Industrial Solutions Contributing to Environmental Protection and Productivity Improvement
Industrial Solutions Contributing to Environmental Protection and Productivity Improvement
[Purpose]
Fuji Electric has been engaged in the development of innovative energy and environmental technologies so that it can help mitigate pressing worldwide issues surrounding the protection of the global environment and socially contribute to both suppliers who create energy and consumers who use energy.
In the field of industrial solutions introduced in this special issue, we have been making use of power electronics technology in our efforts to harmonize environmental protection and productivity from the standpoint of energy consumers.
We will introduce products and systems in all fields related to plants and production facilities, including factory automation related products that contribute to automation, labor savings and energy savings; measuring instruments and sensors that provide safety and security through environment visualization; and transportation system products that contribute to reducing environmental burdens and facilitate the safe operation of railroads as major transportation systems.
[Preface] Today’s Major Challenges and Solutions
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FUJIMOTO, Yasutaka
Industrial Solutions Contributing to Environmental Protection and Productivity Improvement: Current Status and Future Outlook
Currently, power electronics technology has attracted attention as a key technology that is capable of supporting the foundations of social and industrial infrastructure, while also accelerating environmental protection activities and measures on a global scale.
Fuji Electric has been working to efficiently utilize energy so that it can help harmonize global environmental protection measures with productivity improvements that contribute to social and industrial development in each field of the industry solutions introduced in this special issue.
In this paper, we will describe solutions that make use of the latest power electronics technologies in combination with general industrial and plant facility drive systems, measuring instruments and rolling stock equipment that contribute to the fields of factory automation, process automation, and environment and social solutions.
FA Solution That Applies IoT and Motion Control Technology
The rapid development of smart manufacturing technologies has created the need to further improve productivity and create and maximize added values as FA solutions for the manufacturing industry. Fuji Electric has made use of IoT technologies to achieve quality traceability solutions, capable of improving productivity and reducing costs on automobile manufacturing assembly lines. In addition, we have also developed a motion control technology that makes use of high-performance controllers for the packaging lines of food factories. Those technologies make it possible to achieve stable sealing regardless of the packaging speed, as well as optimize control for packaging machine systems.
“FRENIC-eFIT” Environmentally Resistant Inverter Designed for Harshest Installation Conditions
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YOSHIDA, Toshihiro; TAKUBO, Hiromu; SATO, Keisuke
Inverters have been increasingly used in various industrial fields and are sometimes required to endure harsh environmental conditions without being installed in a controlboard. Fuji Electric has developed the “FRENIC-eFIT”as an environmentally resistant inverter especially designed for harsh installation conditions. In addition to protecting electronic components with a totally-enclosed enclosure that adopts a fanless cooling system, the unit has also eliminated thermal issues by utilizing SiC devices, which have characteristics of low-loss and heat resistance.Furthermore, we have applied our developed elemental technologies to mitigate high-speed switching noise while utilizing the technological know-how and fi eld test results of Fuji Electric products to improve environmental resistance reliability.
“FRENIC4800VM6” Medium-Voltage High-Capacity Inverter with Water-Cooling System Designed to Meet Various User Needs
When revamping high-capacity inverters used as major equipment in plants, customers place a heavy emphasis on products that incorporate advanced control function and fulfilling user support tools. The “FRENIC4800VM6” medium- voltage high-capacity inverter with water-cooling system was designed to enhance plant control function and expand output frequency over previous products to achieve better productivity and yield for a wide range of high-quality products. Furthermore, featuring a large programmable operation display and renovated user support functions such as a loader function, the inverter helps users reduce the amount of sophisticated and labor-intensive maintenance work, while also contributing to the overall stability of plant operations.
Plant Operation Support System That Helps Transfer Skills and Improve Productivity
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YOSHIKAWA, Yuzuru; WATANABE, Daisuke; INOUE, Akio
In industrial plant operations, major challenges involve transferring skills and improving productivity. To help solve these two tasks, Fuji Electric has decided to redesign its previously developed plant support system to match current monitoring control systems. As a result, The monitoring control system of target facilities can be connected through a general-purpose interface to support operation. This development also makes it possible to share personal operator skills and to standardize operator knowledge and a skill level, helping users to transfer skills. Moreover, standardizing operating procedures and operation that are independent on operators improves productivity.
Latest Electrical Equipment and Drive Control Systems for Bar and Shape Rolling Mills Outside Japan
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OGAI, Fumikazu; KAWAGUCHI, Teppei
Bar and shape steel rolling mills are constantly required of stable operations. Thus the equipment needs high information processing capability and high speed control to improve productivity, as well as highly accurate processing to increase yield. Fuji Electric has delivered electrical equipment and drive control systems for use in the rolling mills of combined mill plants outside Japan. To achieve high productivity and stable operations, its control systems, mainly comprise inverters and controllers, are interlinked with high precision via high-speed networks. Moreover, to provide timely support from Japan, remote maintenance support systems are installed in the systems to continuously collect and inspect operating and control data.
World’s Smallest SOX Removal Cyclone Scrubber for Marine Vessels
The exhaust gas of marine vessels contains a high concentration of sulfur oxide (SOX), which from the viewpoint of protecting the environment, has become a worldwide problem. Most SOX scrubbers that desulfurize exhaust gas are large in size, and there has been increasing demand for more compact ones. In this respect, cyclone types have the advantage of being smaller in size, but their desulfurization performance in general is inferior to other types of scrubbers. Fuji Electric has developed the world’s smallest cyclone SOX scrubber with high level desulfurization performance and has demonstrated that the scrubber is capable of being used in emission control areas through field tests on ships. Downsizing a SOX scrubber will facilitate its prevalence, allowing low-priced high-sulfur fuel oil to be used continuously. This could contribute to reducing the operating cost of shipping companies that support international logistics.
Radiation Management Solutions Contributing to Environmental Protection
Fuji Electric offers radiation management solutions and radiation measurement equipment that contribute to environmental protection activities involving radiation and/ or radioactive contamination. We have developed an environmental monitoring service using IoT environmental monitors, radiation spectral survey meter with a strontium iodide scintillator, and atmospheric monitor that can monitor radioactive aerosol in atmosphere in real time. We also have developed radiation measurement equipment for earthquake reconstruction: a radioactive aerosol monitor in exhaust gas from the temporary incineration facilities and a radioactive soil sorting equipment to sort contaminated soil produced from decontamination activities based on the radioactive concentration in the intermediate storage facilities.
Passenger Door System for Series E235 Train of East Japan Railway Company (Yamanote Line) Designed to Improve Transportation Quality
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TSUJIMURA, Isao; UMEZAWA, Kotaro; FUJITA, Kenji
Electric door systems for rail cars are motor-powered devices for opening and closing passenger doors in accordance with the door operations of crew members. Fuji Electric has delivered rack-and-pinion type door systems to East Japan Railway Company for the Series E235 train (Yamanote Line), which started operation. The door system uses less permanent magnets than conventional products, thus reducing overall weight by 14%. Furthermore, by reducing the number of parts and adjustment points, the system reduces maintenance costs and failure rates. Moreover, by changing the type of locking device, the system achieves better obstruction pulling and anti-forced opening characteristics. Additionally, by improved control sequencing, the system is increased in sensitivity of obstruction detection and dragging detection.
A long standing customer that tested several competitors’ products over a decade ago, chose a Fuji Electric product that not only meets their application criteria, but exceeded their expectations regarding: performance, quality and reliability for their commercial mixer product lines.
As their standard of choice, our AC Drives continue to surpass expectations as our product models offer the versatility and flexibility required for any demanding environment. Fuji Electric AC Drives prove to be technically superior compared to other products offered in the market. Our compact design, 3-year warranty, and exceptional torque features is ideal for many recipe requirements that make Fuji Electric their sole supplier for all of their AC drives needs.
Our products are designed to operate in 50 deg C ambient under full load conditions with no derating factor. The VFDs also maintains a UL rating under single phase power input. Fuji Electric’s ECO-DY model has a standard feature of a simultaneous control of Pump pressure and water table level control. This feature will control a pump’s output pressure and automatically switch to water table level control when the level sensor goes below an adjustable threshold. This prevents costly dry run damage to the submersible pump.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed for Agriculture Irrigation control. For this case, the ECO-DY model achieves the control by switching between two PID loops. Throughout this process, the first loop, PID1, will control the output pipe pressure. The second loop, PID2, controls the water table level. There is a sensor threshold and time that controls the switching between PID1 or PID2. One of the PID sensors will need to be a 0-10v signal and the second will need to be a 4-20ma input.
Fuji Electric VFDs are a tough, rugged and designed to operate in the harsh conditions of the oil field. Our VFDs are used in thousands of Oil field pump jack applications. For this Oil Field application, they run in 50 deg C ambient at full power without derating.
In this application, our VFDs provided the standard capability to overcome the regeneration portion of the pump jack cycle without needing braking resistors. Our VFD accurately senses the regenerative energy created by the beam pump and precisely increases the speed to eliminate the need for a braking resistor.
Peter Pugger is the world’s leading manufacturer of mixing extruders (pugmills). With the growing demand to mix and extrude new and innovative products, Peter Pugger machines require versatility and efficiency as it relates to motor control, speed control, soft start/stop and remote capability. The utilization of Fuji Electric's FRENIC-Mini and FRENIC-ACE drives has allowed their systems to maintain product quality, durability and performance. The durability of our Fuji Electric drives and the three-year warranty has established our drives as the drive of choice for all of our units. With thousands of machines worldwide, Fuji Electric’s dependability has played a key role in their success.
H2O Technologies is a high quality, highly innovative OEM Control Panels fabricator that specializes in the engineering, designing and building of Bypass Control Panels for hydraulic pump related industries that construct fountains, waterfalls and municipal pools. Fuji Electric’s FRENIC -Eco and EcoPAK Bypass Panels quickly became H2OTechnologies’ exclusive offering due to its high quality, product adaptability, and superb technical & support staff. “We have discovered a hidden gem working with Fuji Electric; it’s their ability to take us back to better days, when there was less bureaucracy, where management decisions and issues resolution were local and only a phone call away. That is a “game-changer” that sets them far apart from almost every other large organization”, exclaims Greg Sills, PPX Central’s President & CEO.
Fuji Regenerative Blowers are used to provide Air agitation for Plating, Cleaning and Rinse Tanks. They can provide high amounts of air at low pressures. They offer the advantages of clean, oil-free air that does not deliver any contaminants to foul or spoil the tank fluid. Fuji Regenerative Blowers offer a form of agitation without any moving parts in the bath. Blowers require no lubrication and that means no contaminated chemical baths. Fuji Blowers are dependable and reliable devices with no wearing, rubbing or sliding components.
Fuji Electric Power Semiconductors are used in Wind Turbines of major Wind Turbine Manufacturers. The PrimePACK™ 3+ improves power conversion efficiency to reduce power loss and increase output power. Amid the beautiful and expansive natural landscape of northern Denmark, you can see lines of wind turbines. These wind turbines use our large-capacity IGBT module PrimePACK™ 3+. In this wind power generation, the force of wind spins the blades of the wind turbine, which in turn rotates the generator to generate electricity. In order to feed this electricity into transmission lines, the voltage and frequency must be changed, and that power conversion is where our power semiconductors play a vital role.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed to run Electric Submersible pumps (ESPs) in the Oil Field. They operate in 50 deg C ambient under full load conditions with no derating factor. VFDs also maintain a UL rating under single phase power input.
For ESPs, Fuji Electric’s FRENIC-Mega is packaged in a Nema 3R enclosure along with a sine wave filter that feeds a step up transformer to create the high voltage needed for the special ESP motor. The ESP motor is sometimes thousands of feet down in the well bore. Some ESP motors are induction style while others are permanent magnet style. The Fuji Electric FRENIC-Mega works on both types of ESPs. Fuji Electric's VFD has a special feature that allows motor base voltage at speed to be adjusted while monitoring current for maximum operating efficiency thus saving valuable electrical power operation costs.
Significant levels of refrigerants and heating are needed to slow down spoilage and maintain preharvest freshness and flavor of ripe fruit and vegetables. Fuji Electric Variable Frequency Drives (VFD) make it possible to quickly provide the necessary cooling or heating to maintain a uniform temperature, humidity, air-circulation or fresh air requirements in cold storage while at the same time the energy consumption is reduced to a minimum. In standard system designs, electric motors are intended to operate at a fixed speed. This speed is determined by the frequency of the power supply and the motor design (number of poles).
The shaft load on the motor is determined by the product of shaft speed and torque. With a fixed speed, motor power is determined by the torque of the load. With a change in speed the motor load will not only benefit from the speed reduction, but also any reduction in torque with speed. Two types of motor load exist; constant torque and variable torque.
VFDs give better control and more efficiency for compressors, fans and pumps:
VFD speed control will reduce the power penalty associated with slide valve, poppet valve or throttling capacity control. On compressors with no capacity control speed control will eliminate other poor control strategies.
VFD speed control provides dramatic fan power reductions at reduced speed. This also translates into reduced motor heat loads in refrigerated spaces.
VFD speed control provides dramatic fan power saving relative to fan cycling
For maintenance of AC Drives, it is best to institute a schedule of routine maintenance which includes cleaning of the drives and their heatsinks. This prevents overheating and also prevents other debris from being lodged inside the drive!
Scheduling a Freight Pick Up
A customer was given incorrect information for scheduling a freight pick up and the terms for shipping the item. The shipment was delayed and stuck in a freight branch location. This led our team to coordinate communications between several stakeholders (Customer, Logistics Company, End User, and the freight company shipping the order). Information had to be confirmed for accuracy and ease of understanding to avoid confusion or delays. Our team at Fuji Electric was able to keep the customer informed of status regularly and get the info needed in order to resolve the issue and get the order completed.
Meeting Production Schedules
Due to material challenges, in order to meet our customer's production schedule, our team members participate in weekly meetings, provide status and shipping updates, and facilitate direct shipments from our factories. It requires daily attention and time management skills to keep track of multiple avenues to achieve delivery. However, there is a great sense of satisfaction knowing we are part of a team doing everything possible to meet their expectations!
Critical Need of Our Parts
An auto supplier was in critical need of parts or they go line down. Our team called members from Fuji Electric Japan's shipping team and got them to move an ocean orders to air drop ship to customer. No lost downtime!
Did you also know Fuji Electric Corp. of America (FECOA) was established in 1970? Fuji Electric Corp. of America is happy to celebrate over 50 years in the United States! Fuji Electric now aims to become a leading-edge company in “energy and the environment” by building upon our core platform of five technology fields which unlock the potential of electricity—energy, industrial systems, social systems, power electronics, and electronic devices.
Industrial Laundry Solutions
Fuji Electric’s FRENIC-Ace model, Variable Frequency Drives (VFDs) are commonly used in commercial laundry equipment for their ability to control the speed of electric motors. In the context of commercial laundry, VFDs are often employed in various machines and systems to enhance efficiency, reduce energy consumption, and provide better control over operations. Here are some ways VFDs are utilized in commercial laundry equipment.
Motor Control: Can regulate the speed of electric motors in washers, dryers, extractors, and other laundry equipment. By adjusting the motor speed according to the load and operational requirements, VFDs help optimize energy consumption and extend the lifespan of the equipment.
Energy Efficiency: Enable soft starts and stops, reducing the energy demand during motor acceleration. They also allow for precise control of motor speed, preventing unnecessary energy consumption when full speed is not required. This contributes to energy savings and overall operational efficiency.
Customized Washing Cycles: In laundry equipment, different fabrics and loads may require varying levels of agitation, spin speed, or drying time. VFDs provide the flexibility to customize washing cycles by adjusting motor speeds, ensuring that each load is treated appropriately.
Load Balancing: Used to balance loads in commercial laundry systems. In situations where multiple machines are connected to a common power supply, VFDs help distribute the load evenly, preventing overloads and optimizing the use of available power.
Maintenance Benefits: By controlling motor speed and providing real-time performance data, VFDs can contribute to predictive maintenance strategies. Monitoring motor parameters allows for early detection of issues, reducing downtime and preventing costly equipment failures.
Environmental Compliance: The ability of VFDs to control motor speed based on demand aligns with energy efficiency requirements and environmental regulations. Using VFDs in commercial laundry equipment helps businesses meet sustainability goals and adhere to energy efficiency standards.
In summary, Variable Frequency Drives play a crucial role in enhancing the performance, energy efficiency, and operational flexibility of commercial laundry equipment. They contribute to cost savings, reduce environmental impact, and improve the overall reliability of laundry systems.