Heavy-duty Vector Frequency Converter

Yibaling Heavy-duty vector frequency converters are the core of high-end power control in industrial drive applications, specifically designed to drive critical equipment in harsh environments. They integrate the robust reliability of heavy-duty with the precise efficiency of vector control.
The so-called "overload" means that it can withstand strong impacts, has an overload capacity of more than 150%, and can operate stably for a long time in harsh environments with high dust and strong vibration. And vector control is its technical essence.
Through advanced algorithms, heavy-duty vector frequency converter can precisely decouple and independently control the torque and magnetic field of the AC motor like a DC motor. This enables the motor to output 100% full-load torque even at zero or extremely low speeds and respond quickly to sudden changes in load within milliseconds.

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Factory inspection process

1. Ensure the quality of core components

Use dedicated testing instruments to conduct static parameter tests (such as saturation voltage Vce(sat) and gate threshold voltage Vge(th)) and some dynamic tests on each IGBT module in the heavy-load vector frequency converter, ensuring parameter consistency and eliminating defective products.
Under simulated load conditions, test the output waveform, isolation voltage, and short-circuit protection response time (must be in the microsecond range) of the vector frequency converter drive circuit through fixtures, and conduct automated scanning tests on the communication interface of the main control board (such as Profibus, Ethernet), analog/digital I/O channels, and memory.

2. Safety and insulation tests

Use a 1000V megohmmeter to measure the insulation resistance between all input terminals, output terminals, and DC bus to the protective ground (require typically > 100 MΩ).
Apply an AC high voltage much higher than the rated voltage (for example, if the input rated voltage is 380V, the test voltage may be 2500V AC, lasting for 1 minute), to test the insulation strength of the main circuit, without breakdown or flashover.

3. Performance tests

Run the heavy-load vector frequency converter continuously at 100% rated current and rated speed for at least 2-4 hours until thermal stability is achieved. Use an infrared thermal imager to accurately measure and record the hot spot temperature of the IGBT heat sink, the temperature of the DC bus capacitor housing, and the temperature of the bus bar connection points, ensuring that the temperature rise of any point is below the design limit (such as ≤ 70K).
Under no-load or light-load conditions, give a step torque command, and use a high-bandwidth current probe and oscilloscope to measure the response time and overshoot of the output torque current (Iq), to verify the dynamic torque response capability of the heavy-load vector frequency converter (up to millisecond level).
At different speed points (including extremely low speeds such as 0.5Hz), use a high-precision speed encoder feedback to measure the steady-state speed accuracy and fluctuation range.
Apply 150% rated load and maintain for 60 seconds to verify that the product does not trip and does not overheat protect.
Simulate motor startup or heavy-load impact, to verify that it can output 180%-200% peak current (lasting for several seconds) and that the drive circuit does not fail.

4. Aging tests

Place the Heavy-duty Vector Frequency Converter in a high-temperature environmental chamber (such as 50-55℃), and run it under rated load or alternating load for 12-24 hours in a cyclic manner.
Let the product frequently switch between no-load, half-load, and full-load cycles, exposing the internal components (especially IGBT, capacitors) of it to repeated thermal expansion and contraction stress, and revealing welding and material defects.

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