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 without detuned reactors tend to create parallel resonance circuits with the upstream power system at harmonic frequencies, especially the 5th and 7th. When resonance aligns with these harmonic orders, it leads to significant amplification of harmonic current into the capacitors, resulting in insulation failure, overheating, and elevated voltage distortion across busbars. Detuned reactors are specified with a tuning frequency typically set to 189 Hz (7%) or 134 Hz (14%) for 50 Hz systems.
Capacitor dielectric systems are designed for sinusoidal voltage conditions and nominal current levels. The presence of harmonics in the system elevates the RMS current flowing through the capacitor, often exceeding the permissible thermal limit. When harmonic current is not mitigated, it contributes to dielectric heating and degradation of the polypropylene film insulation, leading to dielectric breakdown and shortened service life.
Harmonics reflected back from PFC systems without detuned protection result in elevated I²R losses in transformers and cables. Harmonic currents, especially at 5th and 7th orders, increase eddy current losses in transformer cores and cause excessive heating in conductors due to skin effect and proximity effect. These thermal stresses often go unaccounted for in standard thermal design and result in premature derating or insulation aging. Detuned reactors mitigate harmonic re-entry into the upstream network by suppressing the resonance amplification that allows harmonics to circulate in the first place.
Need reliable Reactors for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Used in LV and MV APFC systems to prevent capacitor damage caused by amplified harmonic currents under resonance conditions.
Limits harmonic interaction between VFDs and capacitor banks, avoiding resonance amplification and ensuring stable reactive power compensation.
Suppresses 5th and 7th harmonic resonance generated by arc furnaces and large drives during high-power, cyclic load operations.
Prevents capacitor overheating from distorted waveforms caused by multiple chiller drives and fan systems operating on shared electrical networks.
Protects capacitors from harmonic overload in production environments with dense robotics, servo motors, and high-frequency switching equipment.
Stabilizes reactive power compensation under continuous nonlinear loading from UPS systems, blade servers, and power supplies.
When new nonlinear loads such as VFDs or rectifier banks are introduced into an existing electrical system, the aggregate harmonic profile changes. These changes can alter the system’s natural resonant frequency, leading to inadvertent alignment with dominant harmonic orders. Such alignment causes harmonic resonance and disrupts PFC operation.
Detuned reactors are designed using low-loss CRGO or amorphous magnetic cores to reduce iron losses under continuous operation. The winding material is typically copper or aluminum with high thermal endurance insulation (Class H or F), designed for ambient conditions up to 50°C without derating. Typical detuning percentages range from 5.67% to 14%, selected based on harmonic analysis and target tuning frequency.
Check all our Frequently Asked Question
Frigate performs a detailed harmonic spectrum analysis to determine the dominant harmonic orders present in the system. Based on this data, we typically tune reactors to 189 Hz (7%) or 134 Hz (14%) for 50 Hz systems. This avoids parallel resonance near the 5th or 7th harmonic. Our tuning ensures maximum attenuation without compromising the power factor correction performance.
Frigate uses Class H insulation materials for windings to handle elevated temperatures due to harmonic current heating. Our designs include low-loss CRGO or amorphous cores to minimize iron losses. All reactors are thermally rated for continuous operation at 1.1 times the nominal current. This ensures long-term stability even in high THDi (Total Harmonic Distortion current) environments.
Frigate uses non-saturating core designs to maintain linear inductance across fluctuating current levels. The inductance value is kept stable even when load varies, preventing resonance frequency drift. We also apply vacuum impregnation to reduce acoustic noise and mechanical vibration. This design approach maintains consistent harmonic filtering during system load changes.
Frigate provides application-specific reactor sizing based on reactive power demand and expected harmonic distortion levels. Each reactor is designed to match the capacitor rating and system impedance precisely. Mounting dimensions and connection terminals are tailored for panel builder convenience. Our integration support includes 2D/3D drawings and full thermal-impedance data sheets.
Frigate tests each reactor for impedance accuracy, insulation resistance, and high-voltage dielectric strength. We perform no-load loss tests and temperature rise evaluations under harmonic current simulation. Tuning frequency is verified with frequency response analysis. All tests follow IEC 60289 and IS 5553 standards for low-voltage power reactors.
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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!