This application is a National Stage of International Application No. PCT/JP2014/057371 filed Mar. 18, 2014, the contents of which are incorporated herein by reference in the entirety.
The present invention relates to a mechanical device.
Conventional induction motors have been used in various mechanical devices such as pumps, blowers (fans), and compressors to suppress and reduce energy consumption. To further reduce the power consumption, the efficiency of induction motors themselves has been improved and control methods for mechanical devices have been developed.
For example, Patent Literature 1 discloses a technology in which control is performed in a maximum steady-state rotation-speed range such that the acceleration rotation in which the mechanical device is accelerated and rotated by the motor and the inertial rotation in which the motor is de-energized and the mechanical device is rotated by inertia are repeated alternately, thereby maintaining the rotation of the mechanical device within the maximum steady-state rotation-speed range, and during the inertial rotation in which the motor is de-energized and the mechanical device is rotated by inertia, the motor is de-energized and thus the power consumption is reduced.
Patent Literature 1: Japanese Patent Application Laid-open No. 2001-120880
However, the conventional technology described above cannot be applied to a mechanical device that uses an induction motor rotating at rated speed. When a high-efficiency induction motor is used for a mechanical device, the rotation speed of the high-efficiency induction motor tends to be higher than that of a conventional induction motor (non-high-efficiency induction motor) at the same output. For this reason, there is a problem in that along with an increase in the rotation speed of the induction motor, the mechanical output of the pump device itself is also increased and thus the power consumption cannot be sufficiently reduced because of the increase in the output.
The present invention has been achieved in view of the above and an object of the present invention is to obtain a mechanical device for which a high-efficiency induction motor that can sufficiently reduce the power consumption is used.
In order to solve the above problems and achieve the object, the present invention relates to a mechanical device including: an induction motor that rotates a small-diameter pulley (or a small-diameter gear); and a device including a rotation mechanism having a large-diameter pulley driven by a rotation operation of the small-diameter pulley (or the small-diameter gear) connected thereto, wherein an increment in a rotation speed caused by using a high-efficiency induction motor as the induction motor is offset in the large-diameter pulley (or the large-diameter gear) by increasing a reduction ratio, which is a ratio of a diameter of the large-diameter pulley (or the large-diameter gear) to a diameter of the small-diameter pulley (or the small-diameter gear), and an increase in a rotation speed of the large-diameter pulley (or the large-diameter gear) due to the increment in a rotation speed caused by using a high-efficiency induction motor as the induction motor is suppressed.
According to the present invention, an effect is obtained where it is possible to obtain a mechanical device for which a high-efficiency induction motor that can sufficiently reduce the power consumption is used.
Exemplary embodiments of a mechanical device according to the present invention will be explained below in detail with reference to the drawings. The present invention is not limited to the embodiments.
Embodiment
According to the above equation (1), when a conventional induction motor is changed to a high-efficiency induction motor, if the ratio of the diameter DS of the small-diameter pulley 31 to the diameter DL of the large-diameter pulley 32 is changed from 30:40 to 30:41 as in the example described above, while the relationship between a rotation speed Np1 of the pump in the case of using the conventional induction motor and a rotation speed Nm1 of the conventional induction motor is Np1=0.75Nm1, the relationship between a rotation speed Np2 of the pump in the case using the high-efficiency induction motor and a rotation speed Nm2 of the high-efficiency induction motor becomes Np2=0.73Nm2. Meanwhile, the rotation speed Nm2 of the high-efficiency induction motor becomes higher than the rotation speed Nm1 of the conventional induction motor at the same output (Nm1<Nm2). As in the present embodiment, when the reduction ratio in the case of using the high-efficiency induction motor is increased as compared to the reduction ratio in the case of using the conventional induction motor, the rotation speed Np1 of the pump in the case of using the conventional induction motor becomes substantially equal to the rotation speed Np2 of the pump in the case of using the high-efficiency induction motor. Accordingly, the mechanical output does not change before and after the induction motor is changed, and thus it is possible to reduce the power consumption due to improvement in the efficiency of the induction motor 21.
Next, the rotation speed of the high-efficiency induction motor is explained.
The resistance and the rotation speed of the induction motor are further explained. The motor output of the induction motor can be represented by the following equation (2).
In the equation (2), PM denotes a motor output, V denotes a power supply voltage, s denotes a slip, r1 denotes primary resistance, r2 denotes secondary resistance, x1 denotes primary reactance, and x2 denotes secondary reactance. Generally, an induction motor has a relationship of s<<1 at rated operation, and thus the relationship between the slip and the output can be approximated by the following equation (3) using the above equation (2).
Based on the above equation (3), the slip “s” at constant output is represented by the following equation (4).
Based on the above equation (4), a rotation speed N of a motor at constant output is represented by the following equation (5).
In the equation (5), N0 denotes a synchronous rotation speed, fe denotes a power-supply frequency, and p denotes the number of pole pairs of the induction motor. When the secondary resistance is reduced, the slip of the induction motor at the rated power is also reduced as can be seen from the above equation (4), and the rotation speed thereof is increased as can be seen from the above equation (5).
In
Meanwhile,
The reduction ratio may be determined by focusing attention on the fact that the rotation speed of the induction motor changes depending on the secondary resistance. Assuming that the reduction ratio in the case of using the conventional induction motor is denoted by α, the reduction ratio in the case of using the high-efficiency induction motor is denoted by β, the secondary resistance of the conventional induction motor is denoted by r2, and the secondary resistance of the high-efficiency induction motor is denoted by A·r2 (A is the ratio between the secondary resistance of the conventional induction motor and that of the high-efficiency induction motor), the conditions for causing the rotation speed Np of the mechanical device in the case of using the conventional induction motor to be equal to that in the case of using the high-efficiency induction motor are represented by the following equation (6) on the basis of the above equation (5) and the like and Np=N1/α=N2/β.
Therefore, the reduction ratio β for causing the rotation speed in the case of using the conventional induction motor to be equal to that in the case of using the high-efficiency induction motor is represented by the following equation (7).
β={1+s(1−A)}α (7)
When the reduction ratio β is determined by the above equation (7), the rotation speed in the case of using the conventional induction motor becomes substantially equal to the rotation speed in the case of using the high-efficiency induction motor and the mechanical output does not change before and after the induction motor is changed. As a result, the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
The reduction-ratio increase rate is determined on the basis of the above equation (6).
In the present embodiment, the ratio A between the secondary resistance of the conventional induction motor and that of the high-efficiency induction motor used in the above equation (6) is calculated by performing a lock test on an induction motor, and the reduction ratio β is calculated by the above equation (7). The lock test of an induction motor is a test where a low voltage at rated frequency is applied to the primary winding of the induction motor while the rotator of the induction motor is fixed, a locked current close to the rated current is applied to the primary winding, and the input on the primary side at this point is measured, thereby calculating the secondary resistance. By performing the lock test, it becomes possible to more accurately calculate the reduction ratio that causes the rotation speed before the motor is changed to be equal to the rotation speed after the induction motor is changed and the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
In the present embodiment, the reduction ratio β in the case of using the high-efficiency induction motor is represented by the following equation (8) assuming that the rated rotation speed of the conventional induction motor is denoted by N1, the reduction ratio in the case of using the conventional induction motor is denoted by α, and the rated rotation speed of the high-efficiency induction motor is denoted by N2.
An induction motor is almost always used approximately at the rated rotation speed, and thus by determining the reduction ratio by the above equation (8), in most cases, the rotation speed before the motor is changed becomes equal to the rotation speed after the induction motor is changed. Therefore, the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
While the present embodiment has explained that the diameter of a pulley is changed to change the reduction ratio, the present invention is not limited thereto, and it is possible to configure such that the number of gears is changed in a mechanical device in which a speed reducer has a gear mechanism (
As explained above, the mechanical device according to the present embodiment is a mechanical device including an induction motor that rotates a small-diameter pulley (or a small-diameter gear) and a device including a rotation mechanism having a large-diameter pulley (or a large-diameter gear) driven by a rotation operation of the small-diameter pulley connected thereto, in which an increment in a rotation speed caused by using a high-efficiency induction motor as the induction motor is offset in the large-diameter pulley (or the large-diameter gear) by increasing a reduction ratio, which is a ratio of the diameter of the large-diameter pulley (or the large-diameter gear) to the diameter of the small-diameter pulley (or the small-diameter gear), and an increase in a rotation speed of the large-diameter pulley (or the large-diameter gear) due to the increment in a rotation speed caused by using a high-efficiency induction motor as the induction motor is suppressed. Alternatively, the mechanical device according to the present embodiment is a mechanical device including an induction motor and a speed reducer, in which a reduction ratio of the speed reducer is increased such that a rotation speed of the mechanical device itself in which a non-high-efficiency induction motor is changed to a high-efficiency induction motor is equal to a rotation speed in a case of using a non-high-efficiency induction motor before a change. With such a configuration, the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
In the mechanical device with the configuration described above, the reduction ratio can also be determined on the basis of the secondary resistance of the induction motor. For example, such a mode is represented by the above equation (7). With such a configuration, the rotation speed does not change before and after the induction motor is changed, and thus the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
In the mechanical device with the configuration described above, it is permissible that the secondary resistance of the induction motor is calculated by a lock test. With such a configuration, the reduction ratio is determined accurately and the rotation speed does not change before and after the induction motor is changed, and thus the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
In the mechanical device with the configuration described above, the reduction ratio of the induction motor can also be determined on the basis of the ratio of a rated rotation speed of the induction motor. For example, such a mode is represented by the above equation (8). With such a configuration, the rotation speed does not change before and after the induction motor is changed, and thus the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
In the mechanical device with the configuration described above, it is permissible that the reduction ratio, which is a ratio of the diameter of the large-diameter pulley to the diameter of the small-diameter pulley, is determined to be equal to or larger than 1.0% and equal to or smaller than 6.0% depending on the increment in a rotation speed caused by using a high-efficiency induction motor as the induction motor. With such a configuration, the energy saving effect by improving the efficiency of the motor can be maximized.
Alternatively, in a mechanical device with a configuration identical to the configuration described above, an increment in a rotation speed caused by using a high-efficiency induction motor as the induction motor can be offset in the large-diameter pulley not by increasing the reduction ratio, which is a ratio of the diameter of the large-diameter pulley to the diameter of the small-diameter pulley, but by reducing the frequency of a power supply that supplies power to the induction motor. That is, in a mechanical device including an induction motor and a speed reduction mechanism, when a conventional induction motor that uses a variable frequency power supply such as an inverter is changed to a high-efficiency induction motor, it is desirable that the output frequency of the inverter is reduced such that the rotation speed of the mechanical device is equal to the rotation speed in a case of using the conventional induction motor. The output frequency of the inverter is reduced such that the rotation speed of the mechanical device is equal to the rotation speed in a case of using the conventional induction motor. Specifically, the output frequency of the inverter is reduced by 1/β or approximately 1.0 to 6.0% by using the above equation (7) and the like. Accordingly, the rotation speed does not change before and after the induction motor is changed, and thus the power consumption reduction effect by improving the efficiency of the induction motor can be maximized.
As described above, the mechanical device according to the present invention is useful as a device including an induction motor.
21 induction motor, 22 pump, 23 belt, 31 small-diameter pulley, 32 large-diameter pulley, 41 to 44 curve, 51 to 55 line, 61, 62 gear.
Filing Document | Filing Date | Country | Kind |
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PCT/JP2014/057371 | 3/18/2014 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2015/140929 | 9/24/2015 | WO | A |
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