain use value, and direct replacement will result in waste of resources.

[0011] Technical risks: The compatibility and stability of the new system require a long period of verification and involve certain technical risks. Summary of the invention

[0012] The purpose of this section is to summarize some aspects of embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and the invention title of this application to avoid blurring the purpose of this section, the specification abstract and the invention title, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0013] In view of the above-mentioned problems of high cost, long cycle and waste of resources in the replacement of the whole machine, the present invention is proposed.

[0014] Therefore, the object of the present invention is to provide an intensive frequency conversion method for upgrading a frequency converter.

[0015] In order to solve the above technical problems, the present invention provides the following technical solutions: an intensive frequency-removing transformation method for upgrading a frequency converter, comprising: removing the core components of the old frequency converter, including a rectifier unit and an inverter unit;

[0016] Keep the basic framework structure and communication program control system of the original equipment;

[0017] Install new high-performance inverter core components and connect to the original PLC system through the DP bus protocol;

[0018] Update and upgrade PLC program control software and communication protocols to ensure the compatibility of the new system with the original system.

[0019] As a preferred solution of the intensive frequency-removal transformation method for upgrading the frequency converter described in the present invention, the original equipment retained includes a control cabinet body, a busbar copper plate, a PLC system, and drive motor peripherals.

[0020] As a preferred solution of the intensive frequency-removing transformation method for upgrading the frequency converter described in the present invention, the new high-performance frequency converter core components include motion control module, encoder interface module, incoming line cabinet LCM, filter cabinet AIM, rectifier cabinet ALM, and inverter cabinets of various drive mechanisms.

[0021] As a preferred solution of the intensive frequency-removing transformation method for upgrading the frequency converter of the present invention, it also includes making an installation base plate to install electric control components, including air switches and contactor components.

[0022] As a preferred solution of the intensive frequency-removal transformation method for upgrading the frequency converter described in the present invention, the new frequency conversion system adopts a common DC bus and multiple machines in parallel, and improves the bus voltage stability of the main circuit through the common bus connection between various mechanisms, so as to achieve energy balance of various mechanisms and effective utilization of motor feedback energy.

[0023] As a preferred solution of the intensive frequency-removing transformation method for upgrading the frequency converter described in the present invention, the active rectifier cabinet ALM (IGBT rectifier, IGBT feedback module) on the rectifier side is connected in parallel, which can modulate a controlled DC bus voltage. When the grid voltage fluctuates (within the allowable tolerance), the DC bus voltage can still remain constant.

[0024] As a preferred solution of the intensive frequency conversion transformation method for upgrading the frequency converter described in the present invention, the new frequency conversion system has a power grid feedback function and a full power expansion function, and supports a variety of air cooling forms for the frequency converter.

[0025] As a preferred solution of the intensive frequency-removal transformation method for upgrading the frequency converter described in the present invention, the new frequency conversion system is equipped with an equipment full life cycle management system for analyzing the cumulative use and wear of various components of the frequency converter, and comprehensively judging the use status of each component based on the real-time status, providing a basis for replacement and maintenance, and realizing a theoretical basis for actively maintaining the equipment.

[0026] As a preferred solution of the intensive frequency conversion transformation method for upgrading the frequency converter described in the present invention, the new frequency conversion system must be compatible with all equipment that does not require modification, such as the original PLC, motor, motor temperature measurement point, motor encoder, etc., to ensure that the original operation mode and the original process flow remain unchanged after the system upgrade.

[0027] As a preferred solution of the intensive frequency conversion transformation method for upgrading the frequency converter described in the present invention, the new frequency conversion system has safety integrated functions, such as safe parking and sudden power failure response, to ensure the safe operation of the system.

[0028] Beneficial effects of the present invention: The present invention integrates and replaces the electric drive system to achieve a leapfrog improvement in performance and a significant reduction in R&D costs, and is suitable for various system integrations and various engineering applications. Vector control and servo control can be optimized to meet the needs of single-machine and multi-machine transmission work for complex tasks. A multi-machine transmission system based on a common DC bus system is realized, and it can ensure that the new and old systems can be mixed under the same system conditions. The grid feedback function and full power expansion function can be added. Corresponding safety integration functions can be realized, such as safe parking, sudden power failure response and other safety functions. The air cooling of the inverter can be supported. Various high-performance rectifier frequency conversion solutions can be provided on demand, and industrial IT integration functions can be provided. The inverter is designed as a modular system and is a modular assembly type. The narrow space of the electrical room can be effectively expanded to facilitate daily inspection and maintenance operations. This patent can greatly shorten the construction period and avoid losses caused by shutdowns and production cuts. This patent can make full use of the existing installation foundation to avoid economic losses caused by the reconstruction and expansion of the basic framework. Compared with the usual overall equipment replacement construction plan, it has a greater economic benefit advantage, and the transformation cost is reduced by nearly 50%. Each independent unit considers the unified design and matching of power components, strengthens versatility, reduces the reserve of spare parts, reduces inventory backlogs, and idle funds. Because it is modular assembly, it greatly reduces the maintenance cost and maintenance time of the system. And the standardized installation process forms a standardized process to avoid or reduce the impact of environmental factors on equipment life, reliability, etc. And the system compatibility and development are comprehensively considered, providing development space for the performance expansion of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without any creative labor.

[0030] Figure 1 This is a diagram of the drive system before transformation of an intensive frequency-removing transformation method for frequency converter upgrading.

[0031] Figure 2 The diagram of the modified drive system for an intensive frequency-removal method of frequency converter upgrade DETAILED DESCRIPTION

[0032] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0033] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0034] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0035] Secondly, the present invention is described in detail with reference to the schematic diagram. When describing the embodiments of the present invention in detail, for the sake of convenience, the cross-sectional diagrams showing the device structure will not be partially enlarged according to the general scale, and the schematic diagrams are only examples, which should not limit the scope of protection of the present invention. In addition, in actual production, the three-dimensional dimensions of length, width and depth should be included.

[0036] Example 1, reference Figure 1 , which is the first embodiment of the present invention, and provides an intensive frequency-removing transformation method for upgrading a frequency converter, comprising: removing the core components of the old frequency converter, including a rectifier unit and an inverter unit;

[0037] Keep the basic framework structure and communication program control system of the original equipment;

[0038] Install new high-performance inverter core components and connect to the original PLC system through the DP bus protocol;

[0039] Update and upgrade PLC program control software and communication protocols to ensure the compatibility of the new system with the original system.

[0040] Furthermore, the original equipment retained includes the control cabinet box, busbar copper plate, PLC system, and drive motor peripherals.

[0041] Furthermore, the core components of the new high-performance inverter include motion control module, encoder interface module, incoming line cabinet LCM, filter cabinet AIM, rectifier cabinet ALM, and inverter cabinets of various drive mechanisms.

[0042] Furthermore, it also includes making an installation base plate to install electronic control components, including air switches and contactor components.

[0043] Furthermore, the new frequency conversion system adopts a common DC bus and multiple machines in parallel. The common bus connection between various mechanisms improves the bus voltage stability of the main circuit, balances the energy of various mechanisms, and effectively utilizes the motor feedback energy.

[0044] Example 2, reference Figure 1 , which is the second embodiment of the present invention. This embodiment is different from the first embodiment in that the active rectifier cabinet ALM (IGBT rectifier, IGBT feedback module) on the rectifier side is connected in parallel, which can modulate the controlled DC bus voltage. When the grid voltage fluctuates (within the allowable tolerance), the DC bus voltage can still remain constant.

[0045] Furthermore, the new frequency conversion system has grid feedback function and full power expansion function, and supports a variety of air cooling forms of the frequency converter.

[0046] Furthermore, the new frequency conversion system is equipped with an equipment life cycle management system, which is used to analyze the cumulative use and wear of each component of the frequency converter, and comprehensively judge the use status of each component based on the real-time status, provide a basis for replacement and maintenance, and realize the theoretical basis for proactive maintenance of the equipment.

[0047] Furthermore, the new frequency conversion system must be compatible with all the equipment that does not require modification, such as the original PLC, motor, motor temperature measurement point, motor encoder, etc., to ensure that the original operation mode and original process flow remain unchanged after the system upgrade.

[0048] Furthermore, the new frequency conversion system has integrated safety functions, such as safe parking and emergency power failure response, to ensure the safe operation of the system.

[0049] The rest of the structure is the same as that of Example 1.

[0050] Example 3, reference Figure 1 , which is the third embodiment of the present invention. This embodiment is different from the above embodiments in that the main steps of the system frequency upgrading and transformation are:

[0051] Specifically, electrical drive and control design, supporting component preparation, including incoming line cabinet LCM, filter cabinet AIM, rectifier cabinet ALM, inverter cabinets of various drive mechanisms, etc. Including motion control module, encoder interface module, modified cables, special communication cables and electrical auxiliary materials and CMS system.

[0052] Furthermore, the core components of the old inverter in the cabinet in the electrical room will be removed, including the rectifier unit, inverter unit, etc. All components inside the drive cabinet of each mechanism will no longer be used except for the incoming line switch, and the control and monitoring circuits of the corresponding secondary circuits will be completely removed. All the inverter and external connection lines will be removed, except for some that are still needed.

[0053] Furthermore, after rationally re-layouting the skeleton according to the original electrical cabinet, install the new upgraded inverter core components; make an installation base plate to install the electronic control components, including air switches, contactors and other components.

[0054] Furthermore, the core components of the new complete set of frequency conversion system are connected to the original PLC system through the DP bus protocol. The required hard-connected components and software transformation (including logical configuration) need to be recompiled, and the PLC program control software and communication protocol need to be updated. All signals of the frequency conversion system collected by the upgraded PLC system should be transmitted to the upper monitoring machine.

[0055] Furthermore, the new load-driven rectifier system and rectifier unit have feedback function. The new system adopts a common DC bus and multi-machine parallel connection. The common bus connection between various mechanisms improves the bus voltage stability of the main circuit, balances the energy of various mechanisms, and effectively utilizes the feedback energy of the motor.

[0056] Furthermore, the new system adopts a DC common bus solution, which is conducive to the energy balance between various mechanisms and the effective use of motor feedback energy. The active rectifier cabinet ALM (IGBT rectifier, IGBT feedback module) on the rectifier side is connected in parallel. The active rectifier cabinet ALM can modulate the controlled DC bus voltage. When the grid voltage fluctuates (within the allowable tolerance), the DC bus voltage can still remain constant. ALM can deliver sinusoidal current to the grid, almost without generating any harmful harmonics, and the power factor can reach 1.

[0057] Furthermore, the original operation mode and original process flow must remain unchanged after the system upgrade. When upgrading the variable frequency drive system, considering its system compatibility, the new variable frequency system must be compatible with all the equipment that does not need to be modified, such as the original PLC, motor, motor temperature measurement point, motor encoder, etc. In order to ensure the uniformity of the system functions after the transformation with the original main equipment, the entire system architecture remains unchanged, and all safety protection functions and interlocking must be consistent with the original system.

[0058] Furthermore, the new inverter display panel can accurately display the meaning of the fault code in the event of a fault, which is consistent with the original one. The inverter control panel is equipped with a special host computer communication interface, which can be connected to a computer to upload and download programs or parameters, and perform online monitoring. The PLC control system is modified to ensure the compatibility of the drive system and motor, and to keep the operating methods and habits unchanged.

[0059] Furthermore, the transformation adds data management and maintenance, data statistics, and monitoring management systems, and is compatible with or adds all display screens used for main equipment system monitoring (including simulation diagrams, bar graphs, trend diagrams, operation screens, alarm screens, and operation instructions, etc.). The PLC system configuration software matched with the frequency conversion has good transparency and compatibility.

[0060] Furthermore, the modified inverter is equipped with an equipment life cycle management system, which is used to analyze the cumulative use and wear of each component of the inverter, and comprehensively judge the use status of each component based on the real-time status, provide a basis for replacement and maintenance, and realize the theoretical basis for active maintenance of the equipment, thereby enhancing the stability of equipment operation.

[0061] The rest of the structure is the same as that of Example 2.

[0062] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. An intensive frequency conversion method for frequency converter upgrading, characterized by: include, Remove the core components of the old inverter, including the rectifier unit and inverter unit; Keep the basic framework structure and communication program control system of the original equipment; Install new high-performance inverter core components and connect to the original PLC system through the DP bus protocol; Update and upgrade PLC program control software and communication protocols to ensure the compatibility of the new system with the original system.

2. The intensive frequency conversion method for upgrading the frequency converter according to claim 1 is characterized in that: The original equipment retained includes control cabinet box, busbar copper plate, PLC system, and drive motor peripherals.

3. The intensive frequency conversion method for upgrading the frequency converter according to claim 2, characterized in that: The core components of the new high-performance frequency converter include a motion control module, an encoder interface module, an incoming line cabinet LCM, a filter cabinet AIM, a rectifier cabinet ALM, and inverter cabinets of various drive mechanisms.

4. The intensive frequency conversion method for upgrading the frequency converter according to claim 3 is characterized in that: It also includes making an installation base plate to install electrical control components, including air switches and contactor components.

5. The intensive frequency conversion method for upgrading the frequency converter according to claim 4, characterized in that: The new frequency conversion system adopts a common DC bus and multiple machines in parallel, and improves the bus voltage stability of the main circuit through the common bus connection between various mechanisms, so as to achieve energy balance of various mechanisms and effective utilization of motor feedback energy.

6. The intensive frequency conversion method for upgrading the frequency converter according to claim 5, characterized in that: The active rectifier cabinet ALM (IGBT rectifier, IGBT feedback module) on the rectifier side is connected in parallel, which can modulate a controlled DC bus voltage. When the grid voltage fluctuates (within the allowable tolerance), the DC bus voltage can still remain constant.

7. The intensive frequency conversion method for upgrading the frequency converter according to claim 6, characterized in that: The new frequency conversion system has grid feedback function and full power expansion function, and supports various air cooling forms of the frequency converter.

8. The intensive frequency conversion method for upgrading the frequency converter according to claim 7, characterized in that: The new frequency conversion system is equipped with an equipment full life cycle management system, which is used to analyze the cumulative use and wear of each component of the frequency converter, and comprehensively judge the use status of each component based on the real-time status, provide a basis for replacement and maintenance, and realize a theoretical basis for proactive maintenance of the equipment.

9. The intensive frequency conversion method for upgrading the frequency converter according to claim 8, characterized in that: The new frequency conversion system must be compatible with the original PLC, motor, motor temperature measurement point, motor encoder and other equipment that do not require modification, to ensure that the original operation mode and original process flow remain unchanged after the system upgrade.

10. The intensive frequency conversion method for upgrading the frequency converter according to claim 9, characterized in that: The new frequency conversion system has integrated safety functions, such as safe parking and emergency power failure response, to ensure the safe operation of the system.

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