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Project background:

In textile mills, air compressors are one of the indispensable equipment. Whether it is the pneumatic conveying of the cotton cleaning machine or the weft insertion system of the air jet loom, it is inseparable from the support of compressed air. However, traditional air compressor control methods often have many disadvantages, such as high energy consumption, large pressure fluctuations, and difficult maintenance. These problems not only affect the production efficiency of textile mills, but also increase the operating costs of enterprises. And our electrical control cabinet was born to meet this demand. It integrates advanced control technology, monitoring technology and protection technology, and can achieve precise control, real-time monitoring and comprehensive protection of air compressors, so that air compressors can operate in the best state, providing strong guarantee for the production of textile mills.

Actual combat case

Customer background: A textile group has 8 branches, with a total installed power of air compressors of 3000kW and annual electricity bills exceeding 20 million yuan.

Pain points: Multiple air compressors operating independently lead to pressure fluctuations and increased fabric defect rates; equipment maintenance relies on manual records, and the average repair time for faults exceeds 4 hours.

Solution:We customized an intelligent air compressor group control system for it, and the core configuration includes:

Main control unit: Siemens S7-1500 series PLC is used to achieve linkage control of 6 air compressors;

Variable frequency drive: ABB ACS880 inverter dynamically adjusts the motor speed, and the pressure bandwidth is compressed to ±0.05MPa;

Cloud-edge collaboration: The edge computing gateway collects 200+ parameters in real time, and the data is uploaded to the Alibaba Cloud IoT platform;

Energy efficiency management: Predict gas demand through AI algorithms, automatically start and stop equipment combinations, and avoid "big horses pulling small carts".

Results:

Energy saving of 32%: annual electricity bill savings of 6.4 million yuan, with an investment payback period of only 18 months;

Efficiency increased by 15%: fabric defect rate decreased by 0.8%, and the rate of high-quality products increased to 98.2%;

Operation and maintenance costs reduced by 40%: predictive maintenance reduced unplanned downtime, and spare parts inventory turnover increased by 3 times.

Cooperation

From single-machine control to intelligent production lines, from equipment suppliers to energy efficiency managers, we have always taken "making air compressors better understand textiles" as our mission. Whether you are:

A growing company that wants to upgrade old air compressor stations

An industry leader planning a new digital workshop

An industrial park seeking EPC general contracting services

We can provide one-stop services from solution design → equipment deployment → energy efficiency verification → operation and maintenance hosting. ,

How can our electrical control cabinets help textile mills cope with the challenges of peak production?

A1: During peak production, the demand for compressed air in textile mills will increase sharply. Our electrical control cabinet uses intelligent algorithms to monitor the gas demand of the production line in real time, and automatically adjusts the operating status of the air compressor to ensure stable gas supply.

In terms of energy conservation and emission reduction, what are the specific performances of our electrical control cabinet?

A2: Our electrical control cabinet adopts advanced frequency conversion technology and optimized control strategy, which can dynamically adjust the operating speed of the air compressor according to the actual gas demand to avoid unnecessary energy waste. Take a large textile group as an example. After introducing our intelligent air compressor group control system, the annual electricity bill savings reached 6.4 million yuan, and the investment recovery period was only 18 months.