High frequency electroplating of electric heating tubes

High frequency electroplating of electric heating tubes

Theoretical analysis and practical experience indicate that the volume and weight of transformers, inductors, and capacitors in electrical products are inversely proportional to the square root of the power supply frequency. So when we increase the frequency from 50Hz to 20kHz, a factor of 400, the volume and weight of the electrical equipment will generally decrease to 5-10% of the designed power frequency. Both inverter rectifier welding machines and switching rectifiers used in communication power sources are based on this principle. Similarly, various DC power sources used in the traditional "rectification industry" such as electroplating, electrolysis, machining, charging, floating charging, and power switching can also be modified based on this principle to become "switch conversion power sources". Their main materials can be saved by 90% or more, and they can also save 30% or more electricity. Due to the gradual increase in the upper limit of the working frequency of power electronic devices, many traditional high-frequency devices that originally used electronic tubes have become solid-state, bringing significant economic benefits of energy conservation, water conservation, and material conservation, and reflecting the value of technological content.

3.2 Modularization

Modularization has two meanings: firstly, it refers to the modularization of power devices, and secondly, it refers to the modularization of power units. Our common device modules, consisting of one unit, two units, six units up to seven units, including switching devices and anti parallel freewheeling diodes, are essentially "standard" power modules (SPMs). In recent years, some companies have also incorporated the drive and protection circuits of switch devices into power modules, forming an "intelligent" power module (IPM), which not only reduces the size of the entire machine but also facilitates its design and manufacturing. In fact, due to the continuous increase in frequency, the impact of parasitic inductance and capacitance on the leads is becoming increasingly severe, causing greater electrical stress on the device (manifested as overvoltage and overcurrent burrs). In order to improve the reliability of the system, some manufacturers have developed "User Specific" Power Modules (ASPM), which install almost all the hardware of a complete machine in the form of chips into one module, eliminating the traditional lead connections between components. Such modules undergo strict and reasonable thermal, electrical, and mechanical design to achieve a perfect optimization. It is similar to user specific integrated circuits (ASICs) in microelectronics. As long as the control software is written into the microprocessor chip in the module, and the entire module is fixed on the corresponding heat sink, a new type of switching power supply device is formed. From this, it can be seen that the purpose of modularization is not only to facilitate use and reduce the overall size of the machine, but more importantly, to eliminate traditional wiring and minimize parasitic parameters, thereby minimizing the electrical stress borne by the device and improving the reliability of the system. In addition, high-power switching power supplies, due to the limitation of device capacity and the consideration of increasing redundancy to improve reliability, generally use multiple independent module units to work in parallel, using current sharing technology. All modules share the load current together. Once one module fails, other modules will share the load current equally. This not only improves the power capacity and meets the requirements of high current output with limited device capacity, but also greatly improves system reliability by adding redundant power modules with relatively low power compared to the entire system. Even in the event of a single module failure, it will not affect the normal operation of the system and provide sufficient time for repair.

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