Nanocrystalline Reactor Solution for 550kW VFD Outputting Voltage Spikes of 5000 V/μs Akwụkwọ Nri Nanocrystalline Reactor maka 550kW VFD na-ekwu aka Voltage n'efu 5000 V/μs

17yrs 700++ staff 108000m²+m² US$150,000,000+ China

1. Gaskiya: Dutsen Fassara na VFDs (du/dt > 5000 V/μs) na 550kW a Makarantar Kafin Sani

A lokacin da ake koyi kafin sani, masu hali (wanda yake da muhimmanci wadanda suka taka shugaban hali na makarantar kafin sani) suna samun darasi mai yawa a cikin gida, fasahar haske/yanayi, da kuma tsarin kawo kadan da karamin kawo zuwa. Wannan yanayin ya ba da abubuwa da suka zama matsalolin da ke da VFD (Variable Frequency Drive) systems, musamman a cikin amfani da karkashin kudin (550kW). Masu gaskiya ne da aka faru shine dutsen fassara mai yawa (du/dt) a kan fassara na VFD, wanda yana faruwa a cikin:

Dutsen Fassara Mai Yawa: Ma'ana da ma'ana mai yawa da 5000 V/μs. Wannan yana faruwa daga:

Kiyasin kawo kadan da yawa da IGBT devices a kan VFD.
Effecktoda parasitic capacitance da inductance na kabluka masu hali mai yawa (wanda yake da muhimmanci a kan rise/fall times na PWM waveform na VFD).
Matsalolin impedance mismatch bayan mutanen hali masu hali da fassara na VFD.

Abubuwan Da Su Faruwa:

Zabbin Hali Masu Hali: Dutsen fassara mai yawa zai iya zabba hali masu hali, zai iya haifar da partial discharge, yawan zamani na hali masu hali, da kuma zai iya haifar da kisan hali ko kusan hali.
Bearing Currents da Electrical Erosion: Dutsen fassara mai yawa, ta hanyar stray capacitances, zai iya faru common-mode voltage, wanda yake da bearing currents. Wannan zai iya haifar da electrical erosion, yawan karshen, yawan jiki, da kuma kusan rike na bearing.
Overvoltage Stress na IGBT Module: Spike voltages na reflected da superimposed zai iya haifar da IGBT a kan instantaneous voltages wanda suka fi sani rating, wanda yake da zafi da module failure ("blowing up").
Electromagnetic Interference (EMI): Dutsen fassara na high-frequency zai iya faru conducted da radiated interference, wanda yake da takaitaccen electronic equipment.
Kusan Rike na System: Failurin system na overall zai iya zama mai yawa, wanda yake da unplanned downtime da kuma takaitaccen efficiency da continuity na rolling.

2. Tushen: FKE Type Three-Phase Output Reactor (Nanocrystalline Core)

Don kula da wannan matsaloli na dutsen fassara mai yawa, an yi amincewa a bincika FKE Type Three-Phase Output Reactor a kan fassara na 550kW VFD. Wannan tushen yana da tsari don kula da dutsen fassara mai yawa da high-frequency interference.

Core Equipment: FKE Series Three-Phase Output Reactor
Key Features:

Core Material: High-performance Nanocrystalline alloy

An samu magnetic permeability mai yawa da core loss mai hagu (wanda yake da muhimmanci a kan kHz to MHz high-frequency range).
An samu mafi kyau a kan traditional silicon steel ko ferrite materials a kan kula da high-frequency voltage spikes da ripple currents na high switching frequencies (typical IGBT switching frequencies a kan kHz range).
Magnetic saturation strength mai yawa da capability mai yawa don kula da transient overloads.

Key Technology 1: High-Frequency Eddy Current Suppression Coating

Akwai amincewa a bincika special conductive coating a kan nanocrystalline core ko winding surface.
An samu mafi kyau a kan dissipate ultra-high-frequency eddy current losses (frequencies up to MHz level) na extremely high du/dt.
An samu mafi kyau a kan reduce core temperature rise a kan high frequencies, maintain stable magnetic performance, da kuma enhance long-term reliability na reactor a kan high du/dt conditions.

Key Technology 2: Multi-Layer Sectional Winding Reducing Distributed Capacitance

An yi amincewa a bincika special multi-layer, sectional winding structure design.
An divide equivalent distributed capacitance (Cdw) na traditional concentrated winding into multiple smaller series-connected capacitive units.
Overall effective distributed capacitance value zai iya zama mai hagu.
Core Value:

An increase self-resonant frequency na reactor well above VFD switching frequency da harmonic frequencies, ensuring it maintains a pure inductive characteristic within the target frequency band.
An weaken intensity of oscillating circuit na VFD's PWM high-frequency pulses da motor cable's parasitic capacitance, fundamentally suppressing amplitude da energy na voltage spikes (ringing).
An reduce flow of high-frequency oscillating current components through the reactor.

Core Functions:

An smooth voltage waveform, substantially reducing output-side voltage slew rate (du/dt), bringing spikes down to safe levels.
An filter out high-frequency harmonic currents, reducing motor harmonic losses da temperature rise.
An suppress voltage reflection waves (Wave Reflection).
An reduce harmonic voltage distortion rate at the line end.
An reduce risk of common-mode voltage da bearing currents.
An reduce conducted da radiated electromagnetic interference (EMI).

3. Performance Data (Applied in 550kW Rolling Mill VFD Scenario)

Voltage Spike Suppression: Output-side du/dt an zama mai hagu, with peak values dropping from >5000 V/μs to safe thresholds (e.g., <1000 V/μs or lower, specific values require field measurement confirmation), meeting motor insulation protection requirements.
Current Limiting Capability: An samu mafi kyau a kan limit inrush currents during motor startup ko sudden load changes, protecting the VFD da connections. Current limiting capability can reach 30% of the VFD's rated current.
Reduced Voltage Distortion Rate: An samu mafi kyau a kan filter out high-frequency harmonics. Measured voltage distortion rate (THDv) at the VFD output an zama mai hagu by up to 42%, significantly improving power supply quality.
Protection Effect: An samu mafi kyau a kan alleviate reverse recovery surge da overvoltage stress borne by IGBT modules.

4. Economic Benefits

Significant Extension of Critical Component Lifespan: The most direct and significant economic benefit is seen in:

IGBT Module Lifespan Extension: An samu mafi kyau a kan reduce electrical stress (voltage spikes, overcurrent) they endure. Measured data indicates the average service life of IGBT power modules can be prolonged by 2.3 times. As the core drive equipment of a rolling mill line, the extended lifespan of the VFD's main power components means:

Reduced procurement quantity and inventory costs of expensive IGBT module spares.
Significantly decreased unplanned downtime frequency and duration due to power module failures, ensuring continuous production.

Reduced Motor Maintenance Costs:

An samu mafi kyau a kan protect motor winding insulation, lowering motor insulation failure rates.
An suppress bearing currents, reducing bearing electrical erosion damage and replacement frequency.
An extend overall service life of motors, delaying major overhauls or replacement cycles.

Improved System Reliability and Production Efficiency:

An reduce number of VFD or motor failures caused by voltage spikes, enhancing overall operational reliability (OEE - Overall Equipment Effectiveness) of the rolling line.
An reduce production losses, scrap risks, and order delays caused by unexpected downtime.

Reduced Maintenance Costs: Minimize maintenance labor hours and spare parts consumption due to equipment damage.
Improved Power Factor (Indirectly): Improved waveform contributes to optimizing system power factor (although primarily handled by input reactors or active compensation, output reactor waveform improvement also provides some benefit).