Analysis and Solutions for Inverter Overheating: A Comprehensive Guide

 Analysis and countermeasures of inverter overheating problem

Abstract:

        This article focuses on the problem of overheating of the inverter, and digs into the multiple reasons behind it, including environmental factors, heat dissipation system failure, load conditions, internal component abnormalities, and installation and maintenance defects. In view of these causes, a series of practical countermeasures are proposed, including improving the operating environment, strengthening heat dissipation management, reasonable selection and configuration, accurate fault diagnosis and treatment, and improving the quality of installation and maintenance, aiming to provide comprehensive technical guidance and practical reference for ensuring the stable and efficient operation of the inverter.

 一、Introduction

        In the industrial field, frequency converters are widely used, but overheating problems affect their operation and life. According to statistics, inverter failures are mostly related to overheating, resulting in production interruptions and economic losses. Therefore, it is important to explore the root cause of the overheating and develop a strategy. (Baidu hot search words: inverter application field, inverter fault statistics, industrial equipment stability)

二、the reason for the overheating of the inverter

 1 Environmental factors

（1）High temperature environment

        For example, if the steel smelting workshop exceeds 40°C in summer, it exceeds the suitable range of -10°C to 50°C for the inverter, and the heat is difficult to dissipate, causing the temperature to rise and cause failure. (Baidu hot search words: the working temperature range of the inverter, the impact of the high temperature environment on the inverter)

        1、Poor ventilation: Closed narrow cabinet or surrounding equipment obstruction, such as the layout of the power distribution room is compact, the air circulation is limited and the heat dissipation is blocked. (Baidu hot search words: inverter ventilation design requirements, cabinet ventilation and inverter heat dissipation)

        2、Excessive dust: Dust in the cement and mining industries is easy to block the heat sink, like the accumulation of dust in the cement production workshop, which reduces the heat exchange efficiency and causes the temperature to rise sharply. (Baidu hot search words: industrial dust is harmful to the inverter, and the inverter heat sink is cleaned)

 (2) Failure of the cooling system

        Cooling fan problem: The failure of the motor, bearing, and capacitor causes the fan to slow down or stop, such as overheating and damage to the generator during long-term operation, causing the inverter to overheat. (Baidu hot search words: inverter cooling fan failure causes, cooling fan maintenance points)

        1、Heat sink blockage: Dust, oil and other dirt increase thermal resistance, and the corrosion layer formed by corrosive substances also reduces heat dissipation performance. (Baidu hot search words: heat sink blockage detection method, heat sink cleaning tool)

 (3) Reasons for the load

        1、Heavy load: When the rated capacity is exceeded, the current increases, the power loss increases, and the heat is generated, such as overload operation caused by selection errors or process changes. (Baidu hot search words: inverter load matching principle, the impact of overload operation on inverter)

        2、Load abrupt change: The impact load of stamping and crushing equipment causes the current to change instantaneously, and the fault is caused by the inertial call flow of the circuit over the large heat production. (Baidu hot search words: impact load and inverter protection, load mutation response strategy)

(4) Internal component failure

        1、IGBT module fault: short circuit or open circuit affects the current and causes heat, and high-voltage and high-current scenarios are prone to overheating due to impact damage. (Baidu hot search words: IGBT module fault detection, IGBT module maintenance precautions)

        2、Other component failure: Capacitance leakage and resistance changes make the circuit abnormally heated, such as electrolytic electricity is easy to age and fail at high temperatures. (Baidu hot search words: inverter capacitance fault performance, resistance fault impact on inverter)

(5) Improper installation and maintenance

        1、Installation is not standardized: The screws are not tightened and vibrate, which loosens the electrical connection, hinders heat dissipation, and may also cause electrical sparks to interfere with the circuit. (Baidu hot search words: inverter installation specifications, improper installation hazards)

        2、Lack of regular maintenance: If it is not cleaned and maintained, dust and debris will accumulate, and hidden dangers such as lack of oil in fan bearings will be difficult to find, increasing the risk of overheating damage. (Baidu hot search words: inverter regular maintenance cycle, maintenance project list)

 三、measures to deal with the overheating of the inverter

 (1) Improve the operating environment

        Reduce ambient temperature: Air conditioners or air coolers can be installed in high-temperature places, constant temperature and humidity air conditioners can be used in electronic workshops, and air coolers can be used in general places. (Baidu hot search words: industrial air conditioning selection and the application of inverters and air coolers in the environmental control of inverters)

        1、Optimize ventilation conditions: Choose a good ventilation location and reasonably design the cabinet ventilation, such as up and down or front and rear ventilation, and you can also install ventilation ducts. (Baidu hot search words: cabinet ventilation design case, ventilation duct installation points)

        2、Reduce dust pollution: Dust covers, cabinets and filters are installed in dusty environments, cleaned and replaced regularly, and explosion-proof and dust-proof cabinets and purification systems are used in coal mines. (Baidu hot search words: dust cover material and selection, air filter replacement cycle)

(2) Strengthen the maintenance and management of the heat dissipation system

        1、Check and replace the cooling fan: Regularly check the speed, sound, etc., detect with professional tools, clean, lubricate or replace the motor when abnormal, and change it once every 1-2 years. (Baidu hot search words: cooling fan speed standard, fan fault diagnosis tool)

        2、Clean the heat sink: Clean it with a compressed air spray gun or detergent to avoid damage, dry it after cleaning and then use it, blow it simply every month, and clean it fully every quarter. (Baidu hot search words: heat sink cleaning steps, precautions for the use of detergent)

(3) Reasonable selection and configuration

        1、Accurate calculation of load: Considering the load type, power and other factors, the appropriate torque output inverter is selected for the constant torque load, and the capacity and energy-saving mode are selected according to the characteristics of the fan and pump. (Baidu hot search words: different load types and inverter selection, inverter capacity calculation method)

        2、Consider load characteristics: shock load reactor or filter, frequently start the load selection response fast, high torque inverter and set the parameters. (Baidu hot search words: inverter configuration of impact load, frequent start load parameter setting)

 (4) Fault diagnosis and timely treatment

        1、Monitoring operation status: real-time monitoring of temperature, current and other sensors, over-threshold alarm, remote monitoring and analysis with intelligent monitoring system. (Baidu hot search words: inverter sensor selection, intelligent monitoring system function)

        2、Quickly locate the fault: check the fault record and alarm information, use the instrument to measure the internal circuit components after the appearance inspection, and repair it according to the results. (Baidu hot search words: inverter fault diagnosis process, electrical test instrument use method)

 (5) Improve the quality of installation and maintenance

        1、Standardize the installation process: operate according to the instructions, check the site environment, install firmly, the electrical connection is correct and reliable, and the ground is grounded. (Baidu hot search words: inverter installation site requirements, electrical connection specifications)

        2、Establish a regular maintenance system: set a cycle according to the environment and operation time, monthly inspection, quarterly comprehensive maintenance, annual in-depth maintenance and record filing. (Baidu hot search words: inverter maintenance file management, regular maintenance project implementation)

 IV. Conclusion

        The overheating of the inverter is caused by many factors, and corresponding measures can be taken to reduce the probability of failure. Enterprises should pay attention to the construction of a management system to ensure operation, and pay attention to the development of heat dissipation and monitoring technology to improve performance and reliability. (Baidu hot search words: summary of inverter overheating prevention, industrial equipment reliability improvement strategy)