產(chǎn)品與解決方案/PRODUCT AND SOLUTIONS
少用電 用好電 再生電 存儲電 防爆電
解決方案
硬核出海，精準適配 | 新風光高壓變頻器助力幾內(nèi)亞鐵礦投產(chǎn)，譜寫一帶一路共贏篇章
引言Preface
隨著電力電子技術(shù)、控制技術(shù)和電力器件制作工藝的進步，變頻器技術(shù)得到了迅速發(fā)展。變頻器在風機、水泵、提升機、皮帶機等領(lǐng)域的應(yīng)用已相當成熟。傳統(tǒng)的礦用皮帶輸送機通常采用工頻拖動和液力耦合器傳動，存在傳動效率低、啟動電流沖擊及機械沖擊大、無法實現(xiàn)功率平衡等問題，導(dǎo)致系統(tǒng)運行不經(jīng)濟；同時，皮帶和液力耦合器的磨損嚴重，維修及維護成本高昂，還存在無功環(huán)流損耗。因此，對皮帶運輸機采用變頻控制，能夠有效降低企業(yè)生產(chǎn)成本，提高經(jīng)濟效益；控制系統(tǒng)本身良好的控制性能和完善的保護環(huán)節(jié)，能有效避免事故發(fā)生并延長皮帶機的使用壽命。
With continuous advances in power electronics, control technology, and power device manufacturing, VFD (Variable Frequency Drive) technology has rapidly developed, becoming mature in applications such as fans, pumps, hoists and conveyor belts. Traditional mining conveyors typically use power-frequency drive and hydraulic couplers, resulting in low efficiency, high starting current and mechanical impact, and the inability to achieve power balance—making the system uneconomical. At the same time, belts and couplers suffer heavy wear, leading to high maintenance costs and reactive power circulation losses. Therefore, applying VFD control to belt conveyors effectively reduces production costs, improves operational efficiency, and enhances system reliability and protection, significantly extending the conveyor’s service life
用戶情況介紹Customer Introduction
2025年11月11日，幾內(nèi)亞共和國世界級鐵礦項目投產(chǎn)啟動儀式成功舉行。這一標志性事件吸引了多方代表齊聚一堂，共同見證中非礦業(yè)合作邁向新階段的里程碑時刻。項目的正式投產(chǎn)，將為地區(qū)經(jīng)濟發(fā)展注入強勁動力，進一步深化國際產(chǎn)能與合作共贏。
On November 11, 2025, the commissioning ceremony of the world-class iron ore project in the Republic of Guinea was successfully held. This landmark event brought together representatives from multiple parties to witness a milestone moment as China–Africa mining cooperation enters a new stage. The official commissioning of the project will inject strong momentum into regional economic development and further deepen international capacity cooperation and mutual benefits.
幾內(nèi)亞鐵礦的皮帶機運輸是全礦的流程中樞，一旦皮帶機無法正常工作，將導(dǎo)致全礦停產(chǎn)，造成巨大經(jīng)濟損失。因此，高壓調(diào)速系統(tǒng)必須具備極高的可靠性、穩(wěn)定性和防護性。
基于上述工作特點，變頻器設(shè)計需滿足以下主要技術(shù)條件：
The conveyor system is the central link of the entire Guinea iron mine. Any failure in the belt conveyor would lead to full-site shutdown and cause major economic losses. Therefore, the high-voltage speed-regulation system must provide exceptional reliability, stability and protection. Based on these operational characteristics, the VFD must meet the following requirements:
1高壓變頻器具有高可靠性、穩(wěn)定性和防護性
High reliability, stability and protective performance.
2變頻器具備工頻運行的旁路功能，一旦出現(xiàn)故障，可讓電機切換到工頻運行
Bypass function for power-frequency operation during faults.
3高壓變頻器啟動過程要求平穩(wěn)，啟動力矩大
Smooth start with high starting torque.
4變頻器的輸出力矩不小于電動機2倍額定力矩，滿足負載變化大的承受能力和鐵帶載再起動的能力
Output torque ≥2× rated motor torque for large load variations and heavy-load restart.
5須滿足鐵礦電控系統(tǒng)的功能接口和監(jiān)控要求
Full compatibility with the mine’s control and monitoring interfaces.
6能夠?qū)崿F(xiàn)驗帶功能
Belt-inspection functionality.
經(jīng)過對各類高壓變頻器廠家的調(diào)研和比較，幾內(nèi)亞項目最終選擇了新風光JD-BP38系列高壓變頻器作為皮帶機的控制設(shè)備，現(xiàn)場共配置多臺集裝箱式高壓變頻器進行控制。
After evaluating various suppliers, the project selected FGI’s JD-BP38 Series High-Voltage VFDs as the control solution, with multiple containerized HV VFD units deployed on site.
皮帶機變頻控制方案VFD Control Scheme for the Conveyor
01拖動電機的控制方式 Motor Drive Control Method
由于帶式輸送機的三臺電機控制方式相互關(guān)聯(lián)，為保證系統(tǒng)速度同步和電機轉(zhuǎn)矩平衡，采用新風光自主研發(fā)的主從控制功能。一臺變頻器作為主機控制模式，其余兩臺為從機控制模式，跟隨主電機速度同步運行，并以主電機轉(zhuǎn)矩輸出為依據(jù)，確保三臺電機之間實現(xiàn)轉(zhuǎn)矩平衡。
As the three motors operate in a linked manner, FGI’s self-developed master-slave control is adopted to ensure speed synchronization and torque balance. One VFD serves as the master, while the other two operate as slaves, following the master’s speed and torque commands to maintain real-time torque balance.
02JD-BP38系列高壓變頻器基本性能Basic Performance of the JD-BP38 High-Voltage VFD Series
根據(jù)現(xiàn)場需求，高壓變頻器需實現(xiàn)皮帶系統(tǒng)的軟啟動和調(diào)速運行，采用矢量控制技術(shù)，滿足皮帶機重載啟動、主從電機轉(zhuǎn)矩均衡控制等功能，并具備高可靠性。
According to the site requirements, the high-voltage VFD shall provide soft start and speed regulation for the belt conveyor system. Vector control technology shall be adopted to meet the functions of heavy-load startup and torque balance control between master and slave motors, while ensuring high reliability.
新風光高壓變頻器特點
Characteristics of FGI High-voltage Frequency Convertes
1采用完美無諧波的單元串聯(lián)多電平拓撲結(jié)構(gòu)，電網(wǎng)電流諧波低，滿足電能質(zhì)量要求，輸出線電壓為33電平，無需輸出濾波器，可使用普通異步電動機
Multilevel cascaded topology with low harmonics; 33-level output requires no output filter and supports standard induction motors.
2采用無速度傳感器矢量控制方式，啟動力矩大，有效避免負載波動導(dǎo)致的變頻器過流故障
Sensor-less vector control with high starting torque, preventing over-current during load fluctuations.
3配置轉(zhuǎn)矩協(xié)調(diào)功能，實現(xiàn)多電機驅(qū)動系統(tǒng)的轉(zhuǎn)矩實時均衡控制
Torque coordination for real-time balance in multi-motor systems.
4具備2倍以上電流過載能力，滿足大慣量系統(tǒng)重載啟動要求
Overload capability above 2× rated current for large-inertia heavy-load starts.
5風光高壓變頻器對電網(wǎng)電壓適應(yīng)范圍寬（－65％～115％Un），采用單元故障自動旁路、星點漂移技術(shù)、工頻旁路、瞬時停電再啟動功能、相間短路等多項保護技術(shù)，提高抗電網(wǎng)波動和負載擾動能力，顯著提升產(chǎn)品在皮帶機應(yīng)用現(xiàn)場的可靠性
Wide grid-voltage adaptability (?65% to +115% Un) with advanced protections such as cell bypass, neutral-point shift, grid-frequency bypass and blackout restart, greatly enhancing reliability.
皮帶機變頻主回路接線圖Main Circuit Wiring of the Conveyor VFD System
現(xiàn)場采用3套新JD-BP38系列高壓變頻調(diào)速系統(tǒng)，根據(jù)用戶要求，變頻器控制系統(tǒng)采用主從控制，“一拖一”控制方式。3臺高壓變頻器主回路接線方式相同，以其中一臺裝置為例，一次接線如圖
Three JD-BP38 HV VFD systems are deployed on site, using master-slave mode and “one-to-one” motor control. All three units share the same wiring configuration, shown in Figure 1.
一拖一接線柜（帶緩沖）一次回路圖
One-to-One Wiring Cabinet (with Buffer)
Primary Circuit Diagram
主從控制Master-Slave Control
如皮帶系統(tǒng)簡圖所示，選用1#變頻器為主變頻器，2#和3#變頻器為從變頻器。操作臺向主變頻器發(fā)送給定頻率值，主從變頻器之間采用光纖通信，1#變頻器作為主控，檢測所有變頻器的運行電流，計算并發(fā)出輸出轉(zhuǎn)矩給定值，控制從變頻調(diào)速系統(tǒng)同步運行。
As shown in the simplified conveyor system diagram, VFD No.1 is selected as the master drive, while VFD No.2 and No.3 operate as slave drives. The control console sends the frequency command to the master VFD, and optical fiber communication is used between the master and slave VFDs. Acting as the master controller, VFD No.1 monitors the operating current of all VFDs, calculates the required torque output reference, and issues torque commands to ensure synchronized operation of the slave VFD systems.
高壓變頻調(diào)速系統(tǒng)簡圖（BC4A）
Simplified Diagram of the High-Voltage VFD Speed
Regulation System (BC4A)
皮帶機變頻電控系統(tǒng)的工作過程Operating Process of the VFD Electrical Control System
皮帶電控系統(tǒng)控制原理圖
The control principle of the conveyor electrical control system
皮帶電控系統(tǒng)控制原理Control Principle of
the Conveyor Electrical Control System
起車時，皮帶電控系統(tǒng)首先對皮帶系統(tǒng)傳送的信號進行判斷，如跑偏、堆鐵、縱撕、急停閉鎖等，若各信號正常，方可進入下一程序。
When starting, the conveyor electrical control system first checks all signals from the belt system—such as belt deviation, material buildup, longitudinal tear, and emergency stop interlock. Only if all signals are normal will the system proceed to the next step.
當皮帶機各部分均處于正常狀態(tài)，具備起車條件，才會發(fā)出啟動信號。發(fā)出起車指令后，變頻器啟動。
When all parts of the belt conveyor are confirmed to be in normal condition and meet the start-up requirements, a start signal is issued. After the start command is sent, the VFD begins operation.
同時，操作臺發(fā)出指令使抱閘打開，并檢測抱閘是否完全打開。若抱閘未打開或未完全打開，將關(guān)閉運行信號，并給變頻器發(fā)送抱閘信號使其急停，防止因堵轉(zhuǎn)而過流跳閘。
At the same time, the control console sends a command to release the brake and monitors whether it is fully opened. If the brake does not open or fails to fully open, the system will disable the run command and send a brake signal to the VFD to perform an emergency stop, preventing overcurrent trips caused by motor stalling.
當皮帶達到額定速度，電控系統(tǒng)實時檢測皮帶速度與滾筒速度，若二者速度差值超過規(guī)定值，緊急停車，并發(fā)出打滑報警信號。
When the belt reaches its rated speed, the control system continuously monitors the belt speed and drum speed. If the speed difference exceeds the specified limit, the system will execute an emergency stop and trigger a belt-slip alarm.
系統(tǒng)實時監(jiān)測電機溫度、減速器溫度、軸承溫度、皮帶張力、電機電流、抱閘狀態(tài)、變頻狀態(tài)等參數(shù)。一旦任一指標或狀態(tài)出現(xiàn)異常，系統(tǒng)將立即緊急停車并發(fā)出報警信號。
The system continuously monitors parameters such as motor temperature, gearbox temperature, bearing temperature, belt tension, motor current, brake status, and VFD status. If any parameter or condition becomes abnormal, the system will immediately initiate an emergency shutdown and issue an alarm.
結(jié)束語Conclusion
皮帶機的驅(qū)動系統(tǒng)采用新風光最新研制的高壓變頻器后，確保了運輸皮帶的穩(wěn)定運行，配合自動控制系統(tǒng)，有效解決了皮帶運輸過程中的跑偏、堆煤、超溫等問題，顯著提升了皮帶機的自動化控制水平?，F(xiàn)場應(yīng)用表明，利用技術(shù)先進、成熟可靠的高壓變頻調(diào)速系統(tǒng)拖動皮帶機，不僅大幅提高了皮帶機的自動化控制水平，還降低了現(xiàn)場維護量，帶來顯著的經(jīng)濟效益，值得大力推廣。
With the adoption of FGI’s JD-BP38 series high-voltage VFDs, the conveyor drive system now operates with enhanced stability. Combined with the automated control system, it effectively resolves issues such as belt deviation, coal buildup, and overheating during operation, significantly improving the overall automation level. Field applications have demonstrated that using an advanced, mature, and reliable high-voltage VFD drive system for the conveyor not only greatly enhances automation but also reduces on-site maintenance workload and brings substantial economic benefits, making it highly worthy of widespread promotion.
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