Unlimited optimization power: see where you can use frequency converters

12.09.2024

Imagine an engine that would operate continuously regardless of the actual needs of the system. What do you first associate with it? High bills? Or maybe endless servicing, frequent replacements and short life cycles? Fortunately, there is an alternative: the operation of machines in production plants can be monitored and controlled, and consequently – continuously optimized.

The answer to this situation is frequency converters, which regulate the speed of the engines and are an important element of most drive systems. At Control-Service, we use Danfoss Drives, which have been shaping the approach to energy consumption in industry for years.

The role of frequency converters in control

Inverters regulate the output frequency and sometimes other current parameters to adapt them to the system’s needs. Frequency converters allow the motor to operate smoothly regardless of current fluctuations. They allow the drive to be started and stopped, controlling the acceleration and deceleration time. Due to their diverse functionality and parameters, they can be used in any sector. However, there are industries and specific applications in which the use of inverters is much more noticeable, due to the savings generated.

Application of frequency converters and their advantages

The most beneficial results are achieved by the device in the manufacturing and energy industries, where process continuity and precision are important. Frequency converters are a necessary element of systems in energy-intensive industries, including chemical, metallurgical, ceramics and paper. Due to the drastic increase in electricity costs, their role in reducing consumption is crucial for reducing expenses, sometimes reaching millions of zlotys per year.

Thanks to the optimization of engine operation, inverters generate the greatest savings, with the reduction of energy consumption depending on the application. In the case of variable-speed pump and fan motors, it is enough – with the help of converters – to reduce the average rotational speed by 20% to save half the electricity. In the case of other machines, the speed reduction is proportional to the reduction in energy consumption.

It is worth remembering that converters also bring benefits during processing processes: they increase equipment efficiency and speed up processes.

Hybrid energy systems

In addition to reducing energy consumption, frequency converters support companies that actively use renewable energy sources, hybrid power systems and energy storage. They convert direct current, obtained from renewable energy sources, to alternating current, needed to power engines. In hybrid systems, they combine conventional energy sources and enable its storage.

How to make frequency converters work as long as possible

Inverters can operate for 10, 15 or 20 years. How long they will function properly depends on their environment, among other things – high humidity, high temperatures or dust have a significant impact. But it is even more important to take care of the devices through regular maintenance and verifying the risk of further use. Such audits, called DrivePro® Site Assessment, are conducted by Control-Service specialists. If it is necessary to carry out a more complex service, we finish it with professional dynamometer tests, and for the duration of the repair, we offer our partners equipment from the drive rental. If your converter is at the end of its lifespan, we recommend replacing it under the Exchange to New program.