Power Smoothening Reactor

Power smoothening reactors are inductive components integrated into high-power electrical systems to regulate current waveforms, suppress ripple, and manage transient dynamics. Their role becomes essential in modern infrastructure where voltage stability, harmonic mitigation, and capacitor protection directly impact system integrity, equipment life, and compliance with harmonic distortion standards. 

Rated Voltage

Up to 1200 V DC / 690 V AC

Frequency Range

0 Hz to 20 kHz (suitable for PWM switching frequencies)

Rated Current

Up to 2500 A (customized per application)

Inductance Value

0.1 mH to 50 mH (application-specific)

Harmonic Attenuation

Effective filtering for 5th, 7th, 11th harmonic orders

Product Description

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. 

Insulation Class

Class F (155°C) / Class H (180°C)

Dielectric Strength

3.0 kV for 1 minute (line-to-line and line-to-ground)

Temperature Rise

≤ 80°C over ambient at rated current

Core Material

CRGO Silicon Steel / Amorphous Alloy / Ferrite (on request)

Cooling Type

Natural Air / Forced Air (as per design requirement)

Impedance Tolerance

±5%

Mounting Type

Floor or Panel Mounted with vibration-damping supports

Ambient Temperature Range

-10°C to +55°C without derating

Altitude Rating

Up to 1000 m above sea level (higher with derating)

Noise Level

≤ 65 dBA at 1 meter

Protection Degree

IP00 / IP23 / IP44 (optional enclosures available)

Standards Compliance

IEC 60076-6, IEC 60076-11, IEEE 519, IS 5553

Technical Advantages

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.  

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Industry Applications

Variable Frequency Drives (VFDs)

Limits DC link voltage ripple and suppresses harmonic injection from high-speed switching in motor control applications. 

Renewable Energy Inverters

Stabilizes output current by damping high-frequency harmonics from solar and wind inverter pulse-width modulation. 

Electric Arc Furnaces (EAFs)

Reduces transient current spikes and filters low-order harmonics generated during rapid melting and electrode movement. 

HVDC Converter Stations

Controls ripple content on the DC bus and minimizes voltage fluctuations during power reversal and mode shifting. 

UPS Systems in Data Centers

Mitigates switching noise and controls surge energy transfer between rectifier and inverter sections under fluctuating load conditions. 

Traction Power Substations

Smoothens regenerative braking energy and buffers DC link instability during rapid acceleration and deceleration of electric locomotives. 

EMC and Acoustic Damping for Electromechanical Systems

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.  

Power Smoothening Reactor

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate design power smoothening reactors to handle high harmonic content in multi-pulse drive systems?

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. 

What steps does Frigate take to ensure reactors do not saturate during overcurrent or fault conditions?

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. 

How does Frigate ensure mechanical stability in reactors exposed to high vibration environments like rolling mills?

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. 

How does Frigate handle thermal performance in compact enclosures with limited airflow?

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. 

What customization options does Frigate provide for smoothening reactors in EV charging or energy storage systems?

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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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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