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Uj 21619+SOURCE1+SOURCE1.2
Uj 21619+SOURCE1+SOURCE1.2
Uj 21619+SOURCE1+SOURCE1.2
System
Tawanda. Mushiri Member, IAENG and Charles. Mbohwa
Calculating starting time: Fig. 1. Soft starter components connection to the motor and a gear box
Accelerating torque taken from speed torque curve is D. VARIABLE SPEED DRIVES
180% of full load torque Components of variable speed drives:
For drive efficiency of 95% horse power motor shaft to
Rectifier- Converts Ac power to foxed or
operate a loaded conveyor =263.17hp
adjustable dc power
Taking from specifications in methodology
Inverter- produces controllable AC power
Let Force of acceleration of loaded conveyor at belt speed
output at desire voltage and frequency. The transmitter and the receiver are placed at loading
Regulator- modifies inverter switching point across belt width
characteristics so that the output Belt width= 1.2 m
frequency can be controlled. Take load detecting range to be 2m.
Considerations when selecting a variable speed Select Through beam sensor with inbuilt timer on delay
drive: 5mins and load detection range 3m.
Motor type –squirrel cage induction motor
Motor rated HP= 300HP
Torque load Type-constant torque
Starting methods – soft starting
Select a Variable voltage inverter (VVI) of following
specifications from adjustable speed drives catalogue
(Richard Okrasa, 1997)
Efficiency= 93%
Rated voltage =380V AC
Rated frequency =60 Hz
Output frequency range= 0.5 Hz to
60Hz
The System is being protected against input voltage
overload, output overcurrent and motor load Fig. 3. Through beam switching system connection to the motor
F. ENERGY SAVINGS
Power savings is achieved by:
Reduced operating hours by provision of auto
system switching
Reduced starting current ,voltage thus starting power
with gradual system acceleration by use of a
variable speed drives
G. OPERATING HOURS
The initial systems operate continuously the whole day
giving 8760 hours per year
Fig. 2. Variable speed operation in a closed loop control system
The designed system has average operating hours of
E. LOAD DETECTION SWITCHING SYSTEM hours per day giving 4380 hours per year.
The load detection method to be used is through beam
mode switching system. It consists of a transmitter and a Calculating Operating Annual energy consumption:
receiver. A transmitter sends a beam of radiation to the Annual energy consumption =
receiver and the load is detected .if the beam between the
transmitter and the receiver is interrupted the output of the
Power consumed by belt = 185 kW, Power factor =0.82
receiver switches state. In this case when load is placed on
already calculated in last chapters
the belt it interrupts the beam thus switching on the system.
Initial system operating annual energy
A counting timer is used to set the on time delay in order to
avoid stops when the load moves away from sensor consumption= =2298983 Kilowatts-
detecting range. The timer starts counting when the load is hours per year
placed on the belt and after the time that the material travels Designed system operating annual energy
to the end has elapsed it will confirm if the sensor is
detecting another load, if there is another load it resets and consumption= =1149492 kilowatts-
starts counting again until the sensor detects no load . hours per year.
Calculate the time moved by the load from loading The annual operating energy consumption is being
point to the discharge chute reduced by 50%
IV. CONCLUSION
The design system components were sized according to
standard practice and were capable to meet the objectives of
the projects. The project will boost industry with greater
profit margins by reducing the power costs and maintenance
costs. The system component such as variable speed drives
and soft starters requires careful monitoring for protection
against overcurrent and overvoltage. From cost benefit
Fig. 4 Auto CAD diagram layout. analysis the project investment has shorter payback period
thus making it more beneficial.
ACKNOWLEDGMENT
I would like to thank my supervisor Professor Mbohwa for
support and supervision. University of Johannesburg paid
me all my trip and accommodation expenses.
REFERENCES
[1] Anon., 2012. Fabric conveyor system. Habisat America.
[2] Cema, 2006. Belt hand book. s.l.:s.n.
[3] E3Jk catalogue, 2012. Built in power supply photoelectric sensor.
Fig. 5. Belt and power saving system
s.l.:s.n.
[4] GE Industrial Systems, 1993. AC Motor Selection and motor guide.
Washington Dc: s.n.
I. COST BENEFIT ANALYSIS [5] IDEC, 2010. Switching and controls. s.l.:s.n.
Break down cost of the system is calculated and shown [6] Kling, M. k. a. S., 2003. Soft starter hand book. s.l.: ABB automation
Technology products AB control.
in this section. Table V shows the average cost of variable [7] NHP Electrical Engineering Products Pty Ltd, 2013. Soft starter
speed drive system which is $ 4500, Soft starter is $4100 selection guide. s.l.: NHP NTU SOFT STARTAUSESG 06 13 ©
and for the through beam mode system is $3000 in US Copyright NHP 2013.
[8] Rakesh, V., 2013. DESIGN AND SELECTING THE PROPER
dollars(NHP Electrical Engineering Products Pty Ltd, CONVEYOR-BELT. Advanced Engineering Technology.
2013). [9] Richard Okrasa, P. H., 1997. Adjustable speed drives reference guide.
Toronto: Copyright © 1997 Ontario Hydro.
TABLE V: SYSTEM COMPONENTS VERSUS COSTS. [10] Rulmica, 2009. Technical information and design criteria for belt
conveyors. s.l.:s.n.
System Component Costs in US [11] Sandvik mining and construction, 2008. Idler design manual. s.l.:s.n.
dollars [12] Zhang, S., 2010. Optimum control of operation efficiency of belt
Soft starter 4100 conveyor system. Applied Energy.
[13] Zympay, 2014. www.ziympayadvantage.com. [Online].
VSD system 4500 [14] Rogerio Ferraz, 2009. Soft starter application guide.
Through beam sensor switch 3000 [15] Schneider electric, 2003. Electronic soft starters and variable speed
system drives.
[16] ABB drives,2011.Guide to variable speed drives
Installation 1000 [17] Omron electrinics,1999.Photoelectric sensors
[18] PEPPERL-FUCHS,2014.Through beam sensors
System protection devices 12600 [19] Carlo Gavazzi, 2006. Photoelectric through beam transistor output
TABLE II: ESTIMATED AVERAGE BELT WEIGHT, MULTIPLE- AND REDUCED-PLY BELTS, LBS/FT (CEMA, 2006)
Belt Width Material Carried,
inches (b) lbs/ft3
30-74 75-129 130-
200