The case histories detailed here are examples of the collaborative approach that Bicron shares with customers every day. Check back soon as we add new success stories.
Gate Drive Transformer for High Voltage Switching in Alternative Energy Equipment
Customer Challenge: The customer was using a non-Bicron Gate Drive Transformer design for a wind power alternative energy control system that was already in production. The original transformer was producing unstable performance and was prone to false triggers that were causing damage to the system by gating outputs on at the wrong time and destroying the IGBT and the control circuit. After months of analysis, the customer was unable to determine the root cause of the problem.
Bicron Solution: Bicron modeled the existing transformer magnetically and electrically and identified that the design was unstable due to leakage inductance and the capacitance of the transformer. Bicron then developed a modified design based on unique modeling programs to stabilize the transformer by reducing leakage inductance and capacitance.
The new design enabled the customer to eliminate eight capacitors and the related interconnections from their design.
Benefits to Customer: With Bicron components, the improved system has seen zero transformer-related failures. The customer was also able to eliminate the capacitors from the design and realize savings from the related sourcing and assembly costs.
These changes resulted in fewer interconnects, which further enhanced the system's reliability and reduced the total installed cost.
Case History 2
Transformer for Soft Start Motor Control System for High Horsepower Motor
Customer Challenge: The customer was using non-Bicron transformers in its motor control systems, which had been in production for several years. The transformers — which were used with motors as large as 15,000 horsepower — were being damaged during normal field operation. The customer was unable to determine the cause of the problems.
Bicron Solution: Bicron engineers traveled to the customer's site and collaborated with the customer's engineering team to perform a rapid Root Cause Analysis (RCA).
The three-day visit resulted in the identification of instability in the customer's system that caused voltage spikes above the rating of the existing transformer.
Bicron recommended a change in the circuit and provided a redesigned transformer to increase robustness.
Benefits to Customer: Since switching to Bicron for all of their high-frequency transformer requirements, the customer has experienced zero failures due to circuit performance.
The company has now shipped more than 2000 systems over five years without a single transformer failure.
Case History 3
Control System for High Voltage Switching in Alternative Energy Equipment
Customer Challenge: This customer needed a highly stable control system with a minimum of 89% efficiency. Efficiency losses were costly because of the high cost of electricity, and because thermal losses created additional ambient heat that would reduce system reliability and stability.
The company needed a transformer that could deliver reproducible performance for the high volume of systems it builds.
Bicron Solution: Bicron worked with the customer's engineering staff to optimize the system for efficiency and stability. This included designing and optimizing six magnetic devices including five high-frequency transformers and one inductor.
Bicron was able to develop a design for these magnetic components to optimize the system by tuning the magnetic devices to work with each other over the frequency range and voltage/loading levels required by the system.
Benefits to Customer: With more than 500 systems installed with the new Bicron components. the customer has experienced zero failures and an overall system efficiency of 90.2%.
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