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.
Non-linear loads such as VFDs, UPS systems, and rectifiers introduce high-amplitude current harmonics that distort voltage profiles and compromise grid stability. Power smoothening reactors introduce a distributed impedance across targeted frequency bands—typically tuned for the 5th, 7th, and 11th harmonic orders—allowing for selective filtering and localized harmonic absorption. This approach ensures compliance with IEEE 519 harmonic current limits without requiring active harmonic filters.
DC link fluctuations in PWM-based drives often result from step load variations and regenerative energy flow. Power smoothening reactors deployed at the DC input terminal act as dynamic energy buffers. Their high transient impedance and controlled inductive reactance dampen surge voltages during line-side switching events. This results in reduced dielectric stress on film capacitors and fewer pre-charge cycle failures.
PWM switching introduces ripple currents in the kilohertz range that directly elevate I²R losses in capacitive elements. The reactor’s winding design, with minimal parasitic capacitance and interleaved core segments, enables ripple current attenuation beyond 20 kHz. Core materials such as low-loss cold-rolled grain-oriented (CRGO) silicon steel or amorphous alloy are selected for their superior frequency response and thermal stability.
Need reliable Reactors for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Limits DC link voltage ripple and suppresses harmonic injection from high-speed switching in motor control applications.
Stabilizes output current by damping high-frequency harmonics from solar and wind inverter pulse-width modulation.
Reduces transient current spikes and filters low-order harmonics generated during rapid melting and electrode movement.
Controls ripple content on the DC bus and minimizes voltage fluctuations during power reversal and mode shifting.
Mitigates switching noise and controls surge energy transfer between rectifier and inverter sections under fluctuating load conditions.
Smoothens regenerative braking energy and buffers DC link instability during rapid acceleration and deceleration of electric locomotives.
Electromagnetic interference and structural vibration induced by flux fluctuations create both audible and radiated disturbances. The mechanical design of the reactor includes vacuum pressure impregnation (VPI) with Class F resin and orthogonal coil winding to suppress axial flux movement. Magnetic shielding using laminated flux barriers ensures compliance with CISPR 11 EMC emission limits.
High ambient temperatures, dust ingress, and humidity fluctuations degrade standard magnetic components. Power smoothening reactors are thermally rated to Class H (180°C), with validated performance in ambient conditions up to 55°C without derating. Optional IP23/IP44 enclosures with anti-condensation heaters are available for outdoor or high-humidity deployments.
Check all our Frequently Asked Question
Frigate designs reactors with optimized core geometry and distributed air gaps to maintain linear inductance under non-sinusoidal loading. Harmonic-rich waveforms are analyzed to tune the reactor’s impedance profile for specific harmonic orders like 5th, 7th, and 11th. This ensures minimal harmonic propagation into upstream systems. Thermal and magnetic performance are validated through FEA-based simulations and type testing.
Frigate uses core materials with high saturation flux density and designs the air gap to delay magnetic saturation. Reactors are tested to withstand 150% of rated current without significant drop in inductance. Short-time current withstand and thermal rise are verified per IEC 60076-6. This makes the reactors suitable for drive systems prone to load surges or regenerative peaks.
Frigate applies vacuum pressure impregnation (VPI) with Class F or H varnish to lock windings in place and eliminate coil movement. Mounting frames are designed with anti-vibration pads and rigid baseplates. The coil and core assembly is clamped using non-magnetic hardware for structural rigidity. Each unit is tested for vibration endurance as per IEC 60068-2 standards.
Frigate performs thermal simulations to calculate hot-spot temperatures under worst-case ripple and ambient conditions. Reactors are designed with low-loss core materials and foil windings to reduce I²R and eddy current losses. Forced air cooling is integrated when natural convection is insufficient. Temperature sensors and thermal cut-outs can also be incorporated for overload protection.
Frigate customizes reactors with high ripple current ratings, compact form factors, and optimized EMI shielding for sensitive BMS environments. Designs include low-leakage inductance to reduce circuit noise and improved thermal pathways for continuous charging cycles. Terminal layouts are adjusted for space-constrained cabinet integration. Reactors can also be co-designed with system engineers for dynamic charging profiles.
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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!