Extrusion Press Soft Starter for Nonferrous Metal Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing extrusion presses for nonferrous metal profiles face challenges with high peak switch currents during soft start-ups and inefficient energy usage due to the star-delta connection, leading to frequent motor shutdowns and unnecessary pump operation.
Innovation Solution
The implementation of a soft starter system using thyristors or triacs for phase control in the electric motor, allowing for reduced starting current and controlled power supply, enabling efficient motor operation and easy switching off of unnecessary pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If star-delta connection is used for soft start-up of the motor, then the starting current is reduced to one-third of direct start-up current, but very high peak switch currents occur during phase switching
Solution Approach 1:
The patent applies preliminary action by using a soft starter that gradually increases the voltage to the motor during start-up, rather than suddenly applying full voltage. The soft starter controls the thyristors to progressively reduce the phase clipping, allowing the motor to accelerate smoothly and avoid both high starting current and peak switch currents. This preliminary controlled action prevents the harmful effects of abrupt phase switching.
Solution Approach 2:
The soft starter acts as an intermediary device between the power source and the motor. It uses thyristors to control the voltage supplied to the motor during start-up, mediating the transition from zero voltage to full operating voltage. This intermediary control mechanism eliminates the direct connection that causes peak switch currents while still providing the benefits of reduced starting current.
2Reliability
If fault-voltage protection switch is integrated in motor control, then motor protection is improved, but frequent switching off becomes problematic or impossible
Solution Approach 1:
The patent segments the control functions by separating the soft starter control from the motor protection functions. The soft starter handles gradual voltage increase and pump switching, while the motor controller handles protection functions. This segmentation allows independent optimization of each function, enabling pump switching without compromising motor protection.
Solution Approach 2:
The soft starter serves as an intermediary control device that manages pump operation and motor start-up without interfering with the motor protection system. It provides a layer of control that enables frequent pump switching while the motor protection switch remains available for actual motor protection needs, resolving the conflict between protection and operational flexibility.
3Reliability
If pumps are operated continuously for fault-voltage protection, then motor protection is maintained, but energy consumption increases due to unnecessary pump operation
Solution Approach 1:
The patent applies dynamics by making the pump operation dynamic rather than static continuous operation. The soft starter enables pumps to be switched on and off based on actual production needs, with gradual start-up and shutdown. This dynamic control optimizes energy consumption while maintaining motor protection through the separate motor protection switch.
Solution Approach 2:
The soft starter changes the voltage parameter gradually during pump operation, allowing pumps to be started and stopped efficiently. This parameter control enables energy-efficient operation by matching pump runtime to actual production requirements, eliminating unnecessary energy consumption while maintaining system reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables problem-free start-ups, reduces energy consumption, and allows for efficient operation by limiting starting currents and preventing peak loads, resulting in significant energy savings and reduced waste heat production.
Implementation Method 1
The controller has in particular at least two thyristors or triacs for phase control of at least two of the three phases of the alternating current voltage
Implementation Method 2
a hydraulic piston/cylinder assembly for moving the ram, a pump connected to the assembly for pressurizing same
Data Source
AI summary
An extrusion press for making profiles of nonferrous metal has a ram, a hydraulic piston/cylinder assembly for moving the ram, a pump connected to the assembly for pressurizing same, and an electric motor connected to the pump for driving same. A multiphase source of electricity is connected via a controller to the electric motor for a soft start of the motor.