Application of the Xindashida ME800 High-Voltage Inverter in Internal Mixers for the Rubber Tire Industry
2025-06-05
Application of the Xindashida ME800 High-Voltage Inverter in Internal Mixers for the Rubber Tire Industry
Project Background
With the rapid development of the global automotive industry, tires—key components in automobiles—are also experiencing rapid advancement. In rubber-producing enterprises, where tires are a major product, rubber compounding is the primary process responsible for significant energy consumption and the emission of pollutants.
Rubber compounding refers to the process in tire manufacturing during which rubber, carbon black, oils, vulcanizing agents, and other additives are thoroughly mixed using a #closed-drum mixer# to produce a rubber compound with specific properties. Under the influence of mechanical, thermal, and chemical factors, the rubber temporarily loses its elasticity and becomes more plastic, thereby meeting the various processing requirements throughout the manufacturing process.
Take the production of radial tires as an example: A company that consumes 60,000 tons of raw rubber annually can have annual electricity consumption reaching 130 million kWh. Among this, electricity used for rubber compounding accounts for one-third, with most of it consumed by internal mixers. Therefore, reducing the energy consumption of internal mixer equipment has become a top priority for every tire manufacturer.
So, how can we achieve energy savings and reduce consumption in internal mixers?
Customer needs
Improve rubber compounding efficiency and reduce energy consumption and emissions.
Xinshida Solution
Proposal Description
1. Optimizing the inverter to help reduce energy consumption | ME800 High-Voltage Inverter
The new-generation series-connected internal mixer, developed in collaboration with Dalian Rubber & Plastics Machinery Co., Ltd., adopts a semi-direct-drive drive mode, effectively reducing the mixer’s energy consumption. It has been successfully implemented at a well-known tire manufacturer in Anhui Province. The series-connected internal mixer replaces the single-action mixing method of conventional internal mixers with a combined-action approach, rationally arranging the two process stages—temperature-rise mixing and constant-temperature reaction—across two workstations of different volumes (namely, the upper internal mixer and the lower internal mixer).
2. Optimize motor assistance to reduce energy consumption | Permanent-magnet semi-direct-drive motor
Currently, the conventional configuration for internal mixers in the tire industry typically involves driving the mixer with either a DC motor or an induction motor, combined with a three-stage gearbox. However, this setup not only results in bulky equipment but also increases costs and complicates subsequent maintenance due to the extensive use of high-priced gear oils in the multi-stage gearbox. Moreover, it poses significant environmental challenges. In contrast, adopting a permanent-magnet semi-direct-drive system can effectively address these issues, enabling a more efficient, environmentally friendly, and cost-effective operational solution.
Advantages of the permanent magnet semi-direct drive system:
● Employs a first-stage planetary reduction gear, reducing the size by 30%.
● No additional gearbox oil pump system required; maintenance-free operation.
● The reduction mechanism is simple, and its efficiency is 10% higher than that of a “three-phase asynchronous motor + gearbox” combination.
3. The powerful synergy between the inverter and the motor
We have already learned that the permanent-magnet semi-direct-drive system offers advantages in terms of improved efficiency, reduced losses, and enhanced controllability. When the ME800 is paired with a permanent-magnet synchronous motor, these advantages are further amplified.
Scheme advantages
● High efficiency: The ME800 features an adaptive energy-saving algorithm that automatically adjusts torque output based on changes in load and speed, enabling more efficient operation of permanent-magnet synchronous motors.
● High control accuracy: Thanks to the magnetic field generated by the rotor of the permanent-magnet motor, the ME800 can precisely identify the electrical angle at startup, ensuring smooth load-carrying start-up of the permanent-magnet synchronous motor.
● Rotor Speed Drop Preprocessing: Sudden load increases during operation require the coordination of highly precise control algorithms. This solution can rapidly compensate for speed fluctuations caused by sudden load changes, ensuring stable operating speed.
● Low Noise: The ME800 adopts a 9-unit structure and variable carrier technology, enabling precise control of output voltage harmonics and thereby reducing electromagnetic noise in the motor.
● High-speed response in temperature-controlled rubber mixing: The ME800 can quickly respond to temperature changes in the internal mixer and adjust the rotation speed accordingly.
● Easy to debug: Redundant fuzzy control has been implemented for the permanent magnet synchronous motor model, making it insensitive to motor design parameters and ensuring convenient debugging.
Xinshida ME800 High-Voltage Frequency Converter
Associated products
AS800 High-Voltage Frequency Converter
Project Results
No-load current: 2 A; loaded speed-up and speed-down time: 15 s; speed drop less than 1 rpm; commissioning completed within 1 working day.
