How to control the start, stop and operating load of the motor supporting the BLEY4527-595-4KW cycloidal reducer

The core of controlling the start, stop and operating load of the motor supporting the BLEY4527-595-4kW cycloidal pinwheel reducer is to match the motor characteristics and the working condition requirements of the reducer to avoid start and stop impacts that damage transmission components and overload operation that shortens the life of the equipment. Specifically, precise control can be achieved through the three dimensions of electrical control, mechanical protection, and working condition optimization. The operation method is as follows:

1. Smooth control of motor start and stop (reduce impact load)

The reduction ratio of this reducer is 595, which is a large reduction ratio and low speed model. The instantaneous impact when the motor starts and stops will be amplified, which can easily cause the cycloidal wheel and pin tooth pin to break. The impact needs to be buffered through the following electrical and operating methods:

1. Electrical control scheme (recommended first)

(1) Install a frequency converter for speed regulation start

Choose a general-purpose inverter for the 4kW motor (adaptive motor power ≥5.5kW to avoid overload), set the soft start/soft stop parameters: set the start time to 5~10s, and set the stop time to 3~5s. By gradually increasing/lowering the frequency, the motor speed changes smoothly and eliminates the current impact and torque peak during hard start (the hard start torque peak can reach 2~3 times the rated value).

At the same time, low-frequency torque compensation (5~10Hz range) can be set to solve the 'stuck rotation' problem when starting a large reduction ratio reducer, ensuring sufficient and stable low-speed starting torque.

(2) Use star-delta (Y-Δ) step-down start

If speed regulation is not required, a star-delta starting cabinet can be used to control the motor starting current to 2 to 3 times the rated current (hard starting current is 5 to 7 times) to reduce the impact on the power grid and the starting load of the reducer.

Note: Star-delta starting is only suitable for no-load or light-load starting conditions (such as conveyors, feeders). If the equipment is started with load (such as mixers, elevators), frequency converters are preferred.

(3) Install a braking resistor (for frequent start and stop conditions)

If the equipment needs to start and stop frequently (such as packaging machinery, automated production lines), install a braking resistor on the side of the frequency converter to absorb the regenerated electric energy when the motor decelerates, avoid over-voltage tripping, and reduce the reverse impact load of the reducer.

2. Operation specification control

It is prohibited to start directly with a full load: Before starting, it is necessary to confirm that the equipment load is in an no-load or half-load state. For example, empty the material before starting the mixer, lower the hopper to a low position before starting the elevator, and then gradually load after starting.

Limit the start and stop frequency: This type of reducer has limited heat dissipation capacity. Frequent starts and stops (≥10 times/h) will cause the oil temperature to rise. The start and stop intervals need to be controlled to ≥5 minutes to avoid heat accumulation and damage to the lubrication system.