PowerTech converters for component test benches

DC voltage supply for simulating a catenary line voltage for testing traction converters and motors for electric buses

PowerTech joined forces with the Turkish test bench supplier ‘PCS Process Control Systems’ to set up a drive test bench for electric buses. The DC power supply from PowerTech consists of an air-cooled frequency converter with intermediate voltage circuit and a pulsed line converter (AFE).

One of the major challenges lies in the required dynamics of the PowerTech converter, as the demanding drive train of the electric buses is being tested. The PowerTech converter simulates the DC voltage supply via the catenary line or also via the on-board battery. In practice, these loads can be very dynamic, so this should be represented as realistically as possible in the test bench. It is, therefore, possible to make adjustments to the test specimens to allow for optimal driving operation later on.

AC power supply for new test facility of the manufacturer of semiconductor components and electronic components ‘Vishay Electronic GmbH’

PowerTech was commissioned to supply a converter to Vishay Electronic’s development and test centre, which is responsible for the new development of capacitors of higher power. The converter will be used as an AC power supply for a new test rig and can test both AC and DC capacitors as the AC source. The newly developed capacitors are to be extensively tested within the test bench, including endurance tests, function tests and thermal tests.

One of the special features of this order is that the PowerTech converter is to provide a high output current (1,000 A) at low mains current, since the specified test objects (capacitors) almost exclusively require reactive current.

The PowerTech converter supplied (type AFC 690/1100) was equipped with water cooling and an integrated water-to-water heat exchanger, which keeps the water temperature in the cooling circuit constant. The customer requested this type of converter cooling as it was ideal for the prevailing laboratory conditions.

Not only did PowerTech supply the test converter, it also played a key role in helping the customer design the test rig. Power capacitor testing always calls for an appropriately designed system choke in order to create the necessary test conditions. Based on the customer’s requirements, the PowerTech engineers designed the ideal test arrangement using appropriate simulations of how the system choke and capacitors react together in the test field.

Delivery of a test bench converter for ‘REO Inductive Components AG’, a major manufacturer of electronic and inductive components

The PowerTech scope of delivery included a water-cooled frequency converter (690 V/2,000 A) as AC source for a test rig for testing various chokes & transformers from the REO portfolio, including endurance tests, functional tests and thermal tests.

This project was unique in that the customer required the PowerTech converter to provide an output voltage of up to 700 V from the 400 V grid at maximum currents of up to 2,000 A.

Besides designing and providing the converter, PowerTech also assisted in the overall system design of the test rig for various tests. The customer is now able to perform its tests with variable pulse frequencies, fundamental frequencies and voltages. What’s more, thanks to the PowerTech design of the new test rig for REO, harmonics can be individually adjusted to suit customer needs, making the test rig particularly versatile for customer-specific tests.