Application: Quartz Crucible Manufacturing
Status: Active Project
Developing a retrofit AC to DC IGBT-based liquid cooled power converter system for installation into an existing dual plasma torch system for quartz crucible manufacturing. The power panel is rated for 438kW, 834ADC, 525V. This is large, multi-year effort involving multiple companies.
Phase 1: Design
Completed in early 2019
Scope of work includes product specification development, topology inception, power circuit design, simulation, component selection, thermal management design, bill of material, schematic and assembly drawings, printed circuit board design, test board design, test fixture design, and test specification creation. Powerexpert selected and partnered with a contract manufacturer to provide mechanical drafting, procurement, assembly, and test of the system. Powerexpert also selected and contracted a PCBA company to provide drafting and delivery of tested PCBAs for the project. All aspects of the engineering technical design and project management were provided by Powerexpert.
Phase 2: Prototype Delivery
Completed in November 2021
Scope of work included delivery of one complete power panel system with spare parts. Powerexpert provided procurement support, assembly support, and testing support. The prototype was built and tested in the US and then shipped to a European customer site. Powerexpert provided on-site testing and commissioning support. The system was successfully installed (a true drop-in replacement) and started up. The system is currently running and the customer is making product.
See link below for further information and a demo video of the factor open-air plasma torch!
https://powerexpert.us/powerexpert-demonstration-of-an-open-air-plasma-torch/
Phase 3: Production Delivery
Phase 3 is anticipated to start in early 2022. Scope of work includes delivery of 8 complete power panel systems with spare parts. Powerexpert will re-spin the PCBAs and update the design for production readiness, along with final documentation, contract manufacturing, PCBA, and customer support.