Preface
隨著電力電子技術(shù)、控制技術(shù)和電力器件制作工藝的進(jìn)步，變頻器技術(shù)得到了迅速發(fā)展。變頻器在風(fēng)機(jī)、水泵、提升機(jī)、皮帶機(jī)等領(lǐng)域的應(yīng)用已相當(dāng)成熟。傳統(tǒng)的礦用皮帶輸送機(jī)通常采用工頻拖動(dòng)和液力耦合器傳動(dòng)，存在傳動(dòng)效率低、啟動(dòng)電流沖擊及機(jī)械沖擊大、無(wú)法實(shí)現(xiàn)功率平衡等問題，導(dǎo)致系統(tǒng)運(yùn)行不經(jīng)濟(jì)；同時(shí)，皮帶和液力耦合器的磨損嚴(yán)重，維修及維護(hù)成本高昂，還存在無(wú)功環(huán)流損耗。因此，對(duì)皮帶運(yùn)輸機(jī)采用變頻控制，能夠有效降低企業(yè)生產(chǎn)成本，提高經(jīng)濟(jì)效益；控制系統(tǒng)本身良好的控制性能和完善的保護(hù)環(huán)節(jié)，能有效避免事故發(fā)生并延長(zhǎng)皮帶機(jī)的使用壽命。
With continuous advances in power electronics, control technology, and power device manufacturing, VFD (Variable Frequency Drive) technology has rapidly developed, becoming mature in applications such as fans, pumps, hoists and conveyor belts. Traditional mining conveyors typically use power-frequency drive and hydraulic couplers, resulting in low efficiency, high starting current and mechanical impact, and the inability to achieve power balance—making the system uneconomical. At the same time, belts and couplers suffer heavy wear, leading to high maintenance costs and reactive power circulation losses. Therefore, applying VFD control to belt conveyors effectively reduces production costs, improves operational efficiency, and enhances system reliability and protection, significantly extending the conveyor’s service life.
Customer Introduction
幾內(nèi)亞鐵礦的皮帶機(jī)運(yùn)輸是全礦的流程中樞，一旦皮帶機(jī)無(wú)法正常工作，將導(dǎo)致全礦停產(chǎn)，造成巨大經(jīng)濟(jì)損失。因此，高壓調(diào)速系統(tǒng)必須具備極高的可靠性、穩(wěn)定性和防護(hù)性。
基于上述工作特點(diǎn)，變頻器設(shè)計(jì)需滿足以下主要技術(shù)條件：
The conveyor system is the central link of the entire Guinea iron mine. Any failure in the belt conveyor would lead to full-site shutdown and cause major economic losses. Therefore, the high-voltage speed-regulation system must provide exceptional reliability, stability and protection. Based on these operational characteristics, the VFD must meet the following requirements:
High reliability, stability and protective performance.
Bypass function for power-frequency operation during faults.
Smooth start with high starting torque.
Output torque ≥2× rated motor torque for large load variations and heavy-load restart.
Full compatibility with the mine’s control and monitoring interfaces.
Belt-inspection functionality.
經(jīng)過對(duì)各類高壓變頻器廠家的調(diào)研和比較，幾內(nèi)亞項(xiàng)目最終選擇了新風(fēng)光JD-BP38系列高壓變頻器作為皮帶機(jī)的控制設(shè)備，現(xiàn)場(chǎng)共配置多臺(tái)集裝箱式高壓變頻器進(jìn)行控制。
After evaluating various suppliers, the project selected FGI’s JD-BP38 Series High-Voltage VFDs as the control solution, with multiple containerized HV VFD units deployed on site.
VFD Control Scheme for the Conveyor
Motor Drive Control Method
由于帶式輸送機(jī)的三臺(tái)電機(jī)控制方式相互關(guān)聯(lián)，為保證系統(tǒng)速度同步和電機(jī)轉(zhuǎn)矩平衡，采用新風(fēng)光自主研發(fā)的主從控制功能。一臺(tái)變頻器作為主機(jī)控制模式，其余兩臺(tái)為從機(jī)控制模式，跟隨主電機(jī)速度同步運(yùn)行，并以主電機(jī)轉(zhuǎn)矩輸出為依據(jù)，確保三臺(tái)電機(jī)之間實(shí)現(xiàn)轉(zhuǎn)矩平衡。
As the three motors operate in a linked manner, FGI’s self-developed master-slave control is adopted to ensure speed synchronization and torque balance. One VFD serves as the master, while the other two operate as slaves, following the master’s speed and torque commands to maintain real-time torque balance.
Basic Performance of the JD-BP38 High-Voltage VFD Series
根據(jù)現(xiàn)場(chǎng)需求，高壓變頻器需實(shí)現(xiàn)皮帶系統(tǒng)的軟啟動(dòng)和調(diào)速運(yùn)行，采用矢量控制技術(shù)，滿足皮帶機(jī)重載啟動(dòng)、主從電機(jī)轉(zhuǎn)矩均衡控制等功能，并具備高可靠性。
According to the site requirements, the high-voltage VFD shall provide soft start and speed regulation for the belt conveyor system. Vector control technology shall be adopted to meet the functions of heavy-load startup and torque balance control between master and slave motors, while ensuring high reliability.
Characteristics of FGI High-voltage Frequency Convertes
Multilevel cascaded topology with low harmonics; 33-level output requires no output filter and supports standard induction motors.
Sensor-less vector control with high starting torque, preventing over-current during load fluctuations.
Torque coordination for real-time balance in multi-motor systems.
Overload capability above 2× rated current for large-inertia heavy-load starts.
Wide grid-voltage adaptability (−65% to +115% Un) with advanced protections such as cell bypass, neutral-point shift, grid-frequency bypass and blackout restart, greatly enhancing reliability.
Main Circuit Wiring of the Conveyor VFD System
現(xiàn)場(chǎng)采用3套新JD-BP38系列高壓變頻調(diào)速系統(tǒng)，根據(jù)用戶要求，變頻器控制系統(tǒng)采用主從控制，“一拖一”控制方式。3臺(tái)高壓變頻器主回路接線方式相同，以其中一臺(tái)裝置為例，一次接線如圖
Three JD-BP38 HV VFD systems are deployed on site, using master-slave mode and “one-to-one” motor control. All three units share the same wiring configuration, shown in Figure 1.
一拖一接線柜（帶緩沖）一次回路圖
One-to-One Wiring Cabinet (with Buffer)
Primary Circuit Diagram
Master-Slave Control
如皮帶系統(tǒng)簡(jiǎn)圖所示，選用1#變頻器為主變頻器，2#和3#變頻器為從變頻器。操作臺(tái)向主變頻器發(fā)送給定頻率值，主從變頻器之間采用光纖通信，1#變頻器作為主控，檢測(cè)所有變頻器的運(yùn)行電流，計(jì)算并發(fā)出輸出轉(zhuǎn)矩給定值，控制從變頻調(diào)速系統(tǒng)同步運(yùn)行。
As shown in the simplified conveyor system diagram, VFD No.1 is selected as the master drive, while VFD No.2 and No.3 operate as slave drives. The control console sends the frequency command to the master VFD, and optical fiber communication is used between the master and slave VFDs. Acting as the master controller, VFD No.1 monitors the operating current of all VFDs, calculates the required torque output reference, and issues torque commands to ensure synchronized operation of the slave VFD systems.
高壓變頻調(diào)速系統(tǒng)簡(jiǎn)圖（BC4A）
Simplified Diagram of the High-Voltage VFD Speed
Regulation System (BC4A)
Operating Process of the
VFD Electrical Control System
皮帶電控系統(tǒng)控制原理圖
The control principle of the conveyor electrical control system
Control Principle of
the Conveyor Electrical Control System
起車時(shí)，皮帶電控系統(tǒng)首先對(duì)皮帶系統(tǒng)傳送的信號(hào)進(jìn)行判斷，如跑偏、堆鐵、縱撕、急停閉鎖等，若各信號(hào)正常，方可進(jìn)入下一程序。
When starting, the conveyor electrical control system first checks all signals from the belt system—such as belt deviation, material buildup, longitudinal tear, and emergency stop interlock. Only if all signals are normal will the system proceed to the next step.
當(dāng)皮帶機(jī)各部分均處于正常狀態(tài)，具備起車條件，才會(huì)發(fā)出啟動(dòng)信號(hào)。發(fā)出起車指令后，變頻器啟動(dòng)。
When all parts of the belt conveyor are confirmed to be in normal condition and meet the start-up requirements, a start signal is issued. After the start command is sent, the VFD begins operation.
同時(shí)，操作臺(tái)發(fā)出指令使抱閘打開，并檢測(cè)抱閘是否完全打開。若抱閘未打開或未完全打開，將關(guān)閉運(yùn)行信號(hào)，并給變頻器發(fā)送抱閘信號(hào)使其急停，防止因堵轉(zhuǎn)而過流跳閘。
At the same time, the control console sends a command to release the brake and monitors whether it is fully opened. If the brake does not open or fails to fully open, the system will disable the run command and send a brake signal to the VFD to perform an emergency stop, preventing overcurrent trips caused by motor stalling.
當(dāng)皮帶達(dá)到額定速度，電控系統(tǒng)實(shí)時(shí)檢測(cè)皮帶速度與滾筒速度，若二者速度差值超過規(guī)定值，緊急停車，并發(fā)出打滑報(bào)警信號(hào)。
When the belt reaches its rated speed, the control system continuously monitors the belt speed and drum speed. If the speed difference exceeds the specified limit, the system will execute an emergency stop and trigger a belt-slip alarm.
系統(tǒng)實(shí)時(shí)監(jiān)測(cè)電機(jī)溫度、減速器溫度、軸承溫度、皮帶張力、電機(jī)電流、抱閘狀態(tài)、變頻狀態(tài)等參數(shù)。一旦任一指標(biāo)或狀態(tài)出現(xiàn)異常，系統(tǒng)將立即緊急停車并發(fā)出報(bào)警信號(hào)。
The system continuously monitors parameters such as motor temperature, gearbox temperature, bearing temperature, belt tension, motor current, brake status, and VFD status. If any parameter or condition becomes abnormal, the system will immediately initiate an emergency shutdown and issue an alarm.
Effects of Using High-Voltage VFDs
to Drive the Conveyor
真正實(shí)現(xiàn)了皮帶機(jī)的軟啟動(dòng)。通過電機(jī)慢速啟動(dòng)，帶動(dòng)皮帶機(jī)緩慢啟動(dòng)，逐步釋放膠帶內(nèi)部貯存的能量，將輸送機(jī)啟停時(shí)產(chǎn)生的沖擊降至最低，幾乎不對(duì)膠帶造成損害。
The conveyor achieves true soft starting. The motor starts slowly, driving the conveyor to accelerate gradually and releasing the internal stored energy of the belt step by step. This minimizes shock during start and stop processes and virtually eliminates belt damage.
有效降低膠帶損耗。變頻器的啟動(dòng)時(shí)間可在1至3600秒內(nèi)靈活調(diào)整，皮帶機(jī)的啟動(dòng)時(shí)間通常根據(jù)現(xiàn)場(chǎng)情況設(shè)定在60至120秒之間。
Belt wear is significantly reduced. The VFD’s start-up time can be flexibly adjusted between 1 and 3600 seconds, and the conveyor’s start-up time is typically set between 60 and 120 seconds depending on site conditions.
實(shí)現(xiàn)了皮帶機(jī)三臺(tái)電機(jī)驅(qū)動(dòng)時(shí)的轉(zhuǎn)矩平衡。電機(jī)驅(qū)動(dòng)時(shí)采用主從控制方式，確保轉(zhuǎn)矩平衡。
Torque balance among the three conveyor motors is achieved. The master-slave control method ensures balanced torque output during multi-motor operation.
具備驗(yàn)帶功能。變頻調(diào)速系統(tǒng)為無(wú)級(jí)調(diào)速的交流傳動(dòng)系統(tǒng)，在空載驗(yàn)帶狀態(tài)下，可調(diào)整0至100%額定帶速范圍內(nèi)的任意帶速。
The system supports belt-inspection mode. As a stepless AC drive system, it allows adjustment to any belt speed within 0–100% of the rated speed under no-load inspection conditions.
實(shí)現(xiàn)平穩(wěn)的重載啟動(dòng)。變頻器在低頻運(yùn)轉(zhuǎn)時(shí)可輸出2.2倍額定力矩，適用于重載啟動(dòng)。
Smooth heavy-load starting is achieved. The VFD can deliver up to 2.2 times the rated torque at low frequency, making it suitable for heavy-load start conditions.
Conclusion
皮帶機(jī)的驅(qū)動(dòng)系統(tǒng)采用新風(fēng)光最新研制的高壓變頻器后，確保了運(yùn)輸皮帶的穩(wěn)定運(yùn)行，配合自動(dòng)控制系統(tǒng)，有效解決了皮帶運(yùn)輸過程中的跑偏、堆煤、超溫等問題，顯著提升了皮帶機(jī)的自動(dòng)化控制水平。現(xiàn)場(chǎng)應(yīng)用表明，利用技術(shù)先進(jìn)、成熟可靠的高壓變頻調(diào)速系統(tǒng)拖動(dòng)皮帶機(jī)，不僅大幅提高了皮帶機(jī)的自動(dòng)化控制水平，還降低了現(xiàn)場(chǎng)維護(hù)量，帶來(lái)顯著的經(jīng)濟(jì)效益，值得大力推廣。
With the adoption of FGI’s JD-BP38 series high-voltage VFDs, the conveyor drive system now operates with enhanced stability. Combined with the automated control system, it effectively resolves issues such as belt deviation, coal buildup, and overheating during operation, significantly improving the overall automation level. Field applications have demonstrated that using an advanced, mature, and reliable high-voltage VFD drive system for the conveyor not only greatly enhances automation but also reduces on-site maintenance workload and brings substantial economic benefits, making it highly worthy of widespread promotion.
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