The difference between integrated frequency conversion and split frequency conversion of air compressor
Analysis of integrated frequency conversion and split frequency conversion technology for air compressor
The application of frequency conversion technology in the field of air compressors has significantly improved equipment energy efficiency and operating stability. According to the different integration methods between the frequency converter and the host, it can be divided into two technical routes: integrated frequency conversion and split frequency conversion. Here is a professional explanation on its technical characteristics, performance differences and key selection points:
1. Comparison of system architecture
- Integrated variable frequency air compressor
- structural features: The frequency converter and the air compressor host are integrated in the same cabinet and use a common cooling system
- electrical design: Inverter output cable length ≤5 meters, reducing electromagnetic interference (EMI)
- control logic: Built-in dedicated control algorithm to achieve closed-loop control of pressure, flow and power
- Split type variable frequency air compressor
- structural features: The frequency converter is installed as a separate unit and connected to the host through a power cable
- electrical design: Output reactor needs to be configured, cable length can reach 50 meters
- control logic: Adopt universal frequency converter parameters and require an external pressure sensor to achieve closed loop
2. Performance characteristics comparison
| performance Index | Integrated frequency conversion | Split frequency conversion |
|---|---|---|
| response speed | ≤50ms | ≥100ms |
| speed range | 20%-100% rated speed | 30%-100% rated speed |
| energy efficiency rating | IE4 is super efficient | IE3 is efficient |
| harmonic distortion rate | ≤3% | ≤5% |
| installation space | Reduce footprint by 30% | Additional installation space is required |
| Maintenance convenience | Integrated design for easy maintenance | The mainframe and frequency converter need to be maintained separately |
3. Application scenario adaptation
- Integrated frequency conversion application scenarios
- Frequent start-stop conditions: For example, the automobile stamping production line has more than 20 starts and stops per hour
- Precision pressure control requirements: For example, in pharmaceutical packaging machinery, pressure fluctuations need to be controlled at ±0.01MPa
- Space constrained occasions: For example, for marine air compressors, the installation space is ≤1.5m³
- Split frequency conversion application scenarios
- high power requirements: Single machine power>250kW, such as blast furnace blowing in steel companies
- remote control: The distance between the control room and the air compressor room is>50 meters, such as underground mine ventilation
- Existing frequency conversion system transformation: Use existing inverter resources to reduce transformation costs
4. Energy efficiency optimization strategy
- Integrated frequency conversion special optimization
- permanent magnet synchronous motor: Matching inverter vector control, efficiency increases by 5%-8%
- Intelligent hibernation function: Automatically switch to low frequency mode below 30% load, saving power of 35%
- Special optimization of split frequency conversion
- Common DC bus technology: Multiple air compressors share DC bus, increasing braking energy recovery efficiency by 40%
- Harmonic control solution: Configuration of active filter (APF), power factor compensation to 0.98
V. Selection decision elements
When selecting inverter air compressors, companies need to comprehensively evaluate the following elements:
- load characteristics: Priority is given to integrated type for continuous operating conditions, and priority is given to split type for variable load conditions.
- installation conditions: Select the integrated type when space is limited, and select the split type when there is a frequency conversion cabinet
- energy efficiency target: Pursuing extreme energy efficiency, choosing an integrated approach, focusing on initial investment and choosing a split approach
- maintenance capabilities: Professional teams can choose split type, general maintenance can choose integrated type
By implementing health management of frequency conversion systems, equipment life can be extended by 30%-50%, and comprehensive energy efficiency can be improved by 20%-30%. It is recommended to establish a frequency converter operation database to record parameters such as temperature, current, and harmonics, and identify potential faults in advance through trend analysis to ensure long-term stable and efficient operation of the air compressor system.