In recent years, with the continuous advancement of mechanical and electrical integration in textile machinery, AC frequency conversion speed control has become a prevailing trend. Almost all newly developed textile equipment now incorporates AC asynchronous motor frequency converters, reflecting their widespread adoption and importance in modern textile production.
**1. Features of AC Frequency Conversion Speed Control**
**1.1 Energy Efficiency and Cost Reduction**
Textile mills rely heavily on air conditioning systems. When these systems are controlled by frequency converters, energy consumption is significantly reduced. According to data from a company, 12 air conditioners can save over 240,000 yuan in electricity annually, with an average reduction in power usage of 6 to 7 percentage points. This not only lowers operational costs but also enhances sustainability.
**1.2 Simplified Mechanism and Enhanced Performance**
Through PLC or industrial computer control, frequency converters enable multiple motors to operate synchronously and smoothly. This allows for precise control of machine movements based on production curves, simplifying the mechanical structure. For example, roving frames using AC frequency conversion eliminate the need for cone wheel shifting mechanisms, solving issues like belt slippage and inaccurate positioning. Similarly, spinning frames replace forming cams with frequency converters, preventing pauses at the peach bottom and impacts at the peach top, resulting in better yarn quality and easier high-speed unwinding in subsequent processes.
**2. Applications of AC Frequency Conversion Technology**
There are two main types of AC motors used in textile machinery with inverters: the Y series AC asynchronous motor, commonly used where speed regulation accuracy is not critical, and specialized AC variable frequency motors designed for high precision and wide speed ranges.
Different inverter types include:
**(1) V/F Open-Loop Control**
This method uses simple circuitry and is reliable, but offers limited speed range (up to 10:1) and moderate accuracy (2–5%). It's suitable for less demanding applications like knitting machines.
**(2) Sensorless Vector Control**
This provides excellent low-speed performance, high reliability, and good torque response. With a speed accuracy of 0.5–1% and a range up to 20:1, it’s ideal for printing and dyeing machines.
**(3) Closed-Loop Vector Control with Feedback**
Also known as AC servo drives, this offers a speed range up to 100:1, using IGBTs for faster switching and higher precision. It’s used in high-speed machines such as slitting warping and sizing machines that require constant tension and line speed.
Some advanced equipment, like Barmag winders and DLENES hot rollers, integrate frequency converters with control panels and mechanical components, reducing size and increasing reliability.
**3. Real-World Applications of Inverters in Textile Machinery**
Frequency converters are widely used across all stages of textile production, from opening and carding machines to spinning frames, roving machines, and weaving equipment. They are also essential in knitting, nonwoven, and chemical fiber machinery.
**3.1 FA491 High-Speed Roving Frame**
This advanced Chinese-developed roving machine uses four industrial motors, a PLC, and inverters to control flyer, roller, tube, and dragon rib operations. It eliminates traditional cone wheel and molding mechanisms, improving efficiency, reliability, and ease of maintenance. With a maximum speed of 1,500 rpm, it supports features like man-machine dialogue and automatic parking wing positioning.
**3.2 GA308 Sizing Machine**
Equipped with distributed AC drive systems, this machine uses frequency converters for the sizing tank, drying cylinder, and other components. It includes 5 inverters, 2 servo controllers, and sensors for pressure, temperature, and moisture. Controlled by an industrial computer and PLC, it ensures high precision, stability, and low failure rates, making it a high-performance solution.
**4. Future Prospects of Frequency Converters in Textiles**
As China's textile industry becomes more globalized, there remains a gap compared to international standards. To bridge this, continued improvements in mechatronics and the broader application of AC frequency conversion technology are essential. These advancements will help enhance productivity, reduce costs, and support sustainable development in the textile sector.
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