The characteristics and deficiencies of the permanent magnet variable frequency air compressor
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Features of permanent magnet variable frequency air compressor:
1. The air pressure of the permanent magnet variable frequency air compressor is stable
Since the frequency conversion screw air compressor utilizes the stepless speed regulation characteristics of the frequency converter, it can be started slowly through the controller or the PID regulator inside the frequency converter; it can quickly adjust and respond to occasions with large gas fluctuations. Compared with the upper and lower limit switch control of power frequency operation, the air pressure stability is exponentially improved.
2. The permanent magnet variable frequency air compressor starts without impact
Since the frequency converter itself contains the function of a soft starter, the starting current is larger in 1 of the rated current. Within 2 times, the starting impact is less than that of the power frequency starting, generally more than 6 times of the rated current. This effect is not only detrimental to the grid, but also to the entire mechanical system.
3. Variable flow control of permanent magnet frequency conversion air compressor
The air compressor driven by the working frequency can only work in one displacement, and the variable frequency air compressor can work in a relatively wide range of displacement. The frequency converter adjusts the motor speed in real time according to the actual gas consumption to control the exhaust volume. When the gas consumption is low, the air compressor can also automatically sleep, which greatly reduces energy loss. An optimized control strategy can further improve the energy saving effect.
4. The AC power supply of the permanent magnet variable frequency air compressor has good voltage adaptability
Due to the overmodulation technology adopted by the frequency converter, when the AC power voltage is slightly low, it can still output enough torque to drive the motor; when the voltage is slightly high, the output voltage to the motor will not be too high. For self-generating applications, variable frequency drives can show their advantages. According to the motor VF in the energy-saving state, the frequency conversion air compressor works below the rated voltage), and the effect is obvious for the scene with low grid voltage.
5. Permanent magnet frequency conversion energy-saving air compressor has low noise. Most of the working conditions of the frequency conversion system are lower than the rated speed, which reduces the mechanical noise and wear of the main engine, and prolongs the maintenance and service life. If the fan is also driven by frequency conversion, it can significantly reduce the noise of the air compressor when it is working.
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Summarize the shortcomings of permanent magnet variable frequency air compressors as follows:
1. Fear of demagnetization The motor used in the permanent magnet frequency conversion air compressor is a permanent magnet motor. The weakness of this kind of motor is that it is afraid of demagnetization. The magnetic steel determines demagnetization. The motor is in a high temperature state for a long time and is easy to demagnetize.
2. More troublesome maintenance Compared with ordinary compressors, the maintenance of permanent magnet inverters is relatively troublesome. During maintenance of the machine head, remove the motor before removing the machine head. It also requires the use of specialized tools (the rotor has a strong pull) and professional maintenance.
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Are you in the market for a new air compressor? If so, you may be considering a fixed-speed compressor as an option. But before you make your purchase, you need to understand the limitations and drawbacks of fixed-speed compressors.
In this article, we outline 6 reasons why you may want to consider an alternative. Read on to learn why a fixed-speed compressor may not be the right choice for your plant.
What is a fixed-speed air compressor?
A fixed-speed air compressor operates at a constant speed, regardless of air demand or pressure. This means that the compressor's motor runs at a set RPM, and the air pressure and flow rate remain constant. These types of compressors are generally less expensive than variable-speed compressors but they are also less efficient.
1. Power consumption
The main reason to avoid a fixed-speed rotary screw compressor is its excessive power consumption. Fixed-speed compressors operate continuously, drawing maximum electricity to maintain a top speed, or RPM. This makes them extremely inefficient, particularly during periods of intermittent air usage. Instead of slowing down or switching off to match air usage, a fixed-speed compressor runs at full speed all the time, releasing excess compressed air through a bleed valve.
2. Frequent maintenance
The constant high-speed operation of a fixed-speed compressor results in increased wear and tear on its moving parts. Components like the motor, bearings, gearing and air end are subject to excessive friction over time, leading to longevity issues and malfunctions. Over time this means a lot of plant downtime and is a maintenance expense you could do without.
3. Efficiency
Fixed-speed compressors are often manufactured with smaller air ends to make them more affordable. To achieve the desired free air delivery, a pulley or gearing system is used which can reduce the lifespan of the air end component. For example, when the motor is running at RPM, the air end may be operating at - RPM, putting the part under excessive stress.
On the other hand, variable-speed compressors use direct drive motors that adjust the speed to meet air demands. Additionally, the use of permanent magnet motors in variable-speed drive machines can result in even greater energy savings because they require up to 40% less energy to perform the same work as traditional electric motors. In fact, permanent magnet motors have been a key factor in the success of companies like Tesla.
4. Current spikes
When you turn them on and off, fixed-speed compressors consume a large amount of electricity. They reach full speed instantly, resulting in a large surge in electricity usage. This can result in issues with the power supply for the rest of your plant and equipment. However, with a variable-speed compressor, a 'soft-start' will gradually activate the motor and increase its speed over a period of 10-15 seconds, avoiding any sudden spike in electricity usage.
5. Stops and starts
When air consumption has stopped for an extended period, a fixed-speed compressor will automatically shut down. When the pressure in the tank drops again, it will start back up again. This puts a lot of strain on the motor and moving parts, meaning more repairs and even replacements. With variable-speed compressors, the soft-start feature allows for an unlimited number of starts and stops without putting undue stress on the motor.
6. Future growth
Unfortunately, fixed-speed compressors have to be matched according to your current air demand, with no consideration for the future. That&#;s because they should be running consistently to make the most of limited starts and stops. This requires compressed air to be used at a consistent rate, matching the compressor's output to prevent it from shutting off during periods of low air usage.
As your plant and business grow, this means you will need to purchase additional equipment or replace the current machine to match your usage &#; even if the compressor is relatively new. With a variable-speed compressor, you can safely opt for an oversized model as it can run at as low as 25% of its capacity for extended periods. When your air consumption changes, it can be easily adjusted to match.
In conclusion
While fixed-speed compressors are commonly used, many plants and workplaces would be better off looking at an alternative. Fixed-speed compressors can be:
- Inefficient
- High maintenance
- Costly
- And prone to frequent stops and starts.
What&#;s more, your plant will likely need to invest in another compressor as soon as your air requirements change. For a better long-term investment and lower running costs, a variable-speed compressor will be a wiser choice.
View the Industrial Air Systems range of variable-speed compressors here >>
What are variable-speed air compressors?
As the name suggests, variable-speed air compressors can be adjusted based on air demand or pressure. This means the motor can change its RPM, and the air pressure and flow rate will also change accordingly.
These compressors are generally more expensive up-front than fixed-speed compressors, but they are more energy-efficient, have longer lifespans, and offer better performance. They match the air demand, reducing the amount of energy wasted by running at a constant high speed.
Permanent magnet air compressors
A permanent magnet air compressor is a type of variable speed compressor with permanent magnets to help the motor work more efficiently. It can change its speed depending on the air demand and will produce more torque at lower speeds which is better for maintaining a steady flow and pressure. It also operates at lower noise levels compared to traditional compressors.
Investing in a permanent magnet compressor can save you money in the long run and ensure that your compressed air system is always operating at the optimal level. These compressors have several benefits, such as:
- Energy efficiency
- Low maintenance
- Unlimited starts and stops
- Capacity for changing air demands
- Longer lifespan
- Lower noise levels.
If you're looking to upgrade your air compressor, see our variable-speed compressors and our permanent magnet air compressor range. Whatever your needs, we have a compressed air solution to suit you.
Contact us today to learn more about our products and how we can help you improve your plant&#;s operations. Or take a look at our latest brochure.
The company is the world’s best Double-stage compression permanent magnet variable frequency screw compressor Factory China supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.