Friday, March 29, 2024
HomeElectronicsPower ElectronicsPower converters more efficient in end-of-line functional testing

More efficient power converters in end-of-line functional testing

4
(2)

The energy transition, driven by the continued electrification of industrial consumption, electric mobility and renewable power generation, has led to the rapid deployment of energy conversion systems.

The growing demand for high-efficiency power converters is more and more stringent, requiring a careful procedure both at the design stage and during component production.

To meet these requirements, Prima Electro installed a regenerative system on all inverter production lines to test each product at the end of the assembly process.

These regenerative systems allow the Final Functional Test (FFT) to be performed, verifying the proper functioning of all inverter components to minimize the risk of early failures in the field.

Thanks to this solution, the quality level in Prima Electro's production processes has proven to be highly reliable and high-performing at all times.

Over time, the growing demand for inverters of increasingly larger power sizes has led Prima Electro to develop a new line of converters, with which a power rating of 265kVA is reached, but encountering the relative difficulties in efficiently testing products of such power ratings.

In fact, during the first regenerative end-of-testing performed for this new family of inverters, a number of issues arose that no longer allowed the pre-existing production lines to function properly.

The regenerative system has begun to draw high-frequency currents. These current components are termed "distorted" and can cause an overall increase in the current drawn from the grid, overheating of electrical system components, unwanted tripping of line protection devices, and electromagnetic interference, resulting in malfunction of nearby connected electronic devices.

It was necessary to carry out end-of-line tests at half the rated power of the manufactured inverters to reduce the current drawn from the grid.

To overcome this limitation, Prima Electro has developed an Active Power Filter
(Active Power Filter - APF), connected directly to the plant network, in parallel with each production line, capable of actively compensating for the high-frequency currents produced by the regenerative system.

By installing APFs on the various lines, Prima Electro has increased the quality of the production plant's mains voltage by reducing the harmonic content of the absorbed current.

In addition, the installation of the Active Power Filter has improved grid quality and system utilization, making the electrical systems comply with the latest international standards reported in IEEE 519 and IEC 61000-3-4.

The new generation of inverters is currently being tested on FFT at rated power, and there was no need to modify the existing electrical system, as the current drawn on each production line was reduced by 80% (145Arms vs 30Arms).

During its normal operation, the APF also acts as a power factor correction device, capable of reducing the reactive power absorbed from the grid.

Unlike classical passive power factor correction methods based on the installation of bulky capacitor banks,APF allows real-timepower factor adjustment.

Losses in the various line components such as cables and transformers are thus minimized, current draw from the grid reduced, and oversizing of plant protection devices is not necessary.

For further information click here

How interesting did you find this article?

Average rating 4 / 5. Number of ratings: 2

No ratings yet! Be the first to rate this item.

Register on Elettronica TECHtoo !
Here are the exclusive benefits for registered users:
- FREE Electronic Lab Collection Ed. 1
- FREE subscription to Elettronica AV magazine
- receipt of real-time updates
- ability to review and comment on articles
SIGN UP NOW!

LATEST NEWS

PARTNER

MARKET

SOCIAL

IN EVIDENCE

Register on Elettronica TECHtoo !
Here are the exclusive benefits for registered users:
- FREE Electronic Lab Collection Ed. 1
- FREE subscription to Elettronica AV magazine
- receipt of real-time updates
- ability to review and comment on articles
SIGN UP NOW!