A motor load and energy saving optimization system

Abstract

This invention relates to the field of motor energy-saving control, specifically to a motor load and energy-saving optimization system connected in series between the power supply and the motor. It includes: a control calculation module connected to an input module, used to receive parameters from the input module and calculate the optimal shaft power of the motor under current operating conditions based on data from a preset motor current-voltage characteristic curve; and a high-frequency scanning detection module connected to the control calculation module, which samples and scans the motor operating curve, real-time acquiring load rate, voltage, current, power factor, and speed parameters, and outputting them to the control calculation module. This invention solves the core problems of poor load adaptability, high energy consumption, and insufficient operational stability in existing motor energy-saving control technologies. This invention employs a slip frequency closed-loop control strategy, optimizing torque output characteristics while significantly improving the system's power factor.

Description

Technical Field

[0001] This invention relates to the field of motor energy-saving control, specifically to a motor load and energy-saving optimization system. Background Technology

[0002] Industrial motors generally adopt constant voltage and constant frequency power supply mode, or only achieve VF open-loop control speed regulation through ordinary frequency converter. In ordinary constant voltage power supply mode, the input power cannot be adaptively adjusted when the motor load fluctuates. Under light load and variable load conditions, the proportion of ineffective energy consumption such as copper loss, iron loss, and stray loss is high, resulting in low operating efficiency.

[0003] Traditional frequency converters only achieve open-loop regulation of frequency and voltage, which cannot accurately track load changes. The excitation current is prone to problems such as insufficient or excessive current, resulting in insufficient motor torque, magnetic saturation, and decreased power factor.

[0004] Existing energy-saving devices lack dynamic compensation capabilities, cannot achieve power optimization in all scenarios of constant and variable speed operation, and have poor adaptability to abnormal operating conditions such as grid fluctuations and instantaneous power outages, resulting in large starting shocks and rapid lifespan loss of motors. Therefore, we propose a motor load and energy-saving optimization system. Summary of the Invention

[0005] According to an embodiment of the present invention, a motor load and energy-saving optimization system is provided to solve the problems existing in the prior art.

[0006] This motor load and energy-saving optimization system, connected in series between the power supply and the motor, includes:

[0007] The power supply module, connected to the motor load and energy-saving optimization system, is used for DC and AC power input;

[0008] The input module is used for setting input parameters;

[0009] A control calculation module, connected to the input module, is used to receive parameters from the input module and calculate the optimal shaft power of the motor under the current operating conditions based on data from a preset motor current-voltage characteristic curve.

[0010] A high-frequency scanning detection module is connected to the control and calculation module. It samples and scans the motor's operating curve, and collects the load rate, voltage, current, power factor, and speed parameters in real time and outputs them to the control and calculation module.

[0011] An inverter module, connected to the control and calculation module, is used to output a high-frequency pulse signal according to the optimal shaft power, and to adjust the motor input voltage and current in real time by adjusting the width of the output rectangular pulse.

[0012] A filtering module, connected between the inverter module and the motor, is used to perform harmonic suppression and filtering on the signal output by the inverter module;

[0013] The output module is used to output the processed electrical energy to the motor.

[0014] Preferably, it also includes a human-computer interaction module, a display module, and a network module;

[0015] A network module, connected to the control and calculation module, is used to realize remote data transmission and remote control, and outputs data to the control and calculation module;

[0016] The display module, connected to the network module, is used to display system operating parameters and working status, and output them to the network module;

[0017] The human-computer interaction module is connected to the display module and is used to receive parameter settings from the display module and support remote centralized management and control of the human-computer interaction module.

[0018] Preferably, it also includes a protection module connected to the inverter module, used to monitor abnormal operating conditions such as overcurrent, overvoltage, phase loss, undervoltage, overheating, and instantaneous power outage within 0.1 seconds. When triggered, it cuts off or adjusts the output of the inverter module, and automatically resets after the fault is cleared.

[0019] Preferably, the control calculation module further includes a slip controller. When calculating the reference speed deviation value, the slip controller obtains the target speed corresponding to the optimal shaft power, collects the actual speed of the motor, compares the actual speed with the target speed to obtain the slip deviation value, calculates the frequency compensation amount according to the slip deviation value using a closed-loop control algorithm, and converts the frequency compensation amount into a flux stabilization control command and outputs it to the inverter module.

[0020] Preferably, the closed-loop control algorithm is slip frequency closed-loop control, the frequency compensation amount is obtained through proportional-integral calculation, and the magnetic flux stabilization control command converts the frequency compensation amount into an air gap magnetic flux control amount through a mapping function, the mapping function being pre-established based on the motor characteristic curve.

[0021] Preferably, the high-frequency scanning detection module controls the sampling timing through software driving. The sampling frequency of 10,000 times per second corresponds to a unified sampling period of 100 microseconds. The load rate, voltage, current, power factor and speed parameters are synchronously collected and packaged into a unified data set according to the unified sampling period.

[0022] Preferably, the X / Y / Z inflection point data in the preset motor current and voltage characteristic curve constitute the motor characteristic calibration dataset. The control calculation module performs corresponding analysis on the real-time operation data collected by the high-frequency scanning detection module and the characteristic calibration dataset based on the closest point matching analysis to determine the closest calibration point under the current working condition, and outputs the power reference value corresponding to the calibration point as the optimal shaft power.

[0023] Preferably, the inverter module realizes energy exchange between the inductive load and the inverter module through dynamic inverter technology. The rectangular pulse width of the high-frequency pulse signal output by the inverter module is adjusted in real time according to the change of the optimal shaft power, so that the motor input voltage and current are matched with the most economical shaft power.

[0024] Preferably, the soft-start control performed by the protection module causes the inverter module to output a gradually changing voltage and current by setting start parameters, so that the motor starting current is less than the full-load current.

[0025] The soft shutdown control performed by the protection module causes the inverter module to output a gradually decreasing voltage and current by setting shutdown parameters.

[0026] Preferably, when the protection module detects a momentary power failure within 0.1 seconds, it saves the operating parameters before the power failure, including speed, power and load status.

[0027] After power is restored, the protection module generates a reset or start control sequence based on the saved operating parameters, and adjusts the output voltage and frequency in a gradual manner to complete a smooth start.

[0028] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0029] This invention solves the core problems of poor load adaptability, high energy consumption and insufficient operational stability in existing motor energy-saving control technologies;

[0030] To address the problem of excessive copper losses, iron losses, and stray losses caused by the inability of traditional control strategies to detect load changes in real time under light or variable load conditions, this invention introduces a high-frequency sampling mechanism to achieve millisecond-level real-time tracking of motor operating conditions. By constructing a matching model based on the motor's characteristic curve, the input power reference value is dynamically corrected, ensuring that the motor's input power approaches the optimal shaft power point under the current load in real time, thereby effectively reducing ineffective energy consumption and improving system operating efficiency.

[0031] To address the problems of insufficient excitation current leading to torque limitation or excessive excitation causing magnetic saturation and power factor degradation, which are common in traditional open-loop control of frequency converters, this invention employs a slip frequency closed-loop control strategy. By calculating the deviation between the reference speed and the actual speed in real time, the output frequency is dynamically compensated, and the air gap flux is precisely adjusted based on a preset mapping relationship to ensure that the motor maintains constant flux across the entire speed range. This optimizes torque output characteristics while significantly improving the system's power factor.

[0032] To address the insufficient protection capabilities of existing equipment under power grid fluctuations, instantaneous power outages, and start-stop shocks, this invention integrates multiple intelligent protection logics. By constructing soft-start and soft-stop control curves throughout the equipment's entire lifecycle, the starting current is limited to below the full-load current threshold, reducing mechanical shock and electrical stress. Furthermore, by setting a 0.1-second-level instantaneous power outage detection and parameter memory recovery mechanism, seamless restart after instantaneous power grid faults is achieved, significantly improving the system's continuous operation capability and service life in complex power grid environments.

[0033] It should be understood that the description in the Summary of the Invention is not intended to limit the key or essential features of the embodiments of the present invention, nor is it intended to restrict the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0034] The above and other features, advantages, and aspects of the various embodiments of the present invention will become more apparent from the accompanying drawings and the following detailed description. In the drawings, the same or similar reference numerals denote the same or similar elements, wherein:

[0035] Figure 1 A schematic diagram of a motor load and energy-saving optimization system according to the present invention is shown. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0038] like Figure 1 As shown, this motor load and energy-saving optimization system is connected in series between the power supply and the motor, and includes a power supply module, an input module, a control and calculation module, a high-frequency scanning detection module, an inverter module, a filter module and an output module;

[0039] The power supply module is configured to receive DC or AC power input.

[0040] The input module is connected to the control and calculation module and is configured to receive parameter setting instructions and transmit the parameter setting instructions to the control and calculation module.

[0041] The control and calculation module is connected to the high-frequency scanning detection module and is configured to call the pre-stored motor current and voltage characteristic curve data for calculation and output the optimal shaft power signal.

[0042] The high-frequency scanning detection module is configured to scan the motor's operating curve and collect load rate, voltage, current, power factor, and speed parameters, which are then transmitted to the control and calculation module.

[0043] The inverter module is connected to the control and calculation module and is configured to output a high-frequency pulse signal in response to the optimal shaft power signal. The input voltage and current of the motor are adjusted by adjusting the width of the output rectangular pulse.

[0044] The filtering module is connected between the inverter module and the output module and is configured to perform harmonic suppression and filtering on the signal output by the inverter module.

[0045] The output module is connected between the filter module and the motor and is configured to transmit processed electrical energy to the motor.

[0046] In this embodiment, it also includes a human-computer interaction module, a display module, and a network module;

[0047] The network module is connected to the control and computing module and is configured to perform remote data transmission and transmit remote control commands to the control and computing module.

[0048] The display module is connected to the network module and is configured to acquire and display system operating parameters and working status, and output the display data to the network module.

[0049] The human-computer interaction module is connected to the display module and is configured to receive parameter setting instructions forwarded by the display module, and supports remote centralized management and control through the network module.

[0050] In this embodiment, a protection module is also included;

[0051] The protection module is connected to the control and operation module and the inverter module respectively, and is configured to monitor abnormal operating conditions such as overcurrent, overvoltage, phase loss, undervoltage, overheating and instantaneous power outage within 0.1 seconds;

[0052] The protection module is configured to output a protection command to cut off or adjust the output signal of the inverter module when an abnormal operating condition is detected.

[0053] The protection module is configured to output a reset command to restore the normal operation of the inverter module after the fault is cleared.

[0054] In this embodiment, a slip controller is integrated within the control calculation module;

[0055] The slip controller is configured to obtain the target speed corresponding to the optimal shaft power, and to collect the actual speed of the motor, and compare the actual speed with the target speed to obtain the slip deviation value;

[0056] The slip controller is configured to generate frequency compensation based on the slip deviation value using a closed-loop control algorithm.

[0057] The slip controller is configured to convert the frequency compensation amount into a flux stabilization control command and output the flux stabilization control command to the inverter module.

[0058] In this embodiment, the closed-loop control algorithm is a slip frequency closed-loop control algorithm;

[0059] The slip controller is configured to process the slip deviation value through proportional-integral calculation to generate the frequency compensation amount;

[0060] The slip controller has a pre-stored mapping function based on the motor characteristic curve. The slip controller is configured to call the mapping function to map the frequency compensation quantity to the air gap flux control quantity, and output the air gap flux control quantity as a flux stabilization control command.

[0061] In this embodiment, the high-frequency scanning detection module is configured to respond to software driving signals to control the sampling timing;

[0062] The high-frequency scanning detection module is configured to operate at a sampling frequency of 10,000 times per second, with a uniform sampling period of 100 microseconds.

[0063] The high-frequency scanning detection module is configured to synchronously collect load rate, voltage, current, power factor and speed parameters according to a uniform sampling period, and package the collected parameters into a unified data set for output.

[0064] In this embodiment, the control calculation module pre-stores a motor characteristic calibration dataset consisting of X / Y / Z inflection point data in the motor current and voltage characteristic curves;

[0065] The control and operation module is configured to perform matching operations on the real-time running data collected by the high-frequency scanning detection module and the feature calibration dataset based on the nearest point matching analysis algorithm.

[0066] The control calculation module is configured to determine the calibration point that is closest to the real-time running data under the current operating conditions based on the matching calculation results, and output the power reference value corresponding to the calibration point as the optimal shaft power.

[0067] In this embodiment, the inverter module is configured to realize energy feedback and exchange between the inductive load and the inverter module through a dynamic inverter topology;

[0068] The inverter module is configured to respond to changes in optimal shaft power by adjusting the rectangular pulse width of the output high-frequency pulse signal in real time, thereby regulating the amplitude of the motor input voltage and current to match the motor input power with the optimal shaft power.

[0069] In this embodiment, the protection module is configured to respond to the soft start command by calling a preset set of start parameters to control the inverter module to output a voltage and current with gradually increasing amplitude, so that the motor starting current is limited to less than the full load current.

[0070] The protection module is configured to respond to a soft shutdown command by calling a preset shutdown parameter set to control the inverter module to output a gradually decreasing voltage and current.

[0071] In this embodiment, the protection module is configured to save the operating parameters before the power failure when a momentary power failure is detected within 0.1 seconds. The operating parameters include speed, power and load status.

[0072] The protection module is configured to call the saved operating parameters to generate a reset or start control sequence after power is restored, and adjust the output voltage and frequency in a gradual manner to restore motor operation.

[0073] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A motor load and energy-saving optimization system, characterized in that, Connected in series between the power supply and the motor, including: The power supply module, connected to the motor load and energy-saving optimization system, is used for DC and AC power input; The input module is used for setting input parameters; A control calculation module, connected to the input module, is used to receive parameters from the input module and calculate the optimal shaft power of the motor under the current operating conditions based on data from a preset motor current-voltage characteristic curve. A high-frequency scanning detection module is connected to the control and calculation module. It samples and scans the motor's operating curve, and collects the load rate, voltage, current, power factor, and speed parameters in real time and outputs them to the control and calculation module. An inverter module, connected to the control and calculation module, is used to output a high-frequency pulse signal according to the optimal shaft power, and to adjust the motor input voltage and current in real time by adjusting the width of the output rectangular pulse. A filtering module, connected between the inverter module and the motor, is used to perform harmonic suppression and filtering on the signal output by the inverter module; The output module is used to output the processed electrical energy to the motor.

2. The motor load and energy-saving optimization system according to claim 1, characterized in that, It also includes a human-computer interaction module, a display module, and a network module; A network module, connected to the control and calculation module, is used to realize remote data transmission and remote control, and outputs data to the control and calculation module; The display module, connected to the network module, is used to display system operating parameters and working status, and output them to the network module; The human-computer interaction module is connected to the display module and is used to receive parameter settings from the display module and support remote centralized management and control of the human-computer interaction module.

3. The motor load and energy-saving optimization system according to claim 1, characterized in that, It also includes a protection module connected to the inverter module, used to monitor abnormal operating conditions such as overcurrent, overvoltage, phase loss, undervoltage, overheating, and instantaneous power outage within 0.1 seconds. When triggered, it cuts off or adjusts the output of the inverter module, and automatically resets after the fault is cleared.

4. The motor load and energy-saving optimization system according to claim 1, characterized in that, The control and calculation module also includes a slip controller. When the slip controller calculates the reference speed deviation value, it obtains the target speed corresponding to the optimal shaft power, collects the actual speed of the motor, compares the actual speed with the target speed to obtain the slip deviation value, calculates the frequency compensation amount according to the slip deviation value using a closed-loop control algorithm, and converts the frequency compensation amount into a flux stabilization control command and outputs it to the inverter module.

5. The motor load and energy-saving optimization system according to claim 4, characterized in that, The closed-loop control algorithm is slip frequency closed-loop control. The frequency compensation amount is obtained through proportional-integral calculation. The magnetic flux stabilization control command converts the frequency compensation amount into an air gap magnetic flux control amount through a mapping function. The mapping function is pre-established based on the motor characteristic curve.

6. The motor load and energy-saving optimization system according to claim 1, characterized in that, The high-frequency scanning detection module controls the sampling timing through software. The sampling frequency of 10,000 times per second corresponds to a unified sampling period of 100 microseconds. The load rate, voltage, current, power factor and speed parameters are synchronously collected and packaged into a unified data set according to the unified sampling period.

7. The motor load and energy-saving optimization system according to claim 1, characterized in that, The X / Y / Z inflection point data in the preset motor current and voltage characteristic curve constitute the motor characteristic calibration dataset. The control calculation module performs corresponding analysis on the real-time operation data collected by the high-frequency scanning detection module and the characteristic calibration dataset based on the closest point matching analysis to determine the closest calibration point under the current working condition, and outputs the power reference value corresponding to the calibration point as the optimal shaft power.

8. The motor load and energy-saving optimization system according to claim 1, characterized in that, The inverter module achieves energy exchange between the inductive load and the inverter module through dynamic inverter technology. The rectangular pulse width of the high-frequency pulse signal output by the inverter module is adjusted in real time according to the change of the optimal shaft power, so that the motor input voltage and current are matched with the most economical shaft power.

9. The motor load and energy-saving optimization system according to claim 3, characterized in that, The soft-start control executed by the protection module sets the start parameters to make the inverter module output a gradually changing voltage and current, so that the motor start current is less than the full-load current. The soft shutdown control performed by the protection module causes the inverter module to output a gradually decreasing voltage and current by setting shutdown parameters.

10. A motor load and energy-saving optimization system according to claim 3, characterized in that, When the protection module detects a momentary power outage within 0.1 seconds, it saves the operating parameters before the power outage, including speed, power and load status. After power is restored, the protection module generates a reset or start control sequence based on the saved operating parameters, and adjusts the output voltage and frequency in a gradual manner to complete a smooth start.

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