An energy-saving intelligent speed control device for industrial motors

Abstract

This utility model discloses an energy-saving intelligent speed control device for industrial motors, comprising a main control unit, a signal acquisition module, a power regulation module, and a load adaptation module. The main control unit receives real-time data from the signal acquisition module and dynamically adjusts the output of the power regulation module; the signal acquisition module acquires motor current and voltage parameters; the power regulation module achieves precise power regulation through thyristor voltage regulation and pulse width modulation; the load adaptation module detects load changes and feeds them back to the main control unit. The device also includes an environmental monitoring module, a communication module, an alarm unit, and a storage unit, enabling real-time monitoring, remote transmission, and fault early warning. This application can dynamically adjust operating parameters according to actual load requirements, improving energy efficiency and meeting the high-efficiency and energy-saving needs of modern industry.

Description

Technical Field

[0001] This utility model relates to the field of motor control and energy-saving technology, and in particular to an energy-saving intelligent speed control device for industrial motors. Background Technology

[0002] Industrial motors are core power equipment in modern industrial production, widely used in the drive systems of various mechanical equipment. With increasing demands for energy conservation, motor speed control devices have gradually become an important means of improving energy efficiency. However, existing motor speed control devices have certain limitations in terms of intelligence and energy-saving effects. Their functional design is mostly focused on basic speed regulation operations, making it difficult to dynamically adjust operating parameters according to actual load. Furthermore, traditional devices typically rely on manual settings and lack real-time monitoring and feedback mechanisms, resulting in energy utilization efficiency that falls short of ideal levels and fails to meet the current industrial demands for high-efficiency energy saving. Utility Model Content

[0003] The purpose of this utility model is to provide an energy-saving intelligent speed control device for industrial motors, which solves the problems mentioned in the background art.

[0004] This utility model is implemented as follows: an energy-saving intelligent speed control device for industrial motors, comprising:

[0005] Main control unit, signal acquisition module, power regulation module and load adaptation module;

[0006] The main control unit has an input terminal for connecting to an external power supply and an output terminal for connecting to the power regulation module. The main control unit is configured to receive real-time data from the signal acquisition module and dynamically adjust the output of the power regulation module.

[0007] The signal acquisition module has its input end connected to the output end of the industrial motor's operating status and its output end connected to the main control unit. The signal acquisition module is configured to acquire the operating parameters of the industrial motor in real time and transmit them to the main control unit.

[0008] The power adjustment module has its input end connected to the main control unit and its output end connected to the drive circuit of the industrial motor. The power adjustment module is configured to adjust the output power according to the instructions of the main control unit to match the actual load requirements of the industrial motor.

[0009] The load adapter module has its input end connected to the load sensor of the industrial motor and its output end connected to the main control unit. The load adapter module is configured to detect the actual load change of the industrial motor and transmit the load information to the main control unit.

[0010] In an exemplary embodiment of this utility model, the signal acquisition module includes:

[0011] Current detection unit and voltage detection unit;

[0012] The input terminal of the current detection unit is connected to the current output terminal of the industrial motor, and the input terminal of the voltage detection unit is connected to the voltage output terminal of the industrial motor; the output terminals of both the current detection unit and the voltage detection unit are connected to the main control unit.

[0013] In an exemplary embodiment of this utility model, the power regulation module includes:

[0014] Thyristor voltage regulation unit and pulse width modulation unit;

[0015] The input of the thyristor voltage regulator unit is connected to the main control unit, and the output is connected to the drive circuit of the industrial motor; the input of the pulse width modulation unit is connected to the main control unit, and the output is connected to the thyristor voltage regulator unit; the thyristor voltage regulator unit and the pulse width modulation unit are configured to work together to achieve precise regulation of the output power of the industrial motor.

[0016] In an exemplary embodiment of this utility model, the load adaptation module includes:

[0017] Torque sensor and speed sensor;

[0018] The input end of the torque sensor is connected to the output shaft of the industrial motor, and the input end of the speed sensor is connected to the rotor of the industrial motor; the output ends of both the torque sensor and the speed sensor are connected to the main control unit.

[0019] In an exemplary embodiment of this utility model, the energy-saving industrial motor intelligent speed control device further includes:

[0020] Environmental monitoring module, switch and display unit;

[0021] The input terminals of the switch are connected to the signal acquisition module and the load adaptation module, respectively, the output terminal is connected to the display unit, and the control terminal is connected to the environmental monitoring module.

[0022] In an exemplary embodiment of this utility model, the environmental monitoring module includes:

[0023] Temperature sensors and vibration sensors;

[0024] The input terminal of the temperature sensor is connected to the housing of the industrial motor, and the input terminal of the vibration sensor is connected to the base of the industrial motor; the output terminals of both the temperature sensor and the vibration sensor are connected to the control terminal of the switch.

[0025] In an exemplary embodiment of this utility model, the energy-saving industrial motor intelligent speed control device further includes:

[0026] Communication modules and remote terminals;

[0027] The input end of the communication module is connected to the main control unit, and the output end is connected to the remote terminal; the communication module is configured to transmit the data processed by the main control unit to the remote terminal.

[0028] In an exemplary embodiment of this utility model, the energy-saving industrial motor intelligent speed control device further includes:

[0029] Alarm unit;

[0030] The input terminal of the alarm unit is connected to the main control unit; the alarm unit is configured to issue a warning signal when the industrial motor is operating abnormally.

[0031] In an exemplary embodiment of this utility model, the energy-saving industrial motor intelligent speed control device further includes:

[0032] Storage unit;

[0033] The input terminal of the storage unit is connected to the main control unit; the storage unit is configured to record the operating parameters and historical data of the industrial motor.

[0034] The beneficial effects of this invention are as follows: Through the coordinated operation of the main control unit, signal acquisition module, power adjustment module, and load adaptation module, real-time monitoring and dynamic adjustment of the industrial motor's operating status are achieved. The signal acquisition module collects the current and voltage parameters of the industrial motor, the load adaptation module detects the actual load changes of the industrial motor, and the main control unit controls the power adjustment module based on the collected data and load information, thereby achieving precise adjustment of the industrial motor's output power. This device can dynamically adjust operating parameters according to actual load requirements, avoiding the limitations of traditional devices that rely on manual settings. Furthermore, the cooperation of the environmental monitoring module and alarm unit further enhances the system's reliability and safety.

[0035] Furthermore, the introduction of communication modules and remote terminals allows the real-time transmission of industrial motor operating status to a remote monitoring center, facilitating timely monitoring of equipment operation by management personnel. The storage unit provides fundamental support for subsequent data analysis and fault diagnosis. Through these technical means, this invention significantly improves the energy efficiency of industrial motors, meeting the demands of modern industry for high efficiency and energy conservation. Attached Figure Description

[0036] Figure 1 This is a system block diagram of the present invention.

[0037] The attached diagram is labeled as follows: 1. Main control unit; 2. Signal acquisition module; 3. Power regulation module; 4. Load adaptation module; 5. Thyristor voltage regulation unit; 6. Pulse width modulation unit; 7. Communication module; 8. Remote terminal; 9. Environmental monitoring module; 10. Alarm unit. Detailed Implementation

[0038] like Figure 1 As shown, this utility model provides an energy-saving intelligent speed control device for industrial motors. Its structure consists of multiple modules and units, mainly including a main control unit 1, a signal acquisition module 2, a power adjustment module 3, a load adaptation module 4, a communication module 7, a remote terminal 8, an environmental monitoring module 9, an alarm unit 10, and a storage unit. The modules and units are electrically connected to realize information transmission and collaborative work to complete the intelligent speed control of industrial motors.

[0039] The main control unit 1 is the core component of the entire device. Its input terminal is connected to an external power supply, and its output terminals are connected to the power adjustment module 3 and the display unit, respectively. Simultaneously, the main control unit 1 also maintains signal interaction with the signal acquisition module 2, the load adaptation module 4, the communication module 7, the alarm unit 10, and the storage unit. Figure 1 The main control unit 1 is located at the core of the entire system. It performs data processing and logical judgment functions through an internal embedded processor. By receiving data from the signal acquisition module 2 and the load adaptation module 4, the main control unit 1 can analyze the operating status of the industrial motor in real time and generate control commands based on the results, which are then sent to the power regulation module 3 to adjust the motor output power. In addition, the main control unit 1 also transmits the processed data to the remote terminal 8 through the communication module 7, thereby realizing the functions of remote monitoring and data analysis.

[0040] The signal acquisition module 2 consists of a current detection unit and a voltage detection unit. Its input terminals are connected to the current output terminal and voltage output terminal of the industrial motor, respectively, and its output terminal is connected to the main control unit 1. In practical applications, the current detection unit acquires the real-time current value of the motor through a Hall sensor or a shunt, while the voltage detection unit acquires the real-time voltage value of the motor through a voltage divider circuit or a dedicated voltage sensor. These parameters are transmitted to the main control unit 1 for further processing after analog-to-digital conversion. The signal acquisition module 2 is usually located in the area close to the motor drive circuit to accurately obtain the motor's operating parameters.

[0041] The power regulation module 3 includes a thyristor voltage regulation unit 5 and a pulse width modulation unit 6, such as... Figure 1As shown, the input terminal of the thyristor voltage regulator unit 5 is connected to the main control unit 1, and the output terminal is connected to the drive circuit of the industrial motor. The input terminal of the pulse width modulation unit 6 is also connected to the main control unit 1, and the output terminal is connected to the thyristor voltage regulator unit 5. In actual operation, the main control unit 1 generates corresponding control signals based on the received motor operating parameters. These signals are first sent to the pulse width modulation unit 6. By adjusting the pulse width, the conduction angle of the thyristor voltage regulator unit 5 is changed, thereby achieving precise adjustment of the motor output power. The cooperation between the thyristor voltage regulator unit 5 and the pulse width modulation unit 6 enables the power regulation module 3 to dynamically adjust the motor output power within a wide range to meet the needs under different load conditions.

[0042] The load adaptation module 4 consists of a torque sensor and a speed sensor. The input end of the torque sensor is connected to the output shaft of the industrial motor, and the input end of the speed sensor is connected to the rotor of the industrial motor. The output ends of both are connected to the main control unit 1. In actual operation, the torque sensor obtains the torque information of the load by measuring the rotational torque on the motor output shaft, while the speed sensor measures the speed information of the motor rotor through a photoelectric encoder or a magnetoelectric sensor. This data is transmitted to the main control unit 1 to analyze the actual changes in the load, thereby providing a basis for the power adjustment module 3. The load adaptation module 4 is usually installed at the mechanical output end of the motor to facilitate direct acquisition of load information.

[0043] The environmental monitoring module 9 includes a temperature sensor and a vibration sensor. The input end of the temperature sensor is connected to the housing of the industrial motor, and the input end of the vibration sensor is connected to the motor base. The output ends of both are connected to the control end of the switch. The input ends of the switch are connected to the signal acquisition module 2 and the load adapter module 4, respectively, and the output end is connected to the display unit. In actual operation, the temperature sensor monitors the temperature change of the motor housing through thermistor or infrared temperature measurement technology, and the vibration sensor detects the vibration of the motor base through accelerometer or displacement sensor. When the environmental parameters exceed the preset range, the switch will automatically transmit the abnormal information to the display unit and trigger the alarm unit 10 if necessary.

[0044] The input end of the communication module 7 is connected to the main control unit 1, and the output end is connected to the remote terminal 8. The communication module 7 realizes data transmission through wired or wireless means. In practical applications, the communication module 7 can use technologies such as RS485 interface, Ethernet interface or Wi-Fi module to send the data processed by the main control unit 1 to the remote terminal 8. The remote terminal 8 can be a computer, tablet device or mobile phone, etc. Through the remote terminal 8, the management personnel can view the operating status of the motor in real time and remotely control the device. The communication module 7 is usually located close to the main control unit 1 to reduce signal loss during transmission.

[0045] The input terminal of the alarm unit 10 is connected to the main control unit 1. When the main control unit 1 detects abnormal motor operation, such as overload, overheating, or excessive vibration, it will send a signal to the alarm unit 10. The alarm unit 10 will issue a warning signal through an audible and visual alarm or a buzzer to remind on-site personnel to take timely measures. The alarm unit 10 is usually located on the outer surface of the device so that personnel can quickly detect abnormalities.

[0046] The input terminal of the storage unit is connected to the main control unit 1 and is used to record the motor's operating parameters and historical data. The storage unit can realize data storage function through built-in storage chip or external storage device. In actual operation, the storage unit can not only save the motor's real-time operating parameters, but also record historical data to facilitate subsequent fault diagnosis and performance optimization. The storage unit is usually integrated with the main control unit 1 to reduce data transmission delay.

[0047] In practical applications, the workflow of this device is as follows: First, the signal acquisition module 2 collects the current and voltage parameters of the industrial motor in real time and transmits the data to the main control unit 1. At the same time, the load adaptation module 4 obtains the actual load information of the motor through the torque sensor and speed sensor, and also transmits the data to the main control unit 1. The main control unit 1 analyzes the received data and generates control commands based on load changes. These commands are sent to the pulse width modulation unit 6 in the power regulation module 3. By adjusting the conduction angle of the thyristor voltage regulation unit 5, precise control of the motor output power is achieved. Meanwhile, the environmental monitoring module 9 monitors the temperature and vibration of the motor. When an abnormality is detected, the switch transmits the relevant information to the display unit and issues a warning signal through the alarm unit 10. In addition, the communication module 7 transmits the data processed by the main control unit 1 to the remote terminal 8 for real-time viewing and analysis by management personnel. The storage unit records all operating parameters and historical data for subsequent use.

[0048] The rational layout and close cooperation of the above modules and units enable this device to achieve intelligent speed control of industrial motors. In practical application scenarios, this device is suitable for various industrial motors that require dynamic load adjustment, such as fans, water pumps, and compressors. By monitoring and dynamically adjusting the operating parameters of the motor in real time, this device can effectively improve the energy efficiency of the motor, reduce energy consumption, and extend the service life of the equipment.

[0049] To enable those skilled in the art to fully understand and implement this utility model, the specific implementation principle of this utility model is further explained below in conjunction with a specific application scenario.

[0050] In an industrial plant, an energy-saving intelligent speed control device for industrial motors is applied to an industrial motor that drives a fan. This fan is primarily used to regulate airflow within the workshop, and its load fluctuates dynamically depending on the operating status of the equipment within the workshop. The following describes the specific operating steps and implementation principle of this device in this scenario.

[0051] First, signal acquisition module 2 collects the operating parameters of the industrial motor in real time through current detection unit and voltage detection unit. The current detection unit obtains the real-time current value of the motor through Hall sensor, while the voltage detection unit measures the real-time voltage value of the motor through voltage divider circuit. These data are transmitted to main control unit 1 after analog-to-digital conversion. At the same time, the torque sensor and speed sensor in load adaptation module 4 measure the rotational torque on the motor output shaft and the rotor speed information, respectively, and transmit these load data to main control unit 1. The above data acquisition process ensures that main control unit 1 can fully grasp the operating status of the motor.

[0052] Subsequently, the main control unit 1 analyzes and processes the received signals. The embedded processor calculates the current power consumption of the motor based on the current and voltage data provided by the signal acquisition module 2. Simultaneously, the main control unit 1, in conjunction with the torque and speed information provided by the load adaptation module 4, determines the actual load changes on the motor. For example, when the number of devices started in the workshop increases, the fan needs to provide a larger airflow, at which point the motor load increases significantly. The main control unit 1 generates corresponding control commands based on the load changes and sends these commands to the power regulation module 3.

[0053] After receiving the control command from the main control unit 1, the pulse width modulation unit 6 in the power regulation module 3 begins to adjust the pulse width. This adjustment process directly affects the conduction angle of the thyristor voltage regulation unit 5. By changing the conduction angle, the thyristor voltage regulation unit 5 can precisely adjust the input voltage of the motor, thereby achieving dynamic control of the motor's output power. For example, when the load increases, the main control unit 1 will instruct the power regulation module 3 to increase the conduction angle to improve the motor's output power; while when the load decreases, it will decrease the conduction angle to reduce power output. This dynamic adjustment mechanism enables the motor to maintain efficient operation under different load conditions.

[0054] Meanwhile, the environmental monitoring module 9 continuously monitors the motor's operating environment. A temperature sensor measures the temperature change of the motor casing using a thermistor, while a vibration sensor detects the vibration of the motor base using an accelerometer. When the temperature or vibration parameters exceed the preset range, the switch transmits the abnormal information to the display unit and triggers the alarm unit 10 to issue an audible and visual warning signal. For example, if the motor casing temperature becomes too high due to prolonged high-load operation, the alarm unit 10 will immediately alert on-site personnel to take cooling measures, thereby preventing damage to the motor due to overheating.

[0055] Communication module 7 plays a crucial role in data transmission throughout the process. The main control unit 1 sends the processed motor operating data to the remote terminal 8 via communication module 7. Administrators can monitor the motor's operating status in real time using mobile phones or computers and perform remote control as needed. For example, if administrators detect frequent fluctuations in motor load, they can adjust the control strategy of the main control unit 1 via remote terminal 8 to optimize motor operating efficiency.

[0056] The storage unit records the motor's operating parameters and historical data, providing crucial information for subsequent fault diagnosis and performance optimization. For example, when the motor stops abnormally, technicians can use the historical data in the storage unit to review the motor's operating status, quickly pinpoint the cause of the problem, and take appropriate measures.

[0057] Through the coordinated operation of the aforementioned modules, this device successfully achieves intelligent speed control of industrial motors. In practical applications, this device can not only dynamically adjust the motor's output power according to load changes, but also improve the system's reliability and safety through environmental monitoring and remote monitoring functions. For example, through precise speed control of fan motors, air circulation in the workshop is optimized, energy consumption is significantly reduced, and the motor's service life is extended.

[0058] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An energy-saving intelligent speed control device for industrial motors, characterized in that, include: The main control unit (1), signal acquisition module (2), power regulation module (3), and load adaptation module (4) are included. The main control unit (1) has an input terminal for connecting to an external power supply and an output terminal for connecting to the power adjustment module (3). The main control unit (1) is configured to receive real-time data from the signal acquisition module (2) and dynamically adjust the output of the power adjustment module (3). The signal acquisition module (2) has its input end connected to the output end of the industrial motor's operating status and its output end connected to the main control unit (1); the signal acquisition module (2) is configured to acquire the operating parameters of the industrial motor in real time and transmit them to the main control unit (1); The power adjustment module (3) has its input end connected to the main control unit (1) and its output end connected to the drive circuit of the industrial motor. The power adjustment module (3) is configured to adjust the output power according to the instructions of the main control unit (1) to match the actual load requirements of the industrial motor. The load adaptation module (4) has its input end connected to the load sensor of the industrial motor and its output end connected to the main control unit (1). The load adaptation module (4) is configured to detect the actual load change of the industrial motor and transmit the load information to the main control unit (1).

2. The energy-saving intelligent speed control device for industrial motors as described in claim 1, characterized in that, The signal acquisition module (2) includes: Current detection unit and voltage detection unit; The input terminal of the current detection unit is connected to the current output terminal of the industrial motor, and the input terminal of the voltage detection unit is connected to the voltage output terminal of the industrial motor; the output terminals of both the current detection unit and the voltage detection unit are connected to the main control unit (1).

3. The energy-saving intelligent speed control device for industrial motors as described in claim 1, characterized in that, The power regulation module (3) includes: The thyristor voltage regulation unit (5) and the pulse width modulation unit (6) are included. The input terminal of the thyristor voltage regulating unit (5) is connected to the main control unit (1), and the output terminal is connected to the drive circuit of the industrial motor; the input terminal of the pulse width modulation unit (6) is connected to the main control unit (1), and the output terminal is connected to the thyristor voltage regulating unit (5).

4. The energy-saving intelligent speed control device for industrial motors as described in claim 1, characterized in that, The load adaptation module (4) includes: Torque sensor and speed sensor; The input end of the torque sensor is connected to the output shaft of the industrial motor, and the input end of the speed sensor is connected to the rotor of the industrial motor; the output ends of both the torque sensor and the speed sensor are connected to the main control unit (1).

5. The energy-saving intelligent speed control device for industrial motors as described in claim 1, characterized in that, Also includes: Environmental monitoring module (9), switch and display unit; The input terminal of the switching switch is connected to the signal acquisition module (2) and the load adaptation module (4) respectively, the output terminal is connected to the display unit, and the control terminal is connected to the environmental monitoring module (9).

6. The energy-saving intelligent speed control device for industrial motors as described in claim 5, characterized in that, The environmental monitoring module (9) includes: Temperature sensors and vibration sensors; The input terminal of the temperature sensor is connected to the housing of the industrial motor, and the input terminal of the vibration sensor is connected to the base of the industrial motor; the output terminals of both the temperature sensor and the vibration sensor are connected to the control terminal of the switching switch.

7. The energy-saving intelligent speed control device for industrial motors as described in claim 1, characterized in that, Also includes: Communication module (7) and remote terminal (8); The input end of the communication module (7) is connected to the main control unit (1), and the output end is connected to the remote terminal (8).

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