In aluminum extrusion equipment, the FGI FD100M series low-voltage frequency converter can optimize the operational efficiency of the equipment, reduce energy consumption, and enhance production stability and product quality by precisely controlling the motor speed and torque. The following analysis is conducted from three dimensions: application advantages, specific scenarios, and system integration:

1.Application advantages

(1)energy-efficient

Aluminum extrusion equipment requires frequent adjustment of pressure and flow rate, and the traditional control method has a large energy loss. The FGI FD100M series, through vector control technology, can match the motor output with the load demand in real time and reduce ineffective energy consumption. For instance, when adjusting the extrusion speed, the frequency converter can respond quickly to prevent the motor from idling or overloading, and the overall power-saving rate can reach 20% to 30%.

The permanent magnet synchronous motor and the frequency converter are adopted for coordinated control to further reduce energy consumption. The efficiency of permanent magnet motors can reach over 95%. Combined with the soft start function of frequency converters, it can reduce the impact of starting current and extend the service life of the equipment.

(2) Precise speed regulation and stable operation

The aluminum extrusion process has extremely high requirements for speed stability. The FD100M series features a speed regulation accuracy of 0.01Hz and a speed fluctuation rate of ±0.5%, ensuring a constant extrusion speed and avoiding dimensional deviations or surface defects of the profiles caused by speed fluctuations. Built-in pressure closed loop control, PID controller can achieve according to dynamically adjust the motor speed, extrusion coefficient to ensure steady discharge pressure, improve product consistency.

(3) Easy to integrate and expand

It supports mainstream communication protocols such as Modbus, CANopen, and Profibus, and can be seamlessly integrated with devices like PLC and HMI to achieve automated control. Provide the I/O extension module, convenient access, such as temperature, pressure, position sensors, build a complete monitoring system.

2. Specific application scenarios

(1) Main motor speed regulation

The main motor of an aluminum extruder usually has a relatively large power (such as 100kW-500kW). The FD100M series can achieve stepless speed regulation from 0 to 50Hz, meeting the extrusion requirements of profiles of different specifications. For example, when producing thin-walled profiles, the extrusion speed can be reduced to minimize deformation; When producing thick-walled profiles, the speed can be increased to enhance efficiency.

(2) Hydraulic pump control

The rotational speed of the hydraulic pump is controlled by the frequency converter to achieve on-demand flow supply. The traditional quantitative pump system still operates at full flow during the non-extrusion stage, resulting in energy waste. After adopting the FD100M series frequency converter, the hydraulic pump can adjust its rotational speed according to the actual load, achieving remarkable energy-saving effects.

(3) Auxiliary equipment control

The frequency converter can also be used to control auxiliary equipment such as cooling fans and lubrication pumps, automatically adjusting the rotational speed according to the operating status of the equipment to further reduce energy consumption.

3.System integration and optimization

(1) Closed-loop control system

Combining pressure sensors and encoders, a double closed-loop control system of pressure and speed is constructed. The frequency converter adjusts the motor speed in real time based on the pressure feedback to ensure the stability of the extrusion pressure. For example, when the pressure is too high, the frequency converter automatically reduces the rotational speed to decrease the flow rate. When the pressure is too low, increase the rotational speed to increase the flow rate.

(2) Energy Efficiency Management System

By recording the operation data of the motor (such as current, voltage, power, etc.), the energy consumption distribution of the equipment is analyzed. The FD100M series frequency converter supports energy consumption statistics functions, capable of generating daily, weekly and monthly energy consumption reports, helping enterprises optimize production plans and reduce operating costs.

(3) Remote monitoring and maintenance

It supports Ethernet communication and can upload the data of the frequency converter to the cloud or local server. Through the remote monitoring platform, users can view the operating status of the equipment in real time, receive fault early warning information, and make remote parameter adjustments.

4.Application case

· A certain aluminum profile manufacturing enterprise applied the FGI FD100M series frequency converter to a 1000-ton extruder. After the transformation:

· Energy-saving effect: Annual electricity savings reach 300,000 kWh, with an energy-saving rate of 25%.

· Production efficiency: The dimensional accuracy of profiles has been enhanced to ±0.1mm, and the scrap rate has been reduced by 15%.

· Maintenance cost: The motor failure rate has decreased by 50%, and the service life of the hydraulic system has been extended by 2 years.

5.Sum up

The FGI FD100M series low-voltage frequency converter, with its characteristics of high efficiency and energy saving, precise speed regulation, perfect protection and easy integration, has significant application value in aluminum extrusion equipment. By optimizing the motor control strategy, the operational efficiency of the equipment can be significantly enhanced, energy consumption can be reduced, and enterprises can achieve green production and intelligent upgrading.