In the field of industrial automation , [color=rgb(68, 68, 68) !important] frequency converters are important equipment for driving motors , and their stability and reliability are directly related to the smooth operation of the production line. However, frequency converters often encounter overload or overcurrent problems during use , which not only affects the normal operation of the equipment, but may also adversely affect production efficiency and equipment life. In response to this problem, the following is a comprehensive set of response strategies designed to help companies and technicians effectively deal with the challenges of inverter overload and overcurrent.
1. In-depth inspection of the load condition
First, when the inverter has an overload or over-current alarm, the equipment should be stopped immediately and the load condition should be in-depth checked. For the frequency converter that controls the chain conveyor, special attention should be paid to whether the cargo load on the chain conveyor is too heavy or unevenly distributed. Overload is one of the common causes of inverter failure. Reasonably adjusting the load to ensure it is within the rated load range of the inverter is the first step to solving the problem.
2. Troubleshoot mechanical faults.
After confirming that there are no abnormalities in the load, you should further check whether there are faults in the mechanical part. Check whether key components such as bearings, reducer chains, and gears are severely worn or have abnormal sounds. Mechanical failure will also increase the load on the motor, which will trigger the overload or over-current protection of the frequency converter . Timely detection and repair of mechanical faults are important measures to prevent inverter failures.
3. Adjust the inverter parameters
If it is confirmed that there are no abnormalities in the load and mechanical parts, you can try to adjust the relevant parameters of the inverter to solve the problem. Specifically, the setting value of the thermal overload protection can be appropriately increased to improve the load-carrying capacity of the frequency converter; at the same time, the acceleration and deceleration time can be increased to make the motor more stable during starting and stopping and reduce current impact; in addition, increase The output frequency of the frequency converter also helps to improve the operating efficiency of the equipment. However, it should be noted that when adjusting parameters, you should follow the inverter’s user manual and manufacturer’s recommendations to avoid new problems caused by improper parameter settings.
4. Optimize the working environment
The working environment of the inverter has an important impact on its performance and life. In an environment with a lot of paper dust, the dust and debris in the frequency converter cabinet should be cleaned in time to ensure good heat dissipation of the frequency converter. High temperature is one of the common causes of inverter failure, so it is crucial to establish a mechanism for regular maintenance and cleaning. In addition, attention should be paid to keeping the inverter well ventilated and away from direct sunlight and humid environments to extend its service life.
5. Upgrade the power
of the frequency converter. If after taking the above measures, the frequency converter still frequently experiences overload or overcurrent faults, and it is confirmed that the load and working environment have reached the optimal state, then it may be necessary to consider upgrading the power of the frequency converter. That is, a more powerful frequency converter is selected to drive the current load to achieve the effect of a “big horse-drawn cart”. Although this method will increase a certain amount of equipment cost, it can effectively solve the overload problem and improve the stability and reliability of the production line.
To sum up, dealing with inverter overload and overcurrent problems requires multiple approaches, including checking load conditions, troubleshooting mechanical faults, adjusting inverter parameters, optimizing the working environment, and upgrading inverter power. Through comprehensive measures, the failure rate of frequency converters can be effectively reduced, and the operating efficiency of equipment and the overall performance of the production line can be improved.
