Several Ways to Save Energy on Fiber Laser Air Compressors

In modern manufacturing, laser cutting technology is widely used because of its high efficiency, precision and flexibility. The laser cutting process requires a large amount of compressed air, which is usually provided by an air compressor. Therefore, the energy consumption of the fiber laser air compressor has become an important factor affecting the energy efficiency of laser cutting. In order to reduce energy consumption and improve economic benefits, it is particularly important to implement energy-saving measures for air compressors.

1. Air Compressor Energy Efficiency and Leakage Problems

From the data of the testing agency, it can be seen that only 10% of the electricity consumed by the air compressor is converted into compressed air, and the remaining 90% is converted into heat energy. It can be seen that compressed air is ten times more expensive than electricity, but we often ignore this. In most factories, the sound of air leakage can be heard everywhere, but no one cares. Leakage not only leads to the waste of compressed air, but also increases the burden on the fiber laser air compressor, causing it to start and stop frequently, thereby increasing energy consumption. If we solve the leakage problem, we will save a lot of energy.

Measures to Solve the Leakage

Regularly check the fiber laser air compressor system, especially the leaking points such as pipe connections, valves and joints, to ensure that there is no air leakage.
Use gas detection instruments (such as ultrasonic leak detectors) to identify and locate leaks and ensure timely repairs.
Maintenance and care: Establish regular maintenance and care plans to ensure that all equipment and pipelines are in good condition and reduce the occurrence of leaks.

2. Correct Use of Air

Some factories have a big misunderstanding in the way they use gas. In circuit board manufacturing, many manufacturers use air vibration to enhance the small hole plating capacity of plating lines. Although this method is effective in some cases, its energy consumption is usually more than ten times higher than that of electric vibration. The high energy consumption of using air vibration not only increases production costs, but may also lead to unnecessary energy waste and affect overall production efficiency.

Recommendations for Optimizing Gas Use

Factories should evaluate existing vibration methods and consider using electric vibration or other more efficient vibration technologies to reduce energy consumption.
Explore other technical alternatives, such as ultrasonic vibration, which may be more efficient and less energy-consuming in some applications.

3. Energy-Saving Transformation of Fiber Laser Air Compressors

There are three main ways to transform air compressors for energy saving

3.1 Variable Frequency Speed Regulation

Use variable frequency speed regulation to reduce the shaft power output of the air compressor motor. Before the transformation, when the air compressor pressure reaches the set pressure, it will automatically unload; after the transformation, the air compressor does not unload, but reduces the fiber laser air compressor's gas output by reducing the speed to maintain the lower pressure required for combustion. There are two places where energy can be saved:

• Reduce the power consumption caused by the sudden change of the compressor from unloading state to loading state.
• The motor operating frequency is reduced to below the power supply frequency, reducing the output power of the motor shaft.

The above two methods have reduced the energy consumption of the air compressor in operation to varying degrees, but the air compressor generates too much heat energy during operation, which is usually released into the air and not effectively utilized.

3.2 Centralized Control Method

Multiple fiber laser air compressors are centrally controlled to automatically control the number of laser cutting air compressor operations according to gas consumption. Before the transformation, the number of laser cutting air compressors turned on was fixed, and the laser cutting air compressor would consume electricity even when it was idling if the gas consumption was high. After the transformation, when the gas consumption is reduced to a certain level, the corresponding number of laser cutting air compressors can be stopped, reducing the number of laser cutting air compressors in operation, which undoubtedly saves electricity.

3.3 Air Compressor Heat Recovery

Air compressor heat recovery is a environmentally friendly and energy-saving method.

The fiber laser air compressor generates a lot of heat energy during operation, and the heat recovery system can recycle this heat energy.
Through the heat recovery system, the heat generated by the compressor is used to heat water or other process needs to improve energy utilization efficiency.

Summary

Energy saving of fiber laser air compressors is not only an effective means to reduce the operating costs of enterprises, but also an important measure to improve production efficiency, protect the environment and enhance the corporate image, helping enterprises to achieve higher energy efficiency and lower operating costs in actual operations.

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