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.
Rapid changes in current (high di/dt) across switching devices can cause overshoots, electromagnetic stress, and thermal cycling in power semiconductors such as IGBTs, MOSFETs, and diode bridges. DC reactors act as current-limiting impedance to moderate the rate of current rise during fault or load transition events. This controlled response reduces peak junction temperatures, minimizes stray inductance-induced voltage spikes, and enhances the overall reliability of the power conversion system.
Systems with multiple converters connected to a common DC bus often exhibit resonance phenomena due to interaction between line inductance and distributed capacitance. These resonant conditions amplify low-order and high-frequency harmonics, destabilizing voltage regulation and causing circulating currents. Appropriately tuned DC reactors introduce impedance at problematic frequencies, dampen oscillatory modes, and improve harmonic impedance profiles. This contributes to compliance with IEEE 519 or IEC 61000-3-6 harmonic limits and ensures safe operation of interconnected converters.
Large DC capacitor banks experience high inrush currents during initial energization, often exceeding nominal ratings of upstream switching devices. DC reactors mitigate this by providing a series impedance that limits charging current during power-up or capacitor switching events. This controlled ramp reduces stress on circuit breakers, contactors, and busbars, preventing nuisance tripping and mechanical wear. Reactors also prevent DC link overvoltage conditions during regenerative operations in motor drives by absorbing back-fed energy in the magnetic core.
Need reliable Reactors for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Stabilizes DC link voltage, filters high-frequency transients, and reduces capacitor inrush during charging and load step transitions.
Manages bidirectional current flow, suppresses ripple, and protects converters from fault currents during fast charge/discharge operations.
Damps harmonic oscillations, limits current surges, and filters low-frequency distortion in long-distance high-voltage direct current networks.
Filters ripple between MPPT stage and inverter bridge, reducing electromagnetic noise and stabilizing energy transfer under varying irradiance.
Controls dynamic load transitions, protects rectifier/inverter bridges, and reduces stress on DC bus components during regenerative braking.
Attenuates large ripple and harmonic currents generated during arc formation, protecting power converters and improving voltage regulation.
Each power conversion topology—whether in VFDs, UPS systems, energy storage converters, or HVDC transmission—demands specific inductance, thermal, and frequency response characteristics. DC reactors are tailored for inductance values that consider capacitor ESR, switching frequency, and permissible voltage ripple. Design parameters such as leakage inductance, insulation class, and mounting footprint are selected based on application constraints and environmental stress profiles. Reactors can also be co-designed with filter banks or crowbar circuits for coordinated protection schemes.
Large reactors are subjected to vibration, mechanical shock, and thermal expansion cycles during operation, particularly in mobile or high-power applications. Mechanical design of DC reactors incorporates structural reinforcement, resin encapsulation, and anti-vibration mountings to prevent core delamination and winding movement. Terminations are engineered for high-current, low-resistance connections with busbar or cable entry options. Space constraints are addressed through compact core geometries and modular stacking configurations for panel-mounted or floor-mounted integration.
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Frigate uses precision-wound copper coils and selects core materials with minimal thermal drift in permeability. Finite Element Analysis (FEA) simulations validate thermal hotspots and flux uniformity. This ensures inductance remains stable even under prolonged overload conditions. Reactors are tested across full thermal cycles to guarantee long-term performance.
Frigate incorporates calculated air gaps and selects high-saturation flux density cores like M4-grade silicon steel or amorphous alloys. Saturation limits are modeled based on worst-case regenerative fault currents. This prevents inductance collapse during reverse energy flow. Reactors maintain linear response to protect power semiconductors and capacitors.
Frigate analyzes the impedance profile of the DC bus and models inter-converter harmonic interaction. Custom inductance values are selected to damp resonance without affecting converter control dynamics. Each reactor is tuned based on the equivalent capacitance, switching frequency, and load synchronization. This improves system stability and prevents circulating currents.
Frigate calculates di/dt limits based on IGBT or MOSFET safe operating areas and energy storage system short-circuit levels. Reactors are designed with high mechanical rigidity and low leakage inductance to contain fault energy. Air gaps are optimized to avoid magnetic shock saturation. This protects both upstream and downstream components.
Frigate provides open-frame, resin-encapsulated, and enclosed DC reactors based on the installation environment. Mechanical design is tailored for vibration-prone or high-humidity locations using anti-corrosive coatings and epoxy systems. Forced-air or liquid-cooled variants are available for high ambient temperature zones. All constructions comply with IEC and UL insulation class requirements.
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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!