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https://www.magicmag-tech.com/The-Working-Principle-of-Delayed-Start-Magnetic-Couplings.html
I. Background
Currently, in industries such as large-scale mining and petrochemicals, the majority of fans and pumps employ variable frequency speed control. Given the issues arising from the operation of variable frequency drives, particularly the unpredictability of equipment failures, these have introduced risks to production operations, directly affecting their continuity, stability, and reliability. This has also led to significant economic losses for businesses, usually due to downtime caused by electrical equipment failures. Adopting a high-power adjustable permanent magnet coupler speed control solution instead of the current variable frequency drive scheme can provide an absolute advantage that is unmatched by variable frequency drive solutions.
II. Analysis and Comparison
We will analyze and compare the following four aspects that are of greatest concern to enterprises: (A) System Reliability (B) Long-Term Operational Stability (C) Initial Installation and Maintainability (D) Economic Analysis
(A) System Reliability
The permanent magnet coupler is a purely mechanical product with stable performance, requiring no specific power supply conditions, and does not generate high-order harmonic pollution to the power grid during use (the harm of high-order harmonic pollution to the power grid is well known and will not be elaborated here). Since it does not use electricity, there are no electromagnetic interference issues.
High-Pressure Frequency Converter
Despite the relatively advanced technology of frequency converters, they are highly complex electronic devices with foreseeable and unpredictable operational faults. They require stringent environmental conditions, such as sealed rooms for dust protection and air conditioning in summer to maintain the required operating temperature, resulting in significant investment in auxiliary facilities. Additionally, they have certain requirements for the power supply and are susceptible to electromagnetic interference, leading to unreliable operation of the frequency converter equipment. During operation, frequency converters can also cause high-order harmonic pollution to the power system, degrading the quality of the power grid and potentially affecting the stable operation of electronic equipment, necessitating additional equipment (filters) for mitigation. Moreover, because frequency converters involve contact-type shaft connections between motors and loads, they do not offer the advantages of reducing bearing and seal damage.
(B) Long-Term Operational Stability
Permanent Magnet Coupler
The permanent magnet coupler features a simple mechanical structure, which once installed and put into use, is largely unaffected by the operating environment, ensuring stable and reliable operation. Since it does not use electricity, there are no electromagnetic interference issues. With non-contact shaft connections between motors and loads, vibration from the load does not transfer to the motor. This non-contact connection brings two benefits: firstly, it requires less precision in alignment during installation; secondly, it prevents bearing and seal damage that would occur with direct shaft connections over long periods, ensuring the longevity of the equipment. According to usage by other enterprises (with the longest continuous usage time reaching six years in the United States, and a theoretical lifespan of 30 years), the permanent magnet coupler demonstrates superior long-term operational stability. As a purely mechanical device, its potential operational failures are predictable and do not lead to unexpected accidents for users.
High-Pressure Frequency Converter
The core of a frequency converter is a complex electronic device that is susceptible to environmental interference and difficult to ensure stable and reliable operation after installation. Surveys of many enterprises indicate that frequency converters typically experience a fault once a year on average, demonstrating poor long-term operational stability. As a complex electronic device, its operational failures are unpredictable and can lead to unexpected accidents for users.
(C) Initial Installation and Maintainability
Permanent Magnet Coupler
The structure is simple, with non-contact shaft connections between motors and loads, requiring low precision in alignment and allowing for quick installation and adjustment. Being a purely mechanical device without complex electronic components, after simple training, maintenance personnel or electricians at power plants can quickly identify and resolve faults without needing professional companies for repairs. Its service life can reach up to 30 years.
Medium-Pressure Frequency Converter
Frequency converters are complex electronic devices that, when encountering electrical faults (frequent and unpredictable), make it difficult for maintenance personnel or electricians at power plants to quickly identify the cause and involve part replacements, making it impossible to swiftly resolve faults independently. Repairs must be carried out by the frequency converter manufacturer or a professional company, making rapid repairs challenging and impacting production. The maximum service life of frequency converters is only about 7 to 10 years.
(D) Economic Analysis
Permanent Magnet Coupler
1. Initial Investment The initial investment in permanent magnet couplers is roughly the same as that in frequency converters;
2. Maintenance Costs Since permanent magnet couplers are essentially maintenance-free, maintenance costs are almost zero;
3. Economic Loss Due to Faults Although both permanent magnet couplers and frequency converters are energy-saving devices, permanent magnet couplers genuinely allow users to see the benefits of energy savings because their Mean Time Between Failures (MTBF) is much longer than that of frequency converters, so a single fault does not consume all the energy savings brought by energy efficiency.
4. Spare Part Costs Because permanent magnet couplers are essentially maintenance-free, spare part costs are also nearly zero.
High-Pressure Frequency Converter
5. Initial Investment The initial investment in frequency converters is comparable to that of permanent magnet couplers;
6. Maintenance Costs With an average annual fault, each maintenance and part replacement, along with labor costs, is significant. And due to the unpredictability of faults, the production losses are greater.
7. Economic Loss Due to Faults Although frequency converters are also energy-saving devices, they do not allow users to genuinely see the benefits of energy savings because their MTBF is too short, with an average annual fault causing reduced load generation, increased fuel consumption, etc., consuming all the economic benefits of energy savings (and likely resulting in a net loss).
8. Spare Part Costs To ensure uninterrupted production in case of frequency converter faults, spare parts for frequency converters are often fully stocked, leading to capital占用. And due to the unpredictability of faults, some spare parts may never be used for years. Since electronic components have a limited shelf life, expired parts can only be discarded, causing wasted funds.
III. Conclusion
Whether from the perspective of economic benefits or the safety and stability of production, adopting an adjustable permanent magnet coupler speed control solution has an absolute advantage over high-pressure frequency converter speed control solutions and is the best application choice for enterprises.
https://www.magicmag-tech.com/The-Working-Principle-of-Delayed-Start-Magnetic-Couplings.html
SHANGHAI GAOLV E&M Technology Co.,Ltd.
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