摘要(yao)(yao):電動(dong)機(ji)(ji)設備(bei)是水(shui)泥(ni)企業中(zhong)應(ying)(ying)用廣泛(fan)的動(dong)力裝置(zhi),而水(shui)泥(ni)生(sheng)產企業屬于(yu)能耗高(gao)、污染大(da)又需要(yao)(yao)設備(bei)連續不間斷(duan)工(gong)作(zuo)(zuo)的行業,電動(dong)機(ji)(ji)作(zuo)(zuo)為水(shui)泥(ni)行業設備(bei)的動(dong)力來(lai)源(yuan),其(qi)安全、穩定可靠的運轉(zhuan)對水(shui)泥(ni)行業的平穩生(sheng)產起(qi)著*關重要(yao)(yao)的作(zuo)(zuo)用,本文(wen)綜合(he)介紹安科(ke)瑞(rui)ARD2F智(zhi)能型(xing)電動(dong)機(ji)(ji)保護(hu)器(qi)在某水(shui)泥(ni)廠的實際(ji)應(ying)(ying)用,并(bing)闡述了ARD2F智(zhi)能型(xing)電動(dong)機(ji)(ji)保護(hu)器(qi)產品的特點及其(qi)智(zhi)能化保護(hu)、測(ce)量、控(kong)制和通訊等,供(gong)工(gong)程設計(ji)中(zhong)參考。
關鍵詞:水泥廠、電動機保護、智能化、通訊
一(yi)、 引言
隨(sui)著現代化(hua)(hua)水泥工(gong)業生(sheng)(sheng)產規(gui)模增加(jia),生(sheng)(sheng)產設(she)備(bei)也(ye)越(yue)來越(yue)大(da)型(xing)化(hua)(hua),因此所需(xu)用的(de)拖動電(dian)動機(ji)(ji)的(de)功率(lv)也(ye)越(yue)來越(yue)大(da)。水泥廠生(sheng)(sheng)產工(gong)藝流程(cheng)較(jiao)復雜,可(ke)以(yi)總結水泥生(sheng)(sheng)產過(guo)程(cheng)為(wei)(wei)生(sheng)(sheng)料制(zhi)(zhi)備(bei)(一磨)、熟料煅燒(shao)(一燒(shao))、水泥粉磨(二磨)。因此,低壓電(dian)動機(ji)(ji)作為(wei)(wei)水泥生(sheng)(sheng)產過(guo)程(cheng)中常用的(de)機(ji)(ji)組,數量(liang)多、種類復雜,隨(sui)著科學技術(shu)的(de)不(bu)斷進步和(he)工(gong)藝控(kong)制(zhi)(zhi)過(guo)程(cheng)的(de)不(bu)斷完善,尤其是適(shi)應(ying)自動化(hua)(hua)生(sheng)(sheng)產要求(qiu),迫切(qie)需(xu)要開發和(he)完善電(dian)動機(ji)(ji)的(de)控(kong)制(zhi)(zhi)和(he)保護設(she)備(bei),實(shi)現對整個自動化(hua)(hua)生(sheng)(sheng)產過(guo)程(cheng)和(he)大(da)型(xing)機(ji)(ji)械(xie)設(she)備(bei)的(de)遙控(kong)、遙測、遙調、故障診斷以(yi)及集(ji)中控(kong)制(zhi)(zhi)等功能(neng)。
水泥(ni)生(sheng)(sheng)(sheng)(sheng)產(chan)是一項(xiang)較龐(pang)大的(de)(de)(de)(de)工(gong)程,生(sheng)(sheng)(sheng)(sheng)產(chan)環(huan)(huan)境(jing)比較惡劣,粉(fen)塵污(wu)染嚴重,受生(sheng)(sheng)(sheng)(sheng)產(chan)工(gong)藝的(de)(de)(de)(de)限(xian)制(zhi)(zhi)使(shi)得(de)其工(gong)作(zuo)場(chang)所的(de)(de)(de)(de)通(tong)風條(tiao)件差且環(huan)(huan)境(jing)溫度較高,而且需(xu)要設(she)定大量(liang)的(de)(de)(de)(de)工(gong)作(zuo)站(zhan)(zhan)點,包括原料控(kong)(kong)制(zhi)(zhi)站(zhan)(zhan)、破(po)碎站(zhan)(zhan)、原料粉(fen)磨(mo)站(zhan)(zhan)、熟料庫控(kong)(kong)制(zhi)(zhi)站(zhan)(zhan)、水泥(ni)磨(mo)控(kong)(kong)制(zhi)(zhi)站(zhan)(zhan)、水泥(ni)包裝(zhuang)控(kong)(kong)制(zhi)(zhi)站(zhan)(zhan)等(deng),然而在(zai)這(zhe)些站(zhan)(zhan)點中使(shi)用了大量(liang)低壓電(dian)(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)來控(kong)(kong)制(zhi)(zhi)其他設(she)備(bei)的(de)(de)(de)(de)運(yun)行(xing)(xing),運(yun)用簡(jian)單(dan)的(de)(de)(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)壓表(biao)、電(dian)(dian)(dian)(dian)(dian)(dian)流(liu)表(biao)、電(dian)(dian)(dian)(dian)(dian)(dian)能(neng)表(biao)和(he)頻率(lv)表(biao)等(deng)由于受到通(tong)信功能(neng)不(bu)夠靈活、儀表(biao)功能(neng)單(dan)一等(deng)多種(zhong)條(tiao)件的(de)(de)(de)(de)約束(shu),已經無法滿足電(dian)(dian)(dian)(dian)(dian)(dian)廠設(she)備(bei)自動(dong)(dong)化生(sheng)(sheng)(sheng)(sheng)產(chan)的(de)(de)(de)(de)要求(qiu)。水泥(ni)行(xing)(xing)業生(sheng)(sheng)(sheng)(sheng)產(chan)過程的(de)(de)(de)(de)特點為長周期運(yun)行(xing)(xing),一旦開機(ji)(ji)(ji),在(zai)沒有特殊情(qing)況發(fa)生(sheng)(sheng)(sheng)(sheng)的(de)(de)(de)(de)前提(ti)下,一般不(bu)會(hui)停機(ji)(ji)(ji)。現(xian)代(dai)化大型(xing)水泥(ni)企業年運(yun)轉率(lv)很(hen)高,這(zhe)樣(yang)就須有高質量(liang)的(de)(de)(de)(de)、高可靠性的(de)(de)(de)(de)電(dian)(dian)(dian)(dian)(dian)(dian)氣設(she)備(bei)保證(zheng)其生(sheng)(sheng)(sheng)(sheng)產(chan)過程的(de)(de)(de)(de)連(lian)續不(bu)間斷性,一旦故障停機(ji)(ji)(ji)就會(hui)造成巨(ju)大的(de)(de)(de)(de)經濟損失。智能(neng)型(xing)電(dian)(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)保護(hu)器可實(shi)(shi)現(xian)重載起動(dong)(dong),實(shi)(shi)現(xian)對(dui)電(dian)(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)的(de)(de)(de)(de)溫度保護(hu),還提(ti)供(gong)多種(zhong)測(ce)控(kong)(kong)功能(neng)和(he)控(kong)(kong)制(zhi)(zhi)模式,能(neng)夠滿足水泥(ni)生(sheng)(sheng)(sheng)(sheng)產(chan)過程對(dui)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)(ji)設(she)備(bei)的(de)(de)(de)(de)全(quan)方面保護(hu)及其控(kong)(kong)制(zhi)(zhi)要求(qiu),不(bu)僅能(neng)提(ti)高電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)(ji)設(she)備(bei)的(de)(de)(de)(de)運(yun)行(xing)(xing)能(neng)力、延長電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)(ji)設(she)備(bei)的(de)(de)(de)(de)使(shi)用壽命,同時也能(neng)提(ti)高企業生(sheng)(sheng)(sheng)(sheng)產(chan)效率(lv)、節約能(neng)源(yuan)。本(ben)文以ARD2F智能(neng)型(xing)電(dian)(dian)(dian)(dian)(dian)(dian)動(dong)(dong)機(ji)(ji)(ji)保護(hu)器在(zai)水泥(ni)生(sheng)(sheng)(sheng)(sheng)產(chan)中的(de)(de)(de)(de)實(shi)(shi)際應用進(jin)行(xing)(xing)具體(ti)介紹(shao)。
二、水泥生產對保護器(qi)的功能要求
水泥(ni)行業電(dian)機(ji)是大容(rong)量(liang)、高負荷連續運轉的設備,電(dian)動機(ji)長期承受大負荷,就會使繞組上溫度上升過高而降(jiang)低*緣(yuan)性能甚*損壞*緣(yuan),終會縮短(duan)電(dian)動機(ji)的使用壽(shou)命(ming),因(yin)此,對水泥(ni)生產(chan)過程(cheng)中電(dian)機(ji)設備的可靠性、穩定性及功能要求(qiu)非常高。在生產(chan)運行或設備檢(jian)修過程(cheng)中,常見的電(dian)動機(ji)故障(zhang)可分為以下(xia)幾種:
1、機械故障
1)掃膛:由于軸承損壞、軸彎或者檢修人員(yuan)裝配不當,導致(zhi)定轉子(zi)產生(sheng)摩擦;
2)軸(zhou)(zhou)承損壞(huai):由(you)于軸(zhou)(zhou)承裝配(pei)不當、定/轉(zhuan)子鐵心(xin)軸(zhou)(zhou)向錯位或重(zhong)新對(dui)轉(zhuan)軸(zhou)(zhou)機加工(gong)后精度不夠、電(dian)動機本體運行(xing)溫升過高(gao)等;
3)振動(dong)(dong):由于電動(dong)(dong)機本(ben)身或傳動(dong)(dong)裝置不(bu)良等。
2、電氣故(gu)障(zhang)
1)缺(que)相運(yun)行(xing):電動(dong)機發生堵轉時電流(liu)比正(zheng)常(chang)工作的(de)電流(liu)大(da)得(de)多。在此情況下,運(yun)行(xing)時間過(guo)長或過(guo)于頻繁起(qi)動(dong),將會導致(zhi)電動(dong)機繞(rao)組燒毀;
2)繞(rao)組短路(lu)或(huo)接地:匝(za)間短路(lu)的(de)原(yuan)因是(shi)電(dian)機溫(wen)度異(yi)常升高而導(dao)致的(de),而接地故障大多是(shi)由(you)于繞(rao)組*緣(yuan)損壞;
3)三(san)相電(dian)流不(bu)平衡:由于電(dian)動機外部電(dian)源電(dian)壓不(bu)平衡或內部繞(rao)組匝間短(duan)路或電(dian)動機維修時線圈匝數錯誤或接線錯誤等。
因此,對某水泥廠電機設備進行合理(li)的維護是(shi)很有必要的,對ARD2F智能型(xing)電動機保(bao)護器具體功能要求如(ru)下(xia):
(1)完(wan)善的電機保護功能
保護(hu)器通過(guo)采集電(dian)(dian)(dian)路中的三(san)相(xiang)交流(liu)電(dian)(dian)(dian)流(liu)、三(san)相(xiang)交流(liu)電(dian)(dian)(dian)壓(ya)、剩余電(dian)(dian)(dian)流(liu)、PTC熱電(dian)(dian)(dian)阻阻值、電(dian)(dian)(dian)動(dong)機(ji)電(dian)(dian)(dian)能等(deng)電(dian)(dian)(dian)力(li)參數(shu),以(yi)及電(dian)(dian)(dian)動(dong)機(ji)運(yun)行過(guo)程中的各種運(yun)動(dong)狀態等(deng)信號,經保護(hu)器內部處理運(yun)算,從而(er)實現對過(guo)載(zai)反時限(xian)、過(guo)載(zai)定時限(xian)、接地(di)、起動(dong)超時、漏電(dian)(dian)(dian)、欠(qian)載(zai)、斷相(xiang)、堵轉、阻塞、短路、溢出、不平(ping)衡(電(dian)(dian)(dian)流(liu)、電(dian)(dian)(dian)壓(ya))、過(guo)功(gong)率、欠(qian)功(gong)率、過(guo)壓(ya)、欠(qian)壓(ya)、相(xiang)序(xu)、溫度、tE時間(jian)、外部故障(zhang)、起動(dong)次(ci)(ci)數(shu)限(xian)制、運(yun)行時間(jian)報警(jing)、故障(zhang)次(ci)(ci)數(shu)報警(jing)等(deng)全(quan)方面綜合保護(hu),進而(er)保證水泥(ni)廠生產工作的安全(quan)連(lian)續(xu)運(yun)行。
(2)及時(shi)排除電動(dong)機運行故障功能
水(shui)泥生產現場(chang)電(dian)動機(ji)(ji)運行(xing)過程中通過電(dian)動機(ji)(ji)保(bao)護器對(dui)電(dian)機(ji)(ji)設備進(jin)行(xing)檢測,當電(dian)動機(ji)(ji)出現狀況(kuang)時應及時發(fa)出報(bao)警(jing)信號,并(bing)記(ji)錄故(gu)障信息(xi),方便(bian)維護人員查找故(gu)障原(yuan)因并(bing)作(zuo)(zuo)出及時的處理,保(bao)證故(gu)障發(fa)生時電(dian)機(ji)(ji)設備動作(zuo)(zuo)的可靠性和(he)靈(ling)敏性。
(3)對現(xian)場各設(she)備進(jin)行遠程監測功(gong)能
水泥(ni)生產(chan)(chan)現(xian)(xian)(xian)場(chang)環境比較(jiao)惡劣,保(bao)(bao)護(hu)器(qi)不僅要(yao)提(ti)供電(dian)機設備(bei)(bei)的(de)(de)保(bao)(bao)護(hu)功能,而(er)且要(yao)求能夠帶RS-485通訊接口,經過Modbus-RTU/Profibus-DP通訊協議與上位機管理系(xi)統進行(xing)(xing)(xing)通訊連接,實(shi)現(xian)(xian)(xian)實(shi)時監測(ce)電(dian)動機的(de)(de)運(yun)(yun)行(xing)(xing)(xing)狀(zhuang)態以及運(yun)(yun)行(xing)(xing)(xing)過程中的(de)(de)電(dian)力參數,保(bao)(bao)證后臺(tai)操作人員能讀(du)取、修(xiu)改水泥(ni)成產(chan)(chan)現(xian)(xian)(xian)場(chang)電(dian)動機保(bao)(bao)護(hu)器(qi)的(de)(de)各種整定參數并通過后臺(tai)人機界(jie)面(mian)實(shi)時觀察當前現(xian)(xian)(xian)場(chang)電(dian)動機控制回(hui)路的(de)(de)工(gong)作狀(zhuang)態、供電(dian)電(dian)源(yuan)質量等(deng),實(shi)現(xian)(xian)(xian)對生產(chan)(chan)現(xian)(xian)(xian)場(chang)設備(bei)(bei)遠(yuan)程實(shi)時監控。
三、安科(ke)瑞電動機保護器(qi)在水泥廠應用案例
水泥(ni)生(sheng)產工(gong)(gong)藝流程較多,所以將保(bao)護(hu)器合理(li)的(de)(de)(de)應用于(yu)電(dian)(dian)動機(ji)(ji)(ji)保(bao)護(hu)設備控制(zhi)回(hui)路的(de)(de)(de)同時要(yao)(yao)能夠滿(man)足(zu)水泥(ni)廠(chang)的(de)(de)(de)大型控制(zhi)系統(tong)(tong)(tong)的(de)(de)(de)要(yao)(yao)求。某水泥(ni)廠(chang)控制(zhi)系統(tong)(tong)(tong)通(tong)過Profibus DP通(tong)訊接(jie)口與PC機(ji)(ji)(ji)、接(jie)觸器、電(dian)(dian)動機(ji)(ji)(ji)以及其(qi)他設備構成控制(zhi)系統(tong)(tong)(tong),工(gong)(gong)程師通(tong)過監(jian)控計算機(ji)(ji)(ji)以及生(sheng)產管理(li)軟件(jian)完成對整個系統(tong)(tong)(tong)設備的(de)(de)(de)數據采(cai)集、處理(li)、顯示和監(jian)視功能,并在滿(man)足(zu)權限(xian)和邏輯時,通(tong)過遠程控制(zhi)軟件(jian)實現對現場相(xiang)應的(de)(de)(de)電(dian)(dian)機(ji)(ji)(ji)設備等的(de)(de)(de)控制(zhi)。
圖(tu)1 現場安(an)裝照(zhao)片
水(shui)泥(ni)廠(chang)采用保(bao)(bao)(bao)護(hu)(hu)器(qi)用于電(dian)(dian)(dian)(dian)機(ji)保(bao)(bao)(bao)護(hu)(hu)控(kong)(kong)(kong)制(zhi)(zhi)(zhi)回路,取代熱繼電(dian)(dian)(dian)(dian)器(qi)等作為電(dian)(dian)(dian)(dian)動機(ji)的(de)過(guo)載保(bao)(bao)(bao)護(hu)(hu)和控(kong)(kong)(kong)制(zhi)(zhi)(zhi)元件,而且利用先(xian)進的(de)通訊技術,實現了水(shui)泥(ni)生產中電(dian)(dian)(dian)(dian)機(ji)設(she)備控(kong)(kong)(kong)制(zhi)(zhi)(zhi)的(de)自動化。通過(guo)將90L顯(xian)示模塊(kuai)嵌入安裝在開關抽屜的(de)活動面板內(nei),來(lai)簡化水(shui)泥(ni)廠(chang)控(kong)(kong)(kong)制(zhi)(zhi)(zhi)柜內(nei)接線(xian),使得配電(dian)(dian)(dian)(dian)室內(nei)設(she)備運(yun)行(xing)情況及故障狀(zhuang)態清晰(xi)可見,方便工(gong)程(cheng)師(shi)隨時調整(zheng)系統、設(she)定參數和顯(xian)示、監(jian)控(kong)(kong)(kong)以(yi)及檢修維護(hu)(hu)。將ARD2F保(bao)(bao)(bao)護(hu)(hu)器(qi)應用于某水(shui)泥(ni)廠(chang)生產線(xian)電(dian)(dian)(dian)(dian)機(ji)設(she)備的(de)控(kong)(kong)(kong)制(zhi)(zhi)(zhi)回路,實現水(shui)泥(ni)廠(chang)對電(dian)(dian)(dian)(dian)機(ji)保(bao)(bao)(bao)護(hu)(hu)的(de)要求。如(ru)圖(tu)2是(shi)ARD2F智能型電(dian)(dian)(dian)(dian)動機(ji)保(bao)(bao)(bao)護(hu)(hu)器(qi)應用于某水(shui)泥(ni)廠(chang)電(dian)(dian)(dian)(dian)動機(ji)設(she)備控(kong)(kong)(kong)制(zhi)(zhi)(zhi)回路工(gong)作原理圖(tu):
圖2 ARD2F智能(neng)型電動(dong)機保護器應用于某水泥廠電動(dong)機設備控制回路接線圖
由于現代水(shui)泥(ni)工廠(chang)采用的(de)(de)大型電(dian)(dian)(dian)機(ji)設備較多,大于110KW及以上的(de)(de)電(dian)(dian)(dian)機(ji),均采用在主回路裝設電(dian)(dian)(dian)流互感器。考慮到水(shui)泥(ni)生產工藝的(de)(de)不同(tong)和企業投入的(de)(de)資金,電(dian)(dian)(dian)動(dong)機(ji)需要不同(tong)的(de)(de)起動(dong)方(fang)式,ARD2F智能型電(dian)(dian)(dian)動(dong)機(ji)保(bao)護(hu)器提供靈(ling)活的(de)(de)聯鎖功能,實現直接啟動(dong)、雙向啟動(dong)、星/三角啟動(dong)、自耦(ou)變(bian)壓(ya)器啟動(dong)等,使水(shui)泥(ni)廠(chang)大型設備的(de)(de)電(dian)(dian)(dian)機(ji)得到了合(he)理保(bao)護(hu)和控(kong)制(zhi)[2]。
四、ARD2F產(chan)品(pin)介紹
ARD2F智能電(dian)動(dong)機(ji)保(bao)(bao)護(hu)器(qi)適用于額定電(dian)壓*660V的低壓電(dian)動(dong)機(ji)回路(lu),集保(bao)(bao)護(hu)、測(ce)量、控制(zhi)(zhi)、通訊、運維于一體(ti)。其完善的保(bao)(bao)護(hu)功能確保(bao)(bao)電(dian)動(dong)機(ji)安全運行(xing),帶有(you)邏輯可編程功能,可以(yi)滿(man)足多種控制(zhi)(zhi)方式。可選配不同通訊模塊(kuai)適應現(xian)場通訊需(xu)求。
該產品(pin)采用分體(ti)式結構(gou),由主(zhu)體(ti)、顯示單元(yuan)、互感器組成,可適應各(ge)種柜體(ti)的安(an)裝。
技(ji)術參數(shu)
功能特點
■ 支持基(ji)波和全波電(dian)(dian)力參(can)數測量(liang)(U、I、P、Q、S、PF、F、EP、EQ),電(dian)(dian)流(liu)及電(dian)(dian)流(liu)不平衡度、電(dian)(dian)流(liu)正序、負(fu)序、零序分量(liang)、電(dian)(dian)壓、三相電(dian)(dian)壓相角、剩(sheng)余電(dian)(dian)流(liu)。
■ 保護功(gong)(gong)能包括過(guo)載(zai)反時(shi)限(xian)、過(guo)載(zai)定時(shi)限(xian)、接地、起(qi)動超時(shi)、漏電、欠載(zai)、斷相、堵轉、阻塞、短路、溢出(chu)、不平衡(電流(liu)、電壓(ya)(ya))、過(guo)功(gong)(gong)率(lv)、欠功(gong)(gong)率(lv)、過(guo)壓(ya)(ya)、欠壓(ya)(ya)、相序(xu)、溫(wen)度、tE時(shi)間(jian)(jian)、外部故障、起(qi)動次(ci)數限(xian)制、運行時(shi)間(jian)(jian)報警、故障次(ci)數報警。
■ 9路可(ke)編程DI輸入(ru),默認采用內(nei)置DC24V電源,也可(ke)選擇外部有(you)源濕接點。
■ 5路可(ke)編程DO輸出,滿足直接起動,星—三角(jiao)起動,自耦變壓(ya)器起動,等(deng)多種起動方式(shi),可(ke)通(tong)過通(tong)訊總線實現(xian)主站對電動機(ji)的(de)遙控“起/停”。
■ 可(ke)選抗晃電功能:支持晃電立即再啟動(dong)、失壓(ya)重起動(dong)。
■ 可選配MODBUS_RTU通訊(xun)、PROFIBUS DP通訊(xun),支持2路通訊(xun)接口。
■ 可(ke)選配1路DC4-20mA模(mo)擬量輸出接口,與DCS系(xi)統相接,可(ke)實現(xian)對現(xian)場設備的監控(kong)。
■ 具有故障(zhang)記(ji)(ji)(ji)錄(lu)(lu)、起動記(ji)(ji)(ji)錄(lu)(lu)、停車記(ji)(ji)(ji)錄(lu)(lu)、DI變位記(ji)(ji)(ji)錄(lu)(lu)和再(zai)起動記(ji)(ji)(ji)錄(lu)(lu)等各類事件(jian)記(ji)(ji)(ji)錄(lu)(lu)。
■ 顯示(shi)界面液晶顯示(shi),支持中/英(ying)文切換。
五、結束語(yu)
隨著電(dian)子(zi)技術及通訊技術的(de)不斷(duan)發展。電(dian)動機保護(hu)器也在(zai)朝著多(duo)元化方(fang)(fang)向發展,電(dian)動機保護(hu)器在(zai)水泥企業的(de)應(ying)用也越(yue)來越(yue)廣泛,合理選(xuan)擇電(dian)機設備(bei)的(de)保護(hu)功(gong)能(neng)和保護(hu)方(fang)(fang)式(shi),可提高設備(bei)運行的(de)可靠性,能(neng)夠(gou)預防并(bing)杜*電(dian)機燒(shao)毀,同時減少了(le)因非計劃停車(che)而(er)造成的(de)損失,降低(di)了(le)企業的(de)生(sheng)產成本。
趙雨 18861629037 江蘇安科瑞(rui)電器(qi)制造(zao)有限公司