Low-inductance custom power resistors for energy technology
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- Time of issue:2022-01-07 17:57
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(Summary description)Centralized power generation technology is undergoing a revolution. Traditional power plants such as coal, gas and nuclear power plants are gradually being replaced by renewable, decentralized solutions such as wind, solar or biomass power plants. The latter type of power plants generally follow the same principle, that is to use renewable energy sources (solar, wind and biomass) and generate DC or AC voltage or current through one or more conversion processes. Since energy producers are decentralized, more and more electricity is no longer fed into high-voltage power systems, but into medium-voltage and low-voltage power systems. Therefore, in the future, there will be an increasing need for intelligent power system management using energy storage devices to meet peak load demands in a variable manner. The core components of these power plants are power converters capable of supplying the generated electrical energy to the power system or consumers in a synchronized manner and of suitable quality. Not only do these power plants place extreme demands on the individual components, but they also have to achieve a service life of around 20 years under harsh environmental conditions.
Low-inductance custom power resistors for energy technology
(Summary description)Centralized power generation technology is undergoing a revolution. Traditional power plants such as coal, gas and nuclear power plants are gradually being replaced by renewable, decentralized solutions such as wind, solar or biomass power plants. The latter type of power plants generally follow the same principle, that is to use renewable energy sources (solar, wind and biomass) and generate DC or AC voltage or current through one or more conversion processes. Since energy producers are decentralized, more and more electricity is no longer fed into high-voltage power systems, but into medium-voltage and low-voltage power systems. Therefore, in the future, there will be an increasing need for intelligent power system management using energy storage devices to meet peak load demands in a variable manner. The core components of these power plants are power converters capable of supplying the generated electrical energy to the power system or consumers in a synchronized manner and of suitable quality. Not only do these power plants place extreme demands on the individual components, but they also have to achieve a service life of around 20 years under harsh environmental conditions.
- Categories:Company News
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- Time of issue:2022-01-07 17:57
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Centralized power generation technology is undergoing a revolution. Traditional power plants such as coal, gas and nuclear power plants are gradually being replaced by renewable, decentralized solutions such as wind, solar or biomass power plants. The latter type of power plants generally follow the same principle, that is to use renewable energy sources (solar, wind and biomass) and generate DC or AC voltage or current through one or more conversion processes. Since energy producers are decentralized, more and more electricity is no longer fed into high-voltage power systems, but into medium-voltage and low-voltage power systems. Therefore, in the future, there will be an increasing need for intelligent power system management using energy storage devices to meet peak load demands in a variable manner. The core components of these power plants are power converters capable of supplying the generated electrical energy to the power system or consumers in a synchronized manner and of suitable quality. Not only do these power plants place extreme demands on the individual components, but they also have to achieve a service life of around 20 years under harsh environmental conditions.
In recent years, the focus of power converter development has shifted to higher power densities and higher switching frequencies of semiconductors. The first development makes it possible to improve the price/performance ratio, since the output power can be increased while keeping the system cost almost constant. The second development increases system efficiency because system losses are reduced due to the increase in switching frequency.
The power converter moves from the input side (left) to the consumer side (right) in the circuit diagram, and there is a resistor (RI) for limiting the charging current to protect the capacitor against interference. When energized, the resistor must accept a large amount of pulse energy. This energy flow or application of energy occurs for a short period of time during capacitive charging, and usually only once (during start-up and not periodic). This places special demands on the resistive technology used. Adiabatic boundary conditions exist because of the short duration of the pulses. Therefore, this energy is only applied to the active material of the resistor (acTIve material) and is not propagated throughout the resistor by thermal conduction.
Compared with thick film or thin film technology, wirewound resistors have a large effective mass and can therefore accommodate high pulse energies and continuous power. But low power converters use all resistive technology. These include SMD-MELF thin film resistors, LTO thick film resistors and the aforementioned wirewound resistors. For higher power, wirewound resistors in series or parallel can be combined as printed circuit board (PCB) components (G200, AC, RS, CW, FS and Z300). For powers above 50 W, there are many special wirewound resistors (such as GWK, GWS, CSxx, FST, FSE, EDGx, RSO and GBS series) or thick film resistors (such as LPS or RPS on heat sinks, due to the extremely diverse connection options, which can be mounted away from the PCB) are available.
After the AC voltage is transformed to a suitable voltage level, use the B6 bridge to adjust the AC voltage, and then use the inductor to suppress interference. On the one hand, the series connection of the DC link resistor (RDC) and the DC link capacitor is used to limit the charging current of the DC link capacitor. This current creates a relatively high, but infrequent, pulsed load. On the other hand, this series connection is used to suppress harmonics in the DC link circuit, which are equal to a continuous load (because of the continuously repeating pulse train). Therefore, the resistors used must be limited to withstand both continuous and pulsed power.
The latest power converters have the option of delivering capacitive or inductive reactive power to the power system or power consumers. This is accomplished by increasing or decreasing the DC link circuit voltage. This increase is achieved using an internal boost converter or directly at the input of the power converter. A chopper resistor (RBR) is used to reduce the DC link circuit voltage by converting excess electrical energy into heat. Power MOSFETs, IGBT modules or thyristors provide resistive switching functionality.
Power MOSFET and IGBT modules are capable of high-frequency switching operations, but thyristors only support low-frequency operation. These power switches connect chopper resistors when the DC link circuit voltage is in danger of exceeding the specified maximum value. After the DC link circuit voltage has dropped due to this operation, the chopper resistor is disconnected again. These chopper resistors are easy to install, have numerous connection options, and have a power dissipation of 100 W - 1000 W. A combination of chopper resistors and crowbar resistors is often found in this case. This combination makes it possible to fully dissipate the energy of the DC link into the resistor (RBR) in the event of a downstream component failure, preventing damage to the power converter. Here you can choose a steel grating or a steel plate resistance whose main component is steel. For these resistance types, a wide variety of alloy steel sheets have a ripple structure, and by cascading them, the resistance value, continuous power, pulse power and maximum surface temperature can be set as desired. The insulation between the steel plates can be made of ceramic or mica materials. In addition, these steel plate resistors have very low inductance, so there are no additional voltage spikes during switching.
Steel grating resistors (such as Vishay GREx) are suitable for high continuous power due to the natural convection cooling provided by their large surface or the use of fans. The maximum achievable heat dissipation is limited only by the available installation space and fan output in this case. But if more power is required with less insulation space, water-cooled resistors such as the Vishay WCR series can be used.
In addition to the limitations of transient input inrush current, filtering, and matching of the DC link circuit described, the DC voltage is converted to an AC voltage with variable frequency and pulse width by the H-bridge circuit shown. Filter resistors (RHF) and output capacitors in series are used to suppress harmonics on the output stage. In addition, RHF also has the function of limiting the charging current of the filter capacitor. Capped wirewound resistors such as the GWK and FVT series are suitable for filtering applications due to their ease of installation and their high pulse and continuous power. What sets this range apart is its robust glass insulation that is resistant to moisture and chemical cleaning materials. The GWK and FVT series can also easily achieve low inductance resistance. In this regard, there are two resistive wires wrapped around the resistive body in a double-stranded manner. According to the superposition principle, the magnetic fields generated by the counter-rotating currents cancel each other out.
Next up are the crowbar resistors (RCR) - if they haven't already been put into the DC link. As mentioned earlier, the role of this resistor is to prevent the surrounding components from being overloaded in the event of a failure.
The three resistors of RDC filter resistor, RBR chopper resistor and RHF filter resistor are of great help to the efficiency optimization of the optimized system. In the case of high-speed switching elements such as IGBTs or power MOSFETs, careful design of these resistors is necessary to achieve low inductance. Improper selection of resistors can result in resonant circuits due to parasitic inductance and capacitance. These circuits can generate voltage spikes that can overload or damage semiconductor components. In addition, parasitic inductance "rounds" the signal waveform, which makes it impossible to generate rectangular pulses with steep rising edges. In addition this has a negative impact on the power and efficiency of the overall circuit.
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Low-inductance custom power resistors for energy technology
Centralized power generation technology is undergoing a revolution. Traditional power plants such as coal, gas and nuclear power plants are gradually being replaced by renewable, decentralized solutions such as wind, solar or biomass power plants. The latter type of power plants generally follow the same principle, that is to use renewable energy sources (solar, wind and biomass) and generate DC or AC voltage or current through one or more conversion processes. Since energy producers are decentralized, more and more electricity is no longer fed into high-voltage power systems, but into medium-voltage and low-voltage power systems. Therefore, in the future, there will be an increasing need for intelligent power system management using energy storage devices to meet peak load demands in a variable manner. The core components of these power plants are power converters capable of supplying the generated electrical energy to the power system or consumers in a synchronized manner and of suitable quality. Not only do these power plants place extreme demands on the individual components, but they also have to achieve a service life of around 20 years under harsh environmental conditions.
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