Aiming to help bring about a responsible and sustainable society, Fuji Electric provides environmentally friendly products that can most efficiently use energy for social and industrial infrastructure and other various fields. In order to develop products that meet the needs of the market in a timely manner, it is essential to quantify physical phenomena, which form the basis of the functions and performance of products. As a powerful means to that end, we develop and exploit various simulation technologies.
This special issue presents the simulation technologies that support the product development of Fuji Electric.
[Preface] Mismatch Between Simulation and Experiment? Let’s Consider Mode Systems for Better Interplay
KOYAMA, Michihisa
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Simulation Technologies for Product Development: Current Status and Future Outlook
Along with the recent progress in computational science, simulation technologies have come to be widely used in various phases from R&D to product design. Fuji Electric also takes advantage of device simulation and molecular simulation to improve performance, analyze and estimate electrical characteristics and clarify phenomena at the atomic level of SiC devices. Moreover, we have reduced the cooling fan noise of electrical equipment, analyzed the internal arc discharge of switchgears, and optimized the design of showcases by applying simulation technologies such as electromagnetic noise analysis, acoustic noise analysis, and fluid analysis. With these technologies, we aim to offer high-performance, high-reliability products in short delivery times.
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Simulation Based Prediction of SiC Trench MOSFET Characteristics
The development of semiconductor devices that use SiC (silicon carbide) based materials has been increasing as a means of achieving further energy savings in power electronic products. SiC trench MOSFET are capable of reducing loss even more than conventional planar types. Fuji Electric is implementing simulation based characteristic prediction in order to improve the efficiency of new SiC device development. It is necessary to consider the newly utilized crystal surface characteristics for the simulation of the trench-type because the characteristics of SiC differ by its crystal surfaces. We have established a convenient method for incorporating the parameters into the simulation model, which enabled reproduction of actual observations and prediction of performance improvements.
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Development of SiC Bipolar Devices Using Simulation
MATSUNAGA, Shinichiro; TAKEI, Manabu
In SiC (silicon carbide) devices, which are wide band-gap semiconductors, bipolar devices are considered beneficial for achieving a high withstand voltage in excess of 13 kV. Fuji Electric has improved prediction accuracy by repeatedly adjusting parameters based on the analysis of differences between simulation predictions and actual results. We implemented withstand voltage characteristic simulations, forward characteristic simulations, and switching characteristic simulations, and then reflected the measured physical property values into the parameters, while also taking into account interface charges and parasitic resistance. As a result, we were able to reproduce with a high level of accuracy the characteristics of actual devices.
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Atomic Level Analysis of SiC Devices Using Numerical Simulation
HIROSE, Takayuki; MORI, Daisuke; TERAO, Yutaka
Research and development of power semiconductor devices with SiC (silicon carbide) has been very active because of the increasing need for low-loss power electronics equipment. The electrical properties of the SiC-metaloxide- semiconductor field-effect transistors (SiC-MOSFETs) are affected by charge trapping that is thought to be caused by the atomic level disorder at the interface between the gate oxide and SiC (SiC/SiO2 interface). In order to analyze the origin of the disorder at the interface, we have been implementing the atomic level analysis using both the X-ray photoelectron spectroscopy and the simulation based on the first principles calculations. As a result, we were able to estimate the chemical state of Si at SiC/SiO2 interface, as well as its terminated structure via nitrogen when the interface is nitrided.
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Study of Adhesion of Resin Materials by Molecular Simulation
OGASAWARA, Miki; TACHIOKA, Masaaki
Molecular simulation is a technology for evaluating the various properties of materials based on their molecular structure by using a computer. It has received attention as a method for speeding up the development of products. Semiconductor modules are being employed to an expanding range of applications such as industrial equipment and electric vehicle. In order to ensure high reliability, importance is placed on the adhesion of materials and resin. Against a backdrop of this, we implemented a study using molecular simulation for analyzing auxiliary agents for improving adhesiveness. We evaluated 2 types of adhesion assistants and elucidated molecular level mechanisms related to adhesion with aluminum.
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Residual Stress Distribution and Adhesive Interface Strength Analysis of Thermosetting Resin Molding
GANBE, Tatsuya; ASAI, Tatsuhiko; OKAMOTO, Kenji
The number of products sealed with a thermosetting resin such as semiconductor products has been increasing as the heat resistance and withstand voltage are improved and the size is miniaturized. Currently, structural design for products is being implemented using stress analysis based on CAE analysis in order to ensure reliability in products sealed with a resin. However, this type of analysis cannot predict resin cracks and interfacial peeling between the resin and component materials that cause failure. We have thus established a method for grasping curing behavior of thermosetting resin, a residual stress distribution analysis technology that can be utilized after curing has completed, and an evaluating technology for adhesive interface strength considering the adhering end distance. As a result, we can now construct structural design systems compatible with thermosetting resin sealing, thus enabling us to improve the reliability of products.
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Electromagnetic Noise Simulation Technology for Power Electronics Equipment
TAMATE, Michio; HAYASHI, Miwako; ICHINOSE, Ayako
Power electronics have been becoming more widely used as core products for achieving energy savings and energy creation. However, power electronics equipment may cause electromagnetic noise interference, such as communication failure and malfunction and damage of electronic equipment. For preventing electromagnetic noise interference caused by conduction noise and radiation noise, Fuji Electric has been developing various simulation-based technologies, including the improvement of the analysis accuracy of electromagnetic noise generated by power electronics equipment to comply with relevant regulations, analysis models from which we can select a simplified or detailed one depending on applications, and applications for power electronics systems in addition to that for single equipment.
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Aerodynamic Noise Simulation Technology for Developing Low Noise Products
The size reduction trend of electric power equipment causes increased heat generation density along with an accompanying need for increased airflow for cooling. In this situation, aerodynamic noise can be the dominant noise source for air-cooled electric equipment. Grasping the noise generation mechanism and the noise reduction by measurements are often difficult, getting physical information through simulation can be an effective approach. In order to achieve noise reduction of equipment, we elucidated the aerodynamic noise generating mechanism by focusing the fan, the main source of noise in air cooling equipment, and estimated noise change caused by cooling structure differences. Simulated sound pressure level and peak frequencies are in good agreement with the measurement. This technology can be applied to understand the noise generation mechanism, and can also be used to structure design.
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Analysis of Pressure Rise During Internal Arc Faults in Switchgear
ASANUMA, Gaku; ONCHI, Toshiyuki; TOYAMA, Kentaro
Switchgear include devices that play an important role in operations such as electric circuit switching and power measuring and monitoring, and IEC standards stipulate safety performance criteria regarding arc discharge (internal arc faults) in switchgear. Fuji Electric has developed an analysis technology for predicting pressure rise and pressure discharge performance during internal arc faults in order to design safe switchgear. By incorporating a pressure loss model in the vicinity of devices that discharge pressure and an arc model derived from the results of actual device testing, we have been able to implement highly accurate analysis. We have developed IEC standard compliant switchgear based on this analysis technology.
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Thermo-Fluid Simulation Technique for Achieving Energy Saving in Open Showcases
NAKAJIMA, Masato; ASADA, Tadashi
More than half of the electric power load in open showcases used in stores such as supermarkets and convenience stores is heat invasion that comes from the front opening of the displays. In order to save energy on the showcases, it is necessary to improve the performance of air curtains that suppress this heat invasion. Air curtain performance changes over time based on the impact of frost formation on the evaporator. Fuji Electric has developed a thermal-fluid simulation technique for elucidating this phenomenon, and based on this technique, we have developed a new air curtain system. Demonstration results achieved improved energy saving of more than 30% compared with conventional systems.
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Simulation Technologies Supporting Quality Improvement in Injection Molding
Plastic has excellent electrical insulation properties and is often utilized in various products due to its mechanical properties and characteristics. In order to improve the quality of plastic parts, Fuji Electric has utilized resin flow analysis to elucidate the quality and productivity issues that exist during the early stages of development. Furthermore, we have been reflecting our findings into the design of our products and molds. We have verified ease of assembly in consideration of warping by using the analysis results and a 3D printer, and as a result, we developed parts suitable for automated assembly in a short time. We have also utilized unsteady heat transfer analysis to optimize the temperature control circuit for molds and have significantly reduced the molding cycle. Furthermore, we have been working to estimate the fiber length of fiber-reinforced plastic, and are now able to determine the distribution trends of the fiber length that affects the strength of parts.
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.