In the plastics industry, managing energy consumption and eliminating harmonics are critical to ensuring the quality of finished products and the durability of equipment.
Fuji Electric offers an advanced, alternative solution to harmonic filters, with its PWM-APR power controllers, specially designed to meet the demanding needs of the manufacture of plastic and carbon-fibre articles and products.
This innovative technology optimizes energy efficiency while eliminating any harmonic signal, offering a double benefit for manufacturers: a significant reduction in costs and improved production.
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The plastics industry operates in an increasingly complex environment, marked by stringent regulatory requirements and growing pressure to adopt more sustainable practices.
Harmonic current emissions represent a major challenge for plastics and carbon fiber manufacturers. These electrical disturbances can not only affect the quality of finished products, but also compromise the reliability of industrial equipment, leading to frequent breakdowns and high repair and maintenance costs.
In 2019, the European Union has redefined the EN61000-3-2 standard to impose stricter limits on harmonic current emissions. This change to the standard guarantees a high-quality power supply and protects industrial equipment from damage caused by these forms of disturbance.
For companies, complying with these regulations has become not only a legal obligation, but also an economic imperative to avoid the high costs associated with production interruptions and emergency repairs.
At the same time, energy issues have become crucial in a context of rising energy prices and growing demand for greener production. Reducing energy consumption is no longer just a question of profitability, but also of environmental responsibility.
Companies are looking to reduce their carbon footprint, a goal that involves optimizing every aspect of production, including harmonic management.
Harmonic currents are electrical disturbances that appear as distortions in the normal sine wave of alternating current.
These distortions are mainly generated by the non-linear loads present in production systems, such as the use of variable frequency drives, switch-mode power supplies, and the complex electronic controls used in the plastics industry.
The presence of these non-linear components creates harmonics that affect both current and voltage in electrical systems, disrupting overall plant performance.
In the plastics industry, where process precision is crucial, harmonics can have devastating effects. Harmonic distortions impair the quality of the power supply to the heating and temperature control equipment essential to the manufacture of plastics and carbon fibers.
These disturbances can cause overheating, temperature fluctuations and inaccurate control, compromising the quality of finished products.
The consequences of these problems are manifold. Inaccurate temperature control can lead to significant variations in plastic properties, increasing scrap rates and reducing production profitability.
Moreover, harmonic currents generate additional energy dissipation in the form of heat, reducing the overall energy efficiency of systems and increasing production costs. This energy inefficiency translates into a higher carbon footprint, a result contrary to sustainability objectives and current environmental standards.
The challenge for plastics manufacturers is therefore twofold: how to eliminate harmonic currents and attenuate harmonic distortions to improve product quality and extend equipment life, while complying with energy and regulatory requirements?
Faced with these challenges, Fuji Electric's PWM-APR power controllers offer a state-of-the-art solution.
Designed to eliminate harmonic currents, these controllers stabilize supply voltages and offer precise temperature control, essential for maintaining the quality of finished products.
By optimizing electrical system performance and reducing harmonic distortion, these controllers enable plastics manufacturers to improve energy efficiency, reduce maintenance service costs and meet the most stringent quality and durability standards.
Fuji Electric's non-harmonic PWM-APR power controllers offer an innovative response to the challenges posed by non-linear loads in industrial systems, without the need to install a costly anti-harmonic filter or active filter.
By providing a perfect sine wave, these regulators effectively eliminate the harmonic distortions often generated by complex loads and production networks.
This advanced filtering capability significantly reduces reactive power, avoiding the need for active filters or harmonic filters, which can be costly and complex to install.
The integration of the PWM-APR power controller also enables extremely precise temperature control, a crucial element in guaranteeing the properties of plastics and carbon fibers. By stabilizing the temperature close to the set point, the controller minimizes fluctuations that could damage products during the manufacturing process. This translates into reduced total harmonic distortion (THD) in control systems. This ensures better voltage uniformity and more consistent quality of finished products, limiting losses and increasing customer satisfaction.
The Fuji Electric power controller plays a key role in simplifying maintenance and extending the service life of industrial equipment. By eliminating harmonic currents and reducing harmonic distortion in the system, it reduces the risk of overheating and breakdowns, resulting in a significant reduction in the need for costly technical interventions. The absence of active harmonic filters in the system also reduces installation costs, offering companies a more cost-effective solution right from the start of integration. This approach not only optimizes the electrical network, but also ensures greater voltage stability, which is essential for the smooth operation of sensitive equipment.
The PWM-APR power controller's impact on energy consumption is just as significant. By optimizing power utilization and improving the energy efficiency of industrial processes, this controller helps manufacturers reduce their energy consumption.
This translates into lower total harmonic distortion and better utilization of the voltages available in the system. This gain in efficiency contributes to more sustainable and economically viable production, as part of a global eco-design approach.
The aim is to minimize the environmental footprint while maximizing profitability, reducing energy costs and increasing equipment durability through efficient harmonic filtering without the added complexity of anti-harmonic filters.
In short, Fuji Electric's SCR power controllers offer a complete solution that meets the current needs of the plastics industry: eliminating harmonics, optimizing energy performance, and improving product quality, while simplifying maintenance and reducing overall costs.
Suppression of harmonic currents
Reducing consumption
Improved precision
Simplified maintenance
Cost reduction
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