Electroplating benefits from rectifiers with AFE technology

A new water-cooled direct current source delivers up to 10,000 A at a voltage of 20 V and achieves an efficiency of over 90 percent. With this model, the manufacturer has expanded its range for various applications in electroplating, for example chrome plating, anodizing or aluminium dyeing processes.

In addition to the quality and suitability of the electrolytes, the results of electroplating processes depend on the control of the current and voltage curve. In this respect, direct current sources play a central role in the reproducibility of coating processes. However, the issue of energy consumption and efficiency has also become a decision criterion in today's world. Ultimately, this means that not so old switching power supplies are being replaced, but all the more so the older, but extremely robust and durable rectifiers cooled in an oil bath.

In times when the power supply from the public grid is no longer as stable and has large reserves, it is no longer just a question of how the direct current source sends the voltage to the coating baths, but also what current and voltage curves it demands from the grid, especially for larger electroplating systems and higher outputs.

Sinusoidal extraction from the AC grid

A special feature of the pe5910-W-AFE DC power station is that it is able to draw sinusoidal current from the AC supply grid with the same phase angle of current and voltage thanks to Active Front End (AFE) technology.

According to the manufacturer, this leads to a noticeable reduction in harmonic oscillations to less than 1 percent (THD_I). Rectifiers with AFE technology also achieve an increase in the power factor (cosφ) from the standard 0.95 to 1.00. Another positive side effect of the sinusoidal mains current draw is the reduction of the phase current and therefore a lower load on the supply transformer for the rectifiers.

Despite its high electrical output, the high-current direct current source requires very little space: The installation area is just 800 millimeters × 600 millimeters (width × depth). This ensures flexibility and easy servicing.

High efficiency, reduced reactive power and low distance to the bath

Thanks to the proven switched-mode power supply technology and digital control technology, the DC power source offers precise control accuracy and very low ripple. This leads to optimized process quality and qualitative advantages in many coating processes.

The high efficiency of 90 to 96 percent means lower energy consumption and therefore a reduction in operating costs, a weighty argument in times of high energy costs. The very high power factor of up to 1.0 (AFE) enables further energy cost savings due to improved grid quality and thus reduced reactive power. Additional savings potential results from the compact design and the possibility of installing the direct current source as close as possible to the bathroom. The control range for current and voltage extends from 2 to 100 percent. The device is also optionally available with an integrated electronic pole inverter.

New design facilitates busbar connection

The new design of the DC output opens up further advantages. Busbars can now be routed to the DC connections in any orientation, as the manufacturer explains. This allows flexible and simple integration into systems and therefore shorter busbar routes. Two or four outputs per cabinet are also possible. If required, the power range of the DC source can be multiplied by parallel or series connection according to individual requirements.

The DC power source is integrated and controlled via the familiar interfaces, for example Profibus, Profinet, Modbus, TCP/IP or RS485. An analog interface can even be used to ensure communication with older system controls. As an isolated solution, Plating Electronic also offers manual operation with operating units, which are also suitable for future external connection to the control system.

Plating Electronic GmbH www.plating.de

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