Solusyon ng Intelligent Control Module para sa AC Contactor Voltage Sag Ride-Through

1. disenyo ng background at pagsusuri ng pangangailangan​
Sa panahon ng operasyon ng sistema ng kuryente, ang mga voltage sag—na may kaibahan sa biglaang pagbaba ng RMS voltage sa 10%–90% ng rated value na nagtatagal mula 10 ms hanggang 1 minuto—madalas nangyayari dahil sa pag-atake ng kidlat, short-circuit fault, o pagsisimula ng malaking kagamitan. Ang mga insidente na ito ay maaaring magresulta sa pagkawala ng kontak ng tradisyunal na AC contactor, na nagdudulot ng hindi inaasahang pagtigil sa patuloy na proseso ng produksyon at malaking ekonomiko na pagkawala.

Kahit na ilang solusyon ng intelligent control (halimbawa, high-voltage DC starting, PWM control) ang ipinroporsiyon, isang pangunahing limitasyon pa rin ang naiwan: ang pagkakalito sa integrasyon ng automatic module fault transition functionality kasama ang voltage sag ride-through capability. Upang tugunan ito, ginagamit ng solusyon na ito ang CDC17-115 AC contactor bilang kontrol target at nililikha ang isang intelligent control module na may fault redundancy upang mapanatili ang patuloy na produksyon kahit sa pagkakaroon ng pagkakamali ng module.

​2. prinsipyong paggana ng module at disenyo ng sistema​
​2.1 kabuuang logical na arkitektura ng operasyon​
Ang intelligent control module ay gumagamit ng dual-mode power supply design upang matiyak ang maasintas na operasyon sa iba't ibang kondisyon:

​2.2 teknikal na detalye ng pangunahing komponente​
​2.2.1 disenyo ng switching power supply​
Isang high-performance switching power supply ang nagsisilbing core power unit na may sumusunod na katangian:

• Core Architecture: Pulse-width modulation IC (switching frequency 132 kHz), MOSFET (MTD1N80E), espesyal na transformer (primary inductance 900 μH, leakage inductance 15 μH, turns ratio 0.11), at π-type output filter (L3, C2, C3)
• Multi-Protection Functions: Input overvoltage/undervoltage, output overvoltage/overcurrent/short-circuit/overheat protection, integrated soft-start and frequency jitter technology
• Performance:
• Stable load start-up time < 35 ms, supports rapid switching between ride-through and normal states
• Automatically limits power during short circuits and quickly stabilizes after fault clearance
• Triggers overvoltage protection and immediately shuts off PWM output upon feedback loop open

Table 1: Impact of Filter Parasitic Parameters on Short-Circuit Recovery Voltage

​2.2.2 disenyo ng fault transition circuit​
Isang bagong kombinasyon ng contact at contactless switches ang ginagamit:

• Structural Design: Contact switches handle full breaking and isolation functions for high-power switching; power electronic switches enable arc-free, high-frequency operation
• Intelligent Transition Logic:
• AC power is supplied via normally closed contacts during initial power-up
• Automatically switches to DC supply mode during normal operation
• Upon fault detection, deactivates the contact switch drive; resumes AC direct supply after reset to ensure continuity
• Contact Protection Technology: Uses a universal AC/DC absorption suppression circuit (diode RC + bidirectional TVS diode D3) to effectively clamp overvoltage, dissipate inductive magnetic energy, and significantly reduce arcing

​2.2.3 pag-optimize ng proseso ng transition​

• AC-to-DC Transition: Applies full-wave rectified pulsating voltage via power electronic switches, delays 10 ms before switching to low-voltage DC, effectively preventing core rebound; tested transition is smooth and vibration-free
• DC-to-AC Transition: Cuts off DC upon fault and intelligently introduces AC supply; arc energy is freewheeled through reverse diodes during transition, with phase-angle control to avoid voltage spike interference
• Parameter Optimization (based on simulation results):
• Resistors (R2, R3): Smaller resistance values result in slower voltage amplitude decay but do not affect transition phase angle
• Capacitors (C1, C2): Smaller capacitance values yield higher oscillation decay frequency (f = 174.7 Hz at C = 2 μF; f = 795.4 Hz at C = 0.1 μF)

​3. simulasyon at eksperimental na pag-verify​
​3.1 pagsusuri ng simulasyon​
Ang mga simulasyon ng sistema ay isinagawa gamit ang software na Multisim, kabilang dito:

• Switching power supply start-up characteristics and protection performance simulation
• Analysis of resistance, capacitance, and phase angle effects on voltage oscillation during transition
• Evaluation of parasitic parameter impacts on system stability

​3.2 eksperimental na pag-verify​
Ang mga test sa CDC17-115 AC contactor ay nakumpirma:

• Switching power supply no-load/full-load (50 A contactor) waveforms meet design expectations
• Protection mechanisms respond quickly and effectively under short-circuit/feedback open-circuit faults
• Transition processes are smooth, with no core vibration, and all functions meet design requirements

​4. pangunahing mga abilidad at konklusyon​

1. ​High-Performance Switching Power Supply: Compact size, high efficiency, and comprehensive protection functions significantly enhance electrical reliability, making it ideal for smart electrical applications.
2. ​Intelligent Fault Transition: Innovative design combining contact and contactless switches ensures timely switching to AC operation during module faults, guaranteeing continuous power supply to the contactor system.
3. ​Efficient Energy Management: Universal AC/DC absorption suppression circuit effectively converts overvoltage and arc energy during transitions into stable electromagnetic force, ensuring uninterrupted production.
4. ​Voltage Sag Ride-Through Capability: Automatically activates when system voltage drops to 60% of the rated value, maintaining reliable contactor pull-in to avoid unplanned shutdowns.

Ang solusyon na ito ay matagumpay na nag-integrate ng module fault transition at voltage sag ride-through functionality, nagbibigay ng napakareliable na power assurance solution para sa patuloy na proseso ng produksyon at epektibong nagbabawas ng downtime dahil sa voltage sags.