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.
Electrical devices built to deliver stable voltage and current for power distribution and equipment operation.
Manufactured to provide safe and consistent power delivery for electrical equipment and appliances.
Magnetic components designed to store energy, filter signals, and control current in electrical circuits.
Conductive products manufactured to transmit power or signals with consistent electrical performance.
Electrical bars designed for efficient current distribution in electrical panels and power systems.
Protective housings built to safeguard electrical and mechanical assemblies against operational stresses.
Continuous profiles produced with uniform cross-sections for structural, decorative, and functional applications.
Connection interfaces manufactured for secure pipe joining and leak-free performance in critical systems.
Fluid-handling units built to deliver consistent flow and pressure across industrial applications.
Flow control components engineered to regulate, isolate, or direct fluids in industrial systems.
High-accuracy metal parts produced for industries where performance depends on flawless detailing.
Custom-formed sheets with tight dimensional for sectors ranging from enclosures to structural components.
High-volume molded parts with consistent finish, suited for functional and consumer-grade products.
Metal components shaped to complex profiles for strength, detail, and material efficiency.
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.
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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
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!