In the plastics industry, managing energy consumption and suppressing harmonics are critical issues to ensure the quality of finished products and the durability of equipment.
Fuji Electric offers an advanced, alternative solution to harmonic filtering devices with its SCR power controller PWM-APR, specially designed to meet the demanding needs of the manufacture of plastic and carbon fiber products.
This innovative technology optimises energy efficiency while suppressing any harmonic signal, offering a dual benefit to manufacturers: a significant reduction in costs and an improvement in production.
The plastics industry is operating in an increasingly complex environment, marked by strict regulatory requirements and growing pressure to adopt more sustainable practices.
Harmonics 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 quality power supply and protects industrial equipment from damage caused by any voltage distortion.
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 as energy prices continue to rise and demand for greener production increases. Reducing energy consumption is no longer just a question of profitability, but also of environmental responsibility.
Companies are looking to reduce their carbon footprint, an objective that involves optimising 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 presence of linear and nonlinear loads in production systems, including the use of variable speed drives, switch-mode power supplies, and complex electronic controls commonly found in the plastics processing sector.
The interaction between these linear and nonlinear components creates harmonics that affect both current and voltage in electrical systems, disrupting the overall performance of the devices.
In the plastics industry, where process accuracy is crucial, power harmonics can have devastating effects. Harmonic distortions lead to a deterioration in the quality of the power supply to the heating and temperature control equipment essential to the manufacture of plastics and carbon fiber.
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 the properties of plastic materials, increasing scrap rates and reducing the profitability of production.
In addition, 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, which is 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?
Fuji Electric's SCR power controllers PWM-APR offer a state-of-the-art solution to these challenges.
Designed to suppress the voltage harmonics, these controllers stabilise supply voltages and provide precise temperature control, essential for maintaining the quality of finished products.
By optimising electrical system performance and reducing harmonic phase distortion, these SCR controllers enable plastics manufacturers to improve energy efficiency, reduce maintenance service costs and meet the highest standards of quality and durability.
Fuji Electric's non-harmonic power controllers PWM-APR offer an innovative response to the challenges posed by non-linear loads in industrial power systems, without the need to install a costly anti-harmonic filter or active filter.
By providing a perfect sine wave, these load controllers effectively eliminate the harmonic distortions that are often generated by complex loads and production networks.
This advanced filtering capability significantly reduces reactive power, avoiding the need to install active filters or an anti-harmonic filter, 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 stabilising the temperature close to the set point, the controller minimises fluctuations that could damage the products being manufactured.This results in a reduction in the frequency and 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.
Fuji Electric's power controller plays a key role in the power frequency, simplifying maintenance and extending the life of industrial equipment.By eliminating harmonic frequencies and reducing harmonic voltage distortions, in the power 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 installation also reduces installation costs, offering companies a more cost-effective solution right from the start of integration.This approach not only optimises the electrical distribution systems and network, but also ensures greater voltage stability, which is essential for the smooth operation of sensitive equipment.
The power controller's impact on energy consumption is just as significant. By optimising the use of power and improving the energy efficiency of industrial processes, this controller helps manufacturers to reduce their energy consumption.
This translates into a reduction in total harmonic distortions and better use of the voltage and current available in the system. This gain in efficiency contributes to more sustainable and economically viable production, as part of an overall eco-design approach.
The aim is to minimise the environmental footprint while maximising profitability, reducing energy costs and increasing the durability of equipment thanks to efficient harmonic filtering without the added complexity of anti-harmonic filters.
In summary, Fuji Electric power controllers offer a complete solution that meets the current needs of the plastics industry: eliminating harmonics, optimising 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
APPLICATIONDownload your application sheet and eliminate harmonic currents with temperature control !
