[Purpose]
Today, power electronics is a key technology in all areas where energy is“ created,”“ connected” or“ used,” from social infrastructure that supports lifelines to home appliances. There are also high expectations of it bringing about a low-carbon society through high-efficiency conversion in energy creation such as mega-solar power plants and energy saving in motor drives, and so on.
Fuji Electric has developed and provided to society products that make full use of power electronics technology for various electromotive power based equipment, transportation and logistics infrastructure, as well as uninterruptible power systems for data centers that support Internet society.
This issue provides an outline of power electronics equipment applying SiC (silicon carbide) power devices to dramatically improve efficiency and reduce size and weight, fundamental technology in power electronics technology development, and international standardization for the global market.
Preface to the Special Issue on “Power Electronics”
Johann W. Kolar
Professor, Swiss Federal Institute of Technology Zurich
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Power Electronics: Current Status and Future Outlook
TOMOTAKA, Masatsugu
Power electronics technology and its applied products are widespread in all fields of society and also raising expectations as means to realize energy conservation. Meanwhile, the environment surrounding power electronics equipment is undergoing great changes as shown by the advent of SiC power devices, which are expected to lead dramatic advances in power electronics equipment in place of the conventional silicon devices, and requirements for compliance with international standards in the global market. In order to meet these diverse development needs and support the acceleration of development, Fuji Electric is working on product development by utilizing platforms and the establishment of a development environment that makes full use of advanced simulation technology. In addition, Fuji Electric is developing and offering power electronics equipment intended for various fields such as motor applications, rotating machines, transport equipment and power supply equipment, including the development of products that utilize SiC power devices.
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Mega Solar PCS Incorporating All-SiC Module “PVI1000 AJ-3/1000”
OSHIMA, Masafumi; MAEDA, Tetsuya; MURATSU, Hiroki
In recent years, solar power generation has come to need greater power generation performance. Power conditioning sub-systems (PCSs) are the core of the generation, and they require high efficiency, reliability to continue to generate electricity, and a reduction of total cost. Fuji Electric has developed a highly efficient PCS for mega-solar plants by incorporating an All-SiC module consisting of silicon carbide metal-oxide-semiconductor fi eld-effect transistors (SiC-MOSFETs) and SiC Schottky barrier diodes (SiC-SBDs), which are the next-generation semiconductors.
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Large-Capacity, High-Efficiency 3-Level UPS for North America “7000HX-T3U”
KAWASAKI, Daisuke; HAMADA, Ippei; SATO, Atsushi
Due to the development of information and communications systems in the information society in recent years, the data center market is expanding both in Japan and abroad. At the same time, there are increasing needs for uninterruptible power systems (UPSs) to ensure stable system operation. “7000HX-T3U,” which has been developed for the North American market, is a large-capacity, high-efficiency UPS using a 3-level power conversion circuit with a rated voltage of 480 V. By using Fuji Electric’s original AT-NPC 3-level insulated gate bipolar transistor (IGBT) module, the UPS has achieved a maximum efficiency of as high as 97%. It provides high reliability, as with the conventional models, and also supports UL and NEC standards which must be complied with in North America.
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General-Purpose Inverters Meeting Global Standards, “FRENIC-HVAC/AQUA Series” and “FRENIC-Ace Series”
KONO, Hiroyuki; MIGAKI, Takumi; KAIMI, Takashi
In recent years, general-purpose inverters have been required to be multi-functional. Even in the areas where dedicated controllers or specialized variable speed drives were conventionally used, in an increasing number of cases customized general-purpose inverters are being adopted. The demand for product globalization is also increasing. To satisfy these needs, Fuji Electric has developed the “FRENIC-HVAC/AQUA Series” and “FRENIC-Ace Series” general-purpose inverters that meet global standards. These products are supporting our globalization by featuring a customized logic function as standard and introducing multi-language support and region codes. They also comply with international standards regarding noise immunity and functional safety.
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690-V Inverters Equipped with SiC Hybrid Module, “FRENIC-VG Stack Series”
SATO, Kazuhisa; TAKANO, Makoto; NOMURA, Kazuki
Fuji Electric offers 690-V stack type of the “FRENIC-VG Series” that has the highest-level performance in the industry. The 690-V inverters have seen high demand from the marine industry, overseas chemical plants, mining and water treatment facilities and their conventional capacities were between 90 and 315 kW. Now capacities from 355 to 450 kW have been added to the lineup. Incorporating a SiC hybrid module with low power dissipation prevents the product from becoming larger due to capacity enlargement, and keeps the product width to 220 mm. Connecting multiple stacks in parallel makes it possible to drive multi-winding motors up to 2,700 kW. Having a direct parallel connection enables large-capacity single-winding motors to be driven up to 1,200 kW.
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Fuji Electric’s Top Runner Motor – Loss-Reduction Technology of “Premium Efficiency Motor”
TACHI, Norihiro; KOIBUCHI, Hirobumi; TAKAHASHI, Kazutoshi
Motors are a key component indispensable for social and industrial activities. They consume electric power that accounts for nearly 40% of the global energy consumption. Consequently, improving motor efficiency is a challenge for the major countries of the world. In Japan, the Top Runner Program was introduced in April 2015 to regulate motor efficiency. The “Premium Efficiency Motor” that Fuji Electric has developed satisfi es the efficiency regulation value through various loss-reduction technologies including an optimized slot shape and the adoption of magnetic steel that dissipates less power. This is an environmentally friendly product achieving low noise as well as high efficiency.
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Inverter-Integrated Motor
UTSUNO, Makoto; MATSUI, Kohei
Recently, energy saving by improving motor efficiency and adopting variable speed control systems have come to be accelerated. Fuji Electric has developed an inverter-integrated motor, which incorporates inverter functions into a motor. In addition to adopting a high efficient motor, variable speed operation with inverter control achieves signifi – cant energy saving effect. Moreover, it achieves downsizing by the incorporation. The energy-saving effect amounts to a reduction of 45% (1,923 kWh per year) from standard motors with IE1 class efficiency and 43% (1,742 kWh per year) compared to IE3 “Premium Efficiency Motors.”
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Technologies to Reduce Size and Weight of Power Electronics Equipment for Rolling Stock
TAKIZAWA, Masamitsu; NISHIJIMA, Tomotaka
Recently, there have been strong demands for power electronics equipment mounted on devices and units to be installed in rolling stock to have a smaller size, less weight and also to save energy. Fuji Electric has been meeting these demands by improving its cooling and equipment mounting technologies. For isolation transformers, which had limitations in terms of their downsizing, we have adopted a medium-frequency isolation circuit technology and direct current power supply system and implemented an optimized design to reduce the ratio of their installation space to the unit volume, thereby realizing further size and weight reduction. We offer in Japan and overseas power electronics equipment that uses the latest technologies such as propulsion systems and auxiliary power supplies for rolling stock including the Shinkansen
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Latest Trend and Safety and Reliability Technology of Rolling Stock Doors
TUMEZAWA, Kotaro; TERASAKI, Tomio; INATAMA, Shigeki
Fuji Electric has developed and commercialized a door operating equipment (linear motor system and FCPM system) with a simplified mechanism by applying the motion direction of a motor to the linear motion of the side sliding door. The door operating equipment for the side sliding door of rolling stock is an important component that ensures the safety of passengers when they are boarding, alighting and traveling, and it may affect trains’ punctuality. Consequently, the system is required to be safe, reliable, high functional, and maintenance saving. These characteristics have been achieved in a safety evaluation that was conducted at the design stage and that included failure mode effect analysis and hazard analysis, and they have also been ensured with control technologies such as triple feedback, external force suppression and push-back control.
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Railway Static Power Conditioner for Shin-Kurobe Substation of Hokuriku Shinkansen
OSO, Hiroshi; KANEKO, Tomomi; SUZUKI, Akio
Fuji Electric has delivered a railway static power conditioner (RPC) to Shin-Kurobe Substation, located between Nagano and Kanazawa on the Hokuriku Shinkansen Line. This equipment is composed of an inverter and an inverter transformer. While the trains run, it compensates for the unbalanced load in 3 phases and voltage fluctuation by interchanging power between two circuits in the direction of Nagano and Kanazawa. It also compensates for the harmonic current generated by trains. We developed a high-capacity downsized inverter by engaging a water-cooling system and equalizing the current sharing of insulated gate bipolar transistors (IGBTs). We adopted a gapless transformer for the inverter transformer to achieve low-noise level and high reliability.
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Multifunctional On-Shore Power Systems for Harbors and Shipyards
MIYASHITA, Tsutomu; UMEZAWA, Kazuyoshi; JOICHI, Hiroshi
In recent years, even in the maritime and shipbuilding industries, reduction of environmental impact has come to be required. To meet that issue, Fuji Electric has developed a multifunctional on-shore power system equipped with both power supply functions for the on-board power systems and load testing functions for the on-board generator. Since this system is installed outdoors, we examined its placement to make maintenance easy and give it an effective cooling system and decided to install the main facilities in a container of use outdoors. The containers can be connected in parallel so that it is easy to enlarge the capacity. The facility’s characteristic control functions include abilities to supply power to on-board power systems at the desired voltage/ frequency and to conduct a load test for the on-board generators via load resistor or power regeneration.
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Simulation Technology for Power Electronics Equipment
MATSUMOTO, Hiroyuki; TAMATE, Michio; YOSHIKAWA, Ko
As there is increasing demand for higher efficiency and power density of the power electronics equipment, it has become more important to develop the equipment by connecting the design of wiring structure, cooling structure and electromagnetic interference (EMI), which were previously designed individually. Fuji Electric is working on the realization of such a connection by using a device simulation model. This simulation model makes it possible to understand the switching characteristics after the implementation into circuits. In addition, the simulation result can effectively be applied to the design of the other components. Since it is now possible to estimate the temperature of a component and an EMI noise level precisely at the beginning of the design stage, the cooling structure and EMI filters can be developed effectively shorter period than before.
A long standing customer that tested several competitors’ products over a decade ago, chose a Fuji Electric product that not only meets their application criteria, but exceeded their expectations regarding: performance, quality and reliability for their commercial mixer product lines.
As their standard of choice, our AC Drives continue to surpass expectations as our product models offer the versatility and flexibility required for any demanding environment. Fuji Electric AC Drives prove to be technically superior compared to other products offered in the market. Our compact design, 3-year warranty, and exceptional torque features is ideal for many recipe requirements that make Fuji Electric their sole supplier for all of their AC drives needs.
Our products are designed to operate in 50 deg C ambient under full load conditions with no derating factor. The VFDs also maintains a UL rating under single phase power input. Fuji Electric’s ECO-DY model has a standard feature of a simultaneous control of Pump pressure and water table level control. This feature will control a pump’s output pressure and automatically switch to water table level control when the level sensor goes below an adjustable threshold. This prevents costly dry run damage to the submersible pump.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed for Agriculture Irrigation control. For this case, the ECO-DY model achieves the control by switching between two PID loops. Throughout this process, the first loop, PID1, will control the output pipe pressure. The second loop, PID2, controls the water table level. There is a sensor threshold and time that controls the switching between PID1 or PID2. One of the PID sensors will need to be a 0-10v signal and the second will need to be a 4-20ma input.
Fuji Electric VFDs are a tough, rugged and designed to operate in the harsh conditions of the oil field. Our VFDs are used in thousands of Oil field pump jack applications. For this Oil Field application, they run in 50 deg C ambient at full power without derating.
In this application, our VFDs provided the standard capability to overcome the regeneration portion of the pump jack cycle without needing braking resistors. Our VFD accurately senses the regenerative energy created by the beam pump and precisely increases the speed to eliminate the need for a braking resistor.
Peter Pugger is the world’s leading manufacturer of mixing extruders (pugmills). With the growing demand to mix and extrude new and innovative products, Peter Pugger machines require versatility and efficiency as it relates to motor control, speed control, soft start/stop and remote capability. The utilization of Fuji Electric's FRENIC-Mini and FRENIC-ACE drives has allowed their systems to maintain product quality, durability and performance. The durability of our Fuji Electric drives and the three-year warranty has established our drives as the drive of choice for all of our units. With thousands of machines worldwide, Fuji Electric’s dependability has played a key role in their success.
H2O Technologies is a high quality, highly innovative OEM Control Panels fabricator that specializes in the engineering, designing and building of Bypass Control Panels for hydraulic pump related industries that construct fountains, waterfalls and municipal pools. Fuji Electric’s FRENIC -Eco and EcoPAK Bypass Panels quickly became H2OTechnologies’ exclusive offering due to its high quality, product adaptability, and superb technical & support staff. “We have discovered a hidden gem working with Fuji Electric; it’s their ability to take us back to better days, when there was less bureaucracy, where management decisions and issues resolution were local and only a phone call away. That is a “game-changer” that sets them far apart from almost every other large organization”, exclaims Greg Sills, PPX Central’s President & CEO.
Fuji Regenerative Blowers are used to provide Air agitation for Plating, Cleaning and Rinse Tanks. They can provide high amounts of air at low pressures. They offer the advantages of clean, oil-free air that does not deliver any contaminants to foul or spoil the tank fluid. Fuji Regenerative Blowers offer a form of agitation without any moving parts in the bath. Blowers require no lubrication and that means no contaminated chemical baths. Fuji Blowers are dependable and reliable devices with no wearing, rubbing or sliding components.
Fuji Electric Power Semiconductors are used in Wind Turbines of major Wind Turbine Manufacturers. The PrimePACK™ 3+ improves power conversion efficiency to reduce power loss and increase output power. Amid the beautiful and expansive natural landscape of northern Denmark, you can see lines of wind turbines. These wind turbines use our large-capacity IGBT module PrimePACK™ 3+. In this wind power generation, the force of wind spins the blades of the wind turbine, which in turn rotates the generator to generate electricity. In order to feed this electricity into transmission lines, the voltage and frequency must be changed, and that power conversion is where our power semiconductors play a vital role.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed to run Electric Submersible pumps (ESPs) in the Oil Field. They operate in 50 deg C ambient under full load conditions with no derating factor. VFDs also maintain a UL rating under single phase power input.
For ESPs, Fuji Electric’s FRENIC-Mega is packaged in a Nema 3R enclosure along with a sine wave filter that feeds a step up transformer to create the high voltage needed for the special ESP motor. The ESP motor is sometimes thousands of feet down in the well bore. Some ESP motors are induction style while others are permanent magnet style. The Fuji Electric FRENIC-Mega works on both types of ESPs. Fuji Electric's VFD has a special feature that allows motor base voltage at speed to be adjusted while monitoring current for maximum operating efficiency thus saving valuable electrical power operation costs.
Significant levels of refrigerants and heating are needed to slow down spoilage and maintain preharvest freshness and flavor of ripe fruit and vegetables. Fuji Electric Variable Frequency Drives (VFD) make it possible to quickly provide the necessary cooling or heating to maintain a uniform temperature, humidity, air-circulation or fresh air requirements in cold storage while at the same time the energy consumption is reduced to a minimum. In standard system designs, electric motors are intended to operate at a fixed speed. This speed is determined by the frequency of the power supply and the motor design (number of poles).
The shaft load on the motor is determined by the product of shaft speed and torque. With a fixed speed, motor power is determined by the torque of the load. With a change in speed the motor load will not only benefit from the speed reduction, but also any reduction in torque with speed. Two types of motor load exist; constant torque and variable torque.
VFDs give better control and more efficiency for compressors, fans and pumps:
VFD speed control will reduce the power penalty associated with slide valve, poppet valve or throttling capacity control. On compressors with no capacity control speed control will eliminate other poor control strategies.
VFD speed control provides dramatic fan power reductions at reduced speed. This also translates into reduced motor heat loads in refrigerated spaces.
VFD speed control provides dramatic fan power saving relative to fan cycling
For maintenance of AC Drives, it is best to institute a schedule of routine maintenance which includes cleaning of the drives and their heatsinks. This prevents overheating and also prevents other debris from being lodged inside the drive!
Scheduling a Freight Pick Up
A customer was given incorrect information for scheduling a freight pick up and the terms for shipping the item. The shipment was delayed and stuck in a freight branch location. This led our team to coordinate communications between several stakeholders (Customer, Logistics Company, End User, and the freight company shipping the order). Information had to be confirmed for accuracy and ease of understanding to avoid confusion or delays. Our team at Fuji Electric was able to keep the customer informed of status regularly and get the info needed in order to resolve the issue and get the order completed.
Meeting Production Schedules
Due to material challenges, in order to meet our customer's production schedule, our team members participate in weekly meetings, provide status and shipping updates, and facilitate direct shipments from our factories. It requires daily attention and time management skills to keep track of multiple avenues to achieve delivery. However, there is a great sense of satisfaction knowing we are part of a team doing everything possible to meet their expectations!
Critical Need of Our Parts
An auto supplier was in critical need of parts or they go line down. Our team called members from Fuji Electric Japan's shipping team and got them to move an ocean orders to air drop ship to customer. No lost downtime!
Did you also know Fuji Electric Corp. of America (FECOA) was established in 1970? Fuji Electric Corp. of America is happy to celebrate over 50 years in the United States! Fuji Electric now aims to become a leading-edge company in “energy and the environment” by building upon our core platform of five technology fields which unlock the potential of electricity—energy, industrial systems, social systems, power electronics, and electronic devices.
Industrial Laundry Solutions
Fuji Electric’s FRENIC-Ace model, Variable Frequency Drives (VFDs) are commonly used in commercial laundry equipment for their ability to control the speed of electric motors. In the context of commercial laundry, VFDs are often employed in various machines and systems to enhance efficiency, reduce energy consumption, and provide better control over operations. Here are some ways VFDs are utilized in commercial laundry equipment.
Motor Control: Can regulate the speed of electric motors in washers, dryers, extractors, and other laundry equipment. By adjusting the motor speed according to the load and operational requirements, VFDs help optimize energy consumption and extend the lifespan of the equipment.
Energy Efficiency: Enable soft starts and stops, reducing the energy demand during motor acceleration. They also allow for precise control of motor speed, preventing unnecessary energy consumption when full speed is not required. This contributes to energy savings and overall operational efficiency.
Customized Washing Cycles: In laundry equipment, different fabrics and loads may require varying levels of agitation, spin speed, or drying time. VFDs provide the flexibility to customize washing cycles by adjusting motor speeds, ensuring that each load is treated appropriately.
Load Balancing: Used to balance loads in commercial laundry systems. In situations where multiple machines are connected to a common power supply, VFDs help distribute the load evenly, preventing overloads and optimizing the use of available power.
Maintenance Benefits: By controlling motor speed and providing real-time performance data, VFDs can contribute to predictive maintenance strategies. Monitoring motor parameters allows for early detection of issues, reducing downtime and preventing costly equipment failures.
Environmental Compliance: The ability of VFDs to control motor speed based on demand aligns with energy efficiency requirements and environmental regulations. Using VFDs in commercial laundry equipment helps businesses meet sustainability goals and adhere to energy efficiency standards.
In summary, Variable Frequency Drives play a crucial role in enhancing the performance, energy efficiency, and operational flexibility of commercial laundry equipment. They contribute to cost savings, reduce environmental impact, and improve the overall reliability of laundry systems.