Engine mounts, chassis parts, and machined components for assembly lines.
High-strength fasteners, landing gear parts, and structural assemblies.
Forged housings, armor brackets, and mission-critical structural parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Busbar holders, battery pack parts, and lightweight structural enclosures.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Large welded frames, PEB structures, and assemblies for industrial equipment.
Designed to protect internal components from dust, moisture, and impact in demanding environments.
Engineered to create strong, leak-proof connections between pipes, valves, and equipment.
Built to move liquids or gases with consistent flow and pressure control.
Developed to precisely manage the flow, direction, or pressure of fluids.
Produced by forcing material through a die to achieve exact shapes and dimensions.
Converts alternating current voltage levels through electromagnetic induction for efficient power distribution.
Provides a flexible, insulated pathway for safe transfer of electrical current to devices.
Uses coiled conductors to store energy and control current in electrical circuits.
Transmits electrical power or signals with optimized conductivity and insulation integrity.
Delivers high-current flow through rigid, low-resistance conductive metal strips in power systems.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Frigate CNC Machining offers high-precision, custom solutions for complex casting geometries. Multi-axis capabilities ensure tight tolerances and optimal surface finishes.
Sheet metal fabrication uses laser cutting, punching, and bending for precision.
Frigate Sheet Metal Fabrication utilizes advanced laser cutting and press brake technology for custom casting applications. Tight tolerances, superior welds, and high-strength materials ensure structural integrity.
Injection molding produces high-precision parts with consistent quality.
Frigate Injection Molding delivers custom-engineered parts with micron-level precision and structural integrity. Specialized molds maintain tight tolerances for complex geometries and high-stress applications.
Precision casting ensures accurate, high-quality parts.
Forging services improve material strength with precise tolerances.
Frigate Casting Services provides custom casting with tight tolerances and complex geometries. We enhance material properties using advanced metallurgy, ensuring strength and wear resistance. Our precision methods support high-performance aerospace, automotive, and industrial applications.
End-to-end part production from samples to bulk supply.
Ready-to-use assemblies built to exact fit and function.
Heavy-duty fabrication with high-strength materials for demanding applications. Robust welding for maximum structural durability.
Capacitor banks connected in parallel without proper impedance balancing are prone to internal circulating currents. These currents are not externally visible but contribute to accelerated insulation degradation, dielectric heating, and uneven aging. Balancing reactors are calculated to create an inductive voltage drop proportional to the flowing current, effectively damping inter-bank current oscillations. Reactance values are selected based on the rated current, frequency, and capacitor tolerance spread to ensure that the maximum current deviation remains within ±5% under all operating conditions.
High-order harmonics present in industrial environments can interact with capacitor banks to form resonant circuits, especially at the 5th, 7th, or 11th harmonic. The inclusion of a balancing reactor modifies the parallel resonance frequency of each bank and decouples them from each other, reducing the risk of harmonic amplification. This tuning ensures the system avoids harmonic resonance near known distortion frequencies and contributes to overall network impedance shaping.
Capacitor overheating typically results from excessive RMS current, often originating from unequal reactive current sharing. Balancing reactors reduce RMS deviation by limiting high-frequency transient and steady-state inter-bank flows, which are otherwise unsupported by traditional protection systems. This inductive buffer minimizes the probability of dielectric breakdown and extends capacitor service life. Thermal design accounts for continuous operation at full load with hot-spot temperature calculations based on IEC 60076-6 standards.
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Used to equalize current distribution across multiple capacitor groups, preventing circulating currents and ensuring uniform reactive power compensation.
Stabilizes reactive current flow among capacitor stages, reducing unbalanced loading and extending capacitor lifespan in automated compensation systems.
Improves current symmetry between fixed and switched capacitor banks, avoiding dynamic current imbalances during fast reactive power transitions.
Decouples filter branches to prevent resonance interaction and ensures accurate tuning of each filter stage in harmonic-prone systems.
Dampens transient circulating currents between capacitor groups under rapid load variation, maintaining thermal limits and protecting dielectric insulation.
Ensures balanced current sharing across trackside capacitors under varying inductive load conditions and prevents excessive capacitor stress.
Balancing reactors are typically specified with reactance values ranging between 0.5% to 5% of the capacitor bank impedance, with tolerances tight enough to ensure minimal power losses while achieving effective current balancing. Core material, flux density, air-gap profile, and thermal margins are engineered based on system operating voltage, frequency, and harmonic profile. High-voltage designs up to 33 kV are supported with dry-type or resin-cast construction, offering mechanical rigidity and high partial discharge immunity.
Protection coordination becomes more predictable when current through each capacitor group is stabilized. Balancing reactors reduce nuisance tripping of overload and unbalance relays by eliminating peak deviations in capacitor current. Additionally, they prevent saturation of current transformers used in protection and monitoring circuits. Thermal sensors, embedded RTDs, or thermistors can be integrated into the reactor body for predictive maintenance and condition monitoring.
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Frigate evaluates the harmonic spectrum of the site, including THD levels and dominant harmonic orders, before designing the reactor. The reactor’s inductance is tuned to avoid resonant amplification with capacitor banks under distorted waveforms. Core materials are selected for low-loss performance under non-sinusoidal currents. This ensures thermal stability and resonance avoidance in harsh harmonic conditions.
Frigate designs balancing reactors up to 33 kV with precise inductance control and partial discharge resistance. Each unit is built using high-grade insulation and vacuum pressure impregnation to handle environmental stress and electrical transients. Terminal spacing and creepage distances meet IEC and IEEE standards for high-voltage installations. The reactors integrate seamlessly into busbar and GIS systems without derating.
Cable length variations lead to different impedance paths, creating current flow imbalances between capacitor banks. Frigate uses detailed impedance modeling of the installation to determine appropriate reactor values for each group. The balancing reactor introduces controlled reactance to normalize current distribution regardless of cable route. This approach ensures stable power factor correction and reduces capacitor overheating.
Yes, Frigate designs balancing reactors to handle fast switching conditions common in APFC systems. Reactors are sized to limit transient inrush and manage harmonic stress during rapid step changes. Materials and core geometry are selected to avoid saturation during frequent capacitor bank operations. This enhances operational reliability and ensures compliance with reactive power demand.
Each reactor is thermally rated using IEC 60076-6 guidelines with a focus on hotspot temperature limits and continuous load endurance. Frigate simulates overload behavior under 110–120% rated current for thermal margin verification. Coil windings are designed with optimal airflow and insulation class F or H, depending on duty cycle. Sensors can be embedded for condition monitoring and predictive maintenance planning.
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10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!