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FST-650L 4-D Variable-Speed Inverter Retrofit on Zinser 451 Ring Frame: 50% Fewer Ends-Downs, 8% Energy Saving, 7-Month Payback

Views: 1523 Author: Site Editor Publish Time: 2025-09-10 Origin: Site

Introduction: While the 480-spindle Zinser 451 was still using a "one-size-fits-all" 55 Hz hard start, Sunshine Spinning was plagued by 28 ends-downs per thousand spindles per hour, high noise levels, and high energy consumption.
We turned the "inverter" into its "heartbeat"—the FST-650L four-dimensional variable speed drive—allowing each yarn to follow its own unique S-curve: zero-tension spinning, zero-waste doffing, a low noise level of 68 dB, and a payback period of seven months.
The following 12 months of actual test data demonstrates how an old lathe can be rejuvenated with the "four heartbeats."

Customer Snapshot

Mill: *** Co., Ltd.**
480-spindle Zinser 451 ring frame, Ne 80 compact yarn, 100 % cotton

The Challenge

End-break rate at 55 Hz: 28 breaks / 1 000 spindle-h
5 % waste yarn per doff (manual low-speed “creep” stage)
High noise (82 dB) & lint-clogged inverters → monthly failure
Rising energy & labour cost, only two operators for the frame

AnyHZ Solution

Retro-fit: **FST-650L** 4-D flexible-speed inverter (book-type, 70 mm)
Plug-in replacement of existing 37 kW scalar drive, 0-modification wiring.

Four-Heartbeat Speed Curve (embedded “S-curve Automatic Blending”)

Uniform 8 Hz – zero-tension start → –45 % end-breaks
Low 20 Hz – 3 s waste-free spinning → –60 % waste yarn
Medium 35 Hz – soft tension build → –15 % CVm
High 55 Hz – full package speed → +12 % output
Transition time ≤ 0.1 s, invisible to eye, no extra breaks.

Technology Inside

0.5 Hz pulse-free vector, 150 % torque at 1 Hz – no stall
32-bit DSP + textile PID, real-time bobbin-diameter compensation, tension ±2 %
Triple noise suppression → 68 dB at 1 m
Conformal-coated PCB + isolated air duct, 10 000 h stable with 3 mm lint

One-Click Process Package

Power-on → select count Ne 6-120 → confirm.
Auto-matched speed steps, S-curve, PID.
32 custom recipes Cloud-backup, batch change in 10 s.

Measured Gains (12-month run)

8 % energy saved → 30 000 CNY electricity / year
End-breaks –50 % → single operator (–60 000 CNY labour)
Mechanical shock –70 %, spindle-bearing life ×1.8

Pay-back: 7.2 months

Installation Timeline

Day 1: power off → remove old drive → slide in FST-650L → quick-connect terminals → Modbus RTU auto-link with PLC
Day 1 evening: 30 min commission, same-day production restart

Customer Quote

“The frame now sings in four heartbeats instead of coughing in three. We pack fuller packages, burn fewer kWh, and the operator finally took off his ear-plugs.”
— Mr. Zhou, Production Manager

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