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Overview
Rectifier system electrical cabinets are core power equipment that converts alternating current (AC) into stable direct current (DC), and are widely used in industries such as industry, energy, and transportation.
AC/DC conversion: Rectifier modules efficiently transform electrical energy into stable DC voltages (such as 24V, 48V, and 220V DC).
Power management: Serving as the "intermediate hub" of the power system, it connects upstream distribution systems with downstream loads (such as motors, energy storage devices, and charging stations).
Intelligent control: Integrated digital control systems monitor and adjust output parameters in real time to ensure power quality.
Core Components
Rectification: Three-phase bridge rectifier circuit (thyristor/diode optional)
Transformer: 1000kVA three-phase isolation transformer (with neutral point voltage regulation)
Rectifier module: Thyristor module (such as MFC1000-16, rated current 1000A, withstand voltage 1600V)
Control: PLC intelligent control (supports remote monitoring and local touch screen operation)
Protection: Overcurrent/short-circuit protection (circuit breaker automatic trip), overvoltage protection (varistor), undervoltage protection, overtemperature protection (temperature sensor linked to air/water cooling system)
Operating Principle Flowchart
Mains power input (380V AC)
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Power distribution control cabinet (circuit breaker closing → control transformer power supply → system power on)
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Rectifier main cabinet (three-phase transformer voltage regulation → rectifier module AC→DC conversion)
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Stable DC output (adaptable to load requirements, such as 520V DC, 1600A High Current)
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Backend Load (Electrolysis/Electroplating/DC Motor Operation)
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Fault Trigger (Overload/Short Circuit) → Circuit Breaker Trip → System Power Off
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Key Advantages
High Efficiency and Energy Saving
Conversion Efficiency ≥ 95% (IGBT Solution), Saving Over 15% of Energy Compared to Traditional Thyristor Solutions;
Power Factor ≥ 0.95, Reducing Grid Losses;
High Reliability
Mean Time Between Failures (MTBF) ≥ 100,000 Hours (Vertiv Data);
Overload Capacity: 150% of Rated Current for 2 Hours, 200% of Rated Current for 1 Minute;
Flexible Adaptability
Wide Input Voltage Range (380V ± 15%) Adapts to Unstable Grid Environments;
Customizable Output Voltage (24V~1500V DC) Meets Different Load Requirements.
Basic Parameters
| Category | Specifications |
|---|---|
| Input Specifications | - Voltage: 380V AC ±10% (three - phase, five - wire) - Frequency: 50/60Hz - Power Factor: ≥0.95 (with power factor correction) |
| Output Specifications | - Voltage Range: 0 - 520V DC (continuously adjustable) - Rated Current: 1600A (long - term continuous load) - Maximum Power: 832kW (520V x 1600A) - Current Regulation Accuracy: ≤±0.5% (at load fluctuations of ±10%) - Ripple Factor: ≤3% (typical) |
| Mechanical Parameters | - Cabinet Structure: Dual - cabinet design (distribution control cabinet + rectifier main cabinet) - Material: Rittal SPCC cold - rolled steel, powder - coated (RAL 7035) - Protection Rating: IP54 (dust and splash proof) - Dimensions: Distribution control cabinet: 800 (W) × 600 (D) × 2000 (H) (mm) Rectifier Main Cabinet: 1000 (W) × 800 (D) × 2200 (H) mm - Weight: Approximately 500 kg (total weight of two cabinets) |
Application Scenarios
Industrial Manufacturing
Electroplating/Electrolysis: Provides stable DC current (e.g., 1000A @ 24V) to ensure uniform coating;
DC Motor Drive: Used in equipment such as rolling mills and cranes, with a speed regulation accuracy of ≤0.1%.
Rail Transit
Subway Traction Power Supply: Outputs 750V/1500V DC, supporting dynamic train start and stop response;
High-Speed Rail Auxiliary Power Supply: Provides stable 220V DC power for air conditioning and lighting systems.
New Energy Sector
Photovoltaic Grid-Connected: Converts the AC power output of the inverter into stable DC power for connection to energy storage batteries or the grid;
Wind Power Conversion: Used in conjunction with a frequency converter to achieve variable speed constant frequency control of a doubly-fed motor. Data Center
UPS Support: Works with Eaton/Schneider UPS systems to provide double-conversion power supply support;
Server Power Supply: Outputs 48V DC, supports HVDC (high-voltage direct current) architecture, and improves efficiency by 3%.
Electric Vehicle Charging
Supercharging Station: Outputs 1000V/600A DC, fully charging to 80% in 30 minutes;
Swap Station: Fast-charges battery packs, supporting multiple chargers operating simultaneously.
Energy and Chemical Industry
Hydrogen Production by Water Electrolysis: Provides high-purity DC current (e.g., 5000A@48V), reducing energy consumption to 4.2kWh/Nm³;
Oil Drilling: Drives mud pumps, winches, and other equipment, capable of operating in temperatures as low as -40°C.
By integrating efficient power conversion, intelligent control, and high-reliability design, rectifier system electrical cabinets have become core components of modern power systems, contributing to industrial upgrades and energy transformation.
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