Power Conversion System pcb board

Solar Inverter Motherboard
New Energy PCB

Number of SMT lines: 7 high-speed SMT mating lines
SMT daily production capacity: more than 50 million points
Inspection equipment: X-RAY tester, first piece tester, AOI automatic optical tester, ICT tester, BGA rework station
Mounting speed: CHIP component mounting speed (optimal conditions) 0.036S/chip
Minimum package: 0201, accuracy up to +0.04mm
Minimum device accuracy: PLCC, QFP, BGA, CSP and other devices can be pasted, with pin spacing up to +0.04mm
IC-type placement accuracy: the mounting of ultra-PCB boards, flexible PCB boards, gold fingers, etc. has a high level, can be mounted/inserted/mixed TFT display driver boards, cell phone motherboards, battery protection circuits and other difficult products.

Order information

Power Conversion System (PCS), also known as bidirectional energy storage inverter, serves as the core component facilitating bidirectional energy flow between energy storage systems and the grid. It controls the charging and discharging processes of batteries and performs the conversion between AC and DC. In recent years, there has been a surge in the global energy storage market, leading to increased demand for PCS. Domestic manufacturers are expanding their overseas markets, making PCS research a focal point of attention.

Principle of Operation for PCS

The working principle of the Power Conversion System involves a controllable four-quadrant converter on the AC and DC sides, achieving bidirectional conversion of electrical energy. This principle relies on constant power or constant current control through microgrid monitoring instructions, enabling battery charging or discharging while smoothing the output of fluctuating power sources such as wind and solar energy.

Components of PCS

PCS consists of hardware components such as Insulated Gate Bipolar Transistors (IGBTs), Printed Circuit Boards (PCBs), wires, and cables. Its main functions include power smoothing, information exchange, and protection. PCS determines the quality of output power and dynamic characteristics, significantly impacting the lifespan of batteries.

The operational modes of PCS

PCS operates primarily in three modes: grid-connected, off-grid, and hybrid modes: In the grid-connected mode, PCS facilitates bidirectional energy conversion between energy storage batteries and the grid. Its main function is to perform constant power or constant current control based on microgrid monitoring instructions, enabling battery charging or discharging while smoothing the output of fluctuating sources such as wind and solar energy. In the off-grid mode, PCS can provide AC power to local loads according to actual demand, meeting the quality requirements of grid power. In the hybrid mode, energy storage PCS can switch between grid-connected and off-grid modes.

Key functional features of PCS

The main functions of PCS include protection against overvoltage, undervoltage, overload, overcurrent, short circuit, and overheating. It also possesses islanding detection capability for mode switching, facilitates communication with superior control systems and energy exchange devices, and enables smooth switching control between grid-connected and off-grid modes.

Application Scenarios of PCS

Based on different application scenarios, PCS can be categorized into four main types: energy storage power stations, centralized or string inverters, commercial and industrial, and residential, distinguished mainly by power output.

  1. Energy Storage Power Station PCS typically has a power output exceeding 10MW. It adopts cascaded multi-level topology, utilizing IGBT modules for design. Generally, N AC inverters are installed inside containers, supporting parallel operation of multiple units and requiring transformers for grid connection and voltage boosting.
  2. Centralized PCS has a power output of over 250KW. Currently, it mostly adopts two-level topology, also using modular IGBT design with fewer power devices. The single unit power can reach MW level, with high requirements for system reliability.
  3. Commercial and Industrial PCS typically has a power output below 250KW. It mainly employs three-level topology, combined with distributed photovoltaics, enabling self-consumption and profit-making through grid price differentials.
  4. Residential PCS has a power output below 10KW and is combined with household photovoltaics. It serves as emergency power and electricity cost management, with high requirements for safety standards and noise control.

Power Conversion System pcb board

LST PCB capability

Number of layers 1-48 layers
Materials FR4, Tg=135150170180210, cem-3, cem-1, aluminum substrate, PTFE, Rogers, Nelco
Copper thickness 1/2oz, 1oz, 2oz, 3oz, 4oz, 5oz
Board Thickness 8-236mil (0.2-6.0mm)
Minimum line width/spacing 3/3 million (75/75um)
Minute drilling size 8 million (0.2 mm)
Min HDI laser drill size 3 million (0.067 mm)
Aperture tolerance 2 million (0.05 mm)
PTH copper thickness 1 million (25 microns)
Resistance welding color Green, Blue, Yellow, White, Black, Red
Strippable solder mask layer Yes
Surface treatment HASL (ROHS), ENING, OSP, sinking silver, sinking tin, shining gold, golden fingers
Gold thickness 2-30u “(0.05-0.76um)
Blind hole/buried hole Yes
V-shaped cutting Yes

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