B063S10
日期：2018-7-12一、 行业现状
当前太阳能的大规模应用推动光伏行业整体向前发展，同时，LED技术又刮起了一股新能源节能风。随着砷化镓在光伏太阳能产业、光电子领域、微电子领域以及军事电子领域的应用日益广泛，生产砷化镓晶棒的晶炉控制系统愈发起到举足轻重的作用。在此基础上，如何保障对温度条件要求苛刻的晶炉安全持续生产，如何为整个控制系统选择合适又可靠的供电配置显得至关重要。本案例中，普尔世直流电源和DC UPS冗余方案在单晶炉和多晶炉控制系统中的成功应用使用户避免了严重的经济损失，并从繁琐的人工日常监控中解放出来，获得了用户的高度认可与衷心赞誉。
二、 基于晶炉控制系统的方案
1. 问题描述
本方案中，客户是以砷化镓、锗等半导体材料的生产、销售为主营的高科技企业。这些半导体材料是太阳能、LED、微电子等行业不可或缺的原材料。单晶炉内晶体生长是整个生产中的最关键的工艺。每个砷化镓晶体在炉内的生长周期长达4~6天，生长过程中炉内温度通过控制器调控以阶梯方式增长。在此周期中，一旦对控制器的直流供电中断，控制器的设定温度就会复位到起始值，导致炉内实际温度与晶体生长所需温度无法匹配，致使石英单晶炉或多晶炉内的温度发生不规则变化，进而可能导致晶炉中正在生长的砷化镓晶体报废，甚至会引起炉内温度过高，使得石英炉体膨胀而报废。其整个过程将造成砷化镓晶体、石英炉炉体、时间、电力以及人工成本等近百万元的经济损失。客户曾经发生过几次停电事故，起因是控制系统前端的AC UPS因本身质量问题而使输出供电中断，引起对控制器的直流供电回路中断进而导致控制系统失控。AC UPS系统的体积大，输出干扰强，故障率高等附带缺点也为客户造成了很大的困扰。如图1为原交流UPS供电方案。
综上所述，用户原供电方案的问题可总结为：
原方案只是针对市电断电有所准备，但是一旦AC UPS本身发生故障，会使其后单路连接的控制器的直流供电中断，进而导致全部控制系统瘫痪；
由于AC UPS很难做到绝对的“零切换”，市电断电时，需要一定的切换时间，而如果后续直流电源没有一定的缓冲能力，会造成对控制器的供电不够稳定；
如果AC UPS的输出干扰无法被后续的直流电源有效屏蔽，可能引起控制器的错误关断或其它误动作；
AC UPS附带的电池体积庞大，因此整个供电系统只能放置在晶炉柜外，除了安装非常不方便，其内置风扇还会造成噪声污染。
需求分析
基于以上种种弊端，普尔世向用户建议在既有的双路交流输入的基础上，使用稳定、高可靠性的直流电源和DC UPS，为相应负载提供稳定不间断的输入。因为双路冗余DC UPS无论是在系统外市电缺失的情况下还是其本身发生故障，都能够保证自动切换至电池为其后的电路供电，在本方案中即为晶炉控制器供电，从而使控制器完成最后一次工作然后关机，并按要求进行软硬件通讯，发送相应信号到上位机，方便工作人员及时发现和解决回路问题，以此来有效地保护炉体设备不受意外断电的影响。
此外，客户还希望电源和DC UPS能够安装于专门的空间有限的晶炉控制柜内，这就对冗余系统的体积也做了一定的要求。
方案确定
目前普尔世电源给客户提供的产品包括CS10.244、UB10.241和YR2.DIODE。CS10.244是输出为24V的直流电源，最大额定负载为10A；UB10.241为直流不间断电源，输出为10A，24V；YR2.DIODE是双路10A二极管冗余解耦模块，能够有效隔离冗余的电源，彻底避免输出回路间的耦合，实现真正的冗余备用功能。电源，DC UPS，冗余模块三者构成了最高可靠性的直流回路。以下是普尔世电源产品，图2为CS10.244,输出为24V10A电源，图3为UB10.241，输出为24V，10A DC UPS。
整个直流供电系统还需要配备两块铅酸电池(12V/12Ah)，以及为DC UPS配备信号通讯系统。铅酸电池用来在主回路断电时为DC UPS供电；信号通讯系统则用来告知客户在各个使用情况下的回路状态，以便对故障电路做出第一时间报警。
图4是普尔世为客户提供的解决方案接线图。图中绿灯①亮则表示系统主回路供电正常，DC UPS回路正常；红灯②亮则表明直流UPS处于电池供电缓冲模式；红灯③亮则表示电池本身质量测试不通过，需要更换电池。
图4 典型的双冗余系统接线图
由上述方案的选定，再结合用户的原方案对比可知，PULS普尔世为用户提供的新方案可以解决以下问题：
<!--[if !supportLists]-->1） <!--[endif]-->不管是市电断电还是双路冗余的DC UPS其中一路本身发生故障，都能够切换到电池，持续为其后连接的控制器进行直流供电，并及时作出报警，便于相关人员采取一定措施，避免造成损失；
<!--[if !supportLists]-->2） <!--[endif]-->市电断电时，由于是直流电源切换到电池，中间不会产生停顿，真正做到“零切换”时间，使其对控制器的供电足够稳定；
<!--[if !supportLists]-->3） <!--[endif]-->直流输出的干扰相对较小，不易引起控制器的错误关断或其它误动作
<!--[if !supportLists]-->4） <!--[endif]-->不仅其附带电池体积小，而且整个供电系统的体积总和也十分小巧，放置在狭窄的晶炉柜内非常合适，降低了接线的复杂度，免除了不必要的安装麻烦。
<!--[if !supportLists]-->4. <!--[endif]-->普尔世电源的综合优势
在本案例中，普尔世的直流不间断冗余系统还具有一些独特的优势，因此也为用户带来了更多的便利。
4.1稳定的UPS输出电压
通常的直流不间断电源在缓冲模式（即电网断电由电池供电的状态）下，输出电压会随着电池的放电而降低，整个放电过程中电压变化可能超过几伏，在最后的约五分之一时间里的电压还可能低于20伏（如下图5），并且也无法很好的满足负载的峰值电流需求。而根据工业控制器标准（PLC标准）EN 61131-2，要求工业控制器可耐受的电压暂降不得超过10ms，电压最低能降到20.4Vdc，因此普通的电池如长期未经维修或更换，可能无法起到可靠的保障作用。
基于这个原因，普尔世特别在技术方面设计做到了在缓冲模式下的直流不间断电源UB10.241能够输出稳定的电压，保持恒定的输出电压22. 5V（如图6），同时具有4秒内的50％额外功率，即在保持电压的条件下，可以输出150％的额定电流，使负载能够正常工作，尤其是像晶炉控制器这样关键的重要负载。
4.2优秀的电池管理技术
普尔世精确的电池管理技术能够避免电池过充、欠充或深度放电，有效地延长电池的使用寿命。
熟悉电池管理的人都知道，在一定环境温度下，电池有一定的满充电压，与该满充电压完全一致时，电池可以达到最长的使用寿命。传统的双电池串联充电方案由于电池特性不尽相同，很容易造成其中某一电池的过充或欠充（如图7）。而普尔世电源的DC UPS独有的单电池供电方案，只需要对单个电池充电和管理（如图8），能更准确地监测充电截止电压以保护电池，延长其使用寿命，为用户节约大量维护及更换的成本。
另外，普尔世DC UPS可以根据现场的环境温度设定满充电压，电池相应被充电至该电压，保证电池最优的使用寿命。尽管如此，普尔世DC UPS也可以选配其它厂家电池，用户不会因此受到电池品牌限制的困扰。
43 强大的自身保护能力
普尔世电源产品都有很强的过载能力以及保护能力。例如，普尔世电源具有短路保护，过温保护，过载保护和过压保护等能力。DC UPS除此之外还具有电池极性反向保护，错误电池电压保护，电池深度放电保护的功能。其中输出过压保护能预防对负载产生大电压冲击，保护负载免受伤害，尤其是控制器等关键负载。因此，不仅能够保证电源本身的使用寿命，对用户方的设备和操作人员亦可进行全方面的保护。
4.4 卓越的电源综合特性
在市场上以产品特点“简约、强劲、稳健、高效”而著称的普尔世电源，其优势还在于其电源本身高技术含量的综合性能。以本案例中的CS10.244为例：其重量仅为700g，转换效率达到91.3%（输入230V AC，输出24V，10A）；更为重要的是它以60*124*117 mm的灵巧尺寸，不仅能够顺利地置入狭窄的晶炉控制柜，降低接线的复杂度，甚至还节省出更多的空间；其独特而卓越的系统散热可以增强内部零件的使用寿命，提高产品的转换效率与可靠性，从电能利用率和后期维护角度为客户节约了不容忽视的成本；它本身超过15年（输入230V，输出24V，10A，环境温度为25℃）的预期使用寿命，又能够大大增加了用户更换的周期。此外，CS10.244的使用环境温度为0℃—70℃，60℃以上才需要适当降额。综合看来它是一款足以适应各种恶劣复杂应用环境的高可靠电源产品。
总结
普尔世电源的卓越技术，高可靠性，高效率，强大的输出能力，配套电池的长寿命，最快捷的更换维修时效，最优质的服务不但能为客户带来最稳定的电力输出，最高的可用性以及方便的后期维护性，也为客户带来了最满意的使用效果。
普尔世电源是一家专业生产DIN导轨式工控电源的德国公司，在导轨式工控电源市场具有先进的生产研发技术和领先的全球市场份额。在中国的产业升级和出口复苏的大环境下，作为世界公认的工控电源领域的技术领袖，普尔世电源时刻密切关注国内整体行业的走向，并全力支持国内的工控行业的技术升级。
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6：ABB：工业机器人备件DSQC系列、Bailey INFI 90等。
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