Components for power conversion
Mersen's advanced power conversion components are engineered for superior efficiency and reliability in renewable energy, railways, and industrial applications.
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Power Conversion
The next-generation of power conversion components
Our components for power conversion help make systems for renewable energy, railways, and industrial applications more protected, efficient, reliable, and sustainable. With our undisputed reputation in bus bar, cooling, fusing, and capacitor design and manufacturing, Mersen stands as your preferred partner. We assist our clients during the development phase of their Inverter/Stack, bringing technical cross-expertise across these four key products to push optimization to the limit.
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Powering progress with efficient power conversion solutions
In today's rapidly evolving energy landscape, the quest for efficient power conversion systems has never been more critical. As industries and technologies converge towards cleaner and more sustainable energy sources, the challenges of converting power efficiently, reliably, and safely have become paramount.
With innovative solutions in power conversion efficiency and optimization, we are not just responding to the demands of the present ; we are paving the way for a future where power conversion efficiency marks the difference between progress and stagnation. Our dedication to advancing power conversion technologies underlines our commitment to excellence and sustainability, ensuring that our clients and the planet alike benefit from the highest standards of energy efficiency and reliability.
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Impact of Mersen's Power Conversion Solutions
"Working with Mersen has tangibly improved our operational efficiency and sustainability efforts. Their power conversion components have not only met our rigorous demands for reliability and efficiency but have also supported us in achieving our environmental objectives. It's Mersen's hands-on support and operational expertise that have made them an invaluable part of our progress."Jordan Fisher
Chief Operating Officer
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Power Conversion
Need to get information about power conversion solutions ?
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What is power conversion?
Power conversion is the process of transforming electrical energy from one form to another to meet specific requirements of power distribution and usage. It plays a crucial role in enabling the efficient use of electricity across various applications, from charging electric vehicles and harnessing renewable energy sources to powering industrial machinery.
At its core, power conversion ensures that electrical energy is delivered in the right form, voltage, and current level, maximizing both performance and energy efficiency. As we move towards a more electrified and sustainable future, the importance of advanced power conversion technologies continues to grow, marking a pivotal step in the global energy transition.
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What applications can power conversion be used for?
Power conversion technology spans a vast array of fields, each with its unique demands and challenges. From energy storage solutions to the electrification of transport, let’s delve into how power conversion is pivotal across different sectors.
Power conversion for battery energy storage
In battery energy storage systems, power conversion serves as a critical function, transforming DC energy stored in batteries to AC energy, suitable for everyday use or grid distribution. This conversion process is fundamental in bridging renewable energy sources with consistent power supply, ensuring that energy is available precisely when and where it's needed.
Mersen's expertise in power conversion for battery energy storage shines through in the development of solutions that not only promise superior efficiency and reliability but also enhance the overall sustainability of energy networks.
Power conversion for electric vehicle chargers
With power ranging from AC 3.7kW to DC 350kW and up, and voltage now reaching 800VDC for ultra-fast chargers, EV chargers require very specific power management and electrical protection features.
Mersen has developed a comprehensive product offering covering overcurrent and surge protection, low-voltage switches, liquid or air cooling solutions, bus bar connections, and DC-link capacitors to serve the EV chargers market.
Power conversion for railways
In the railway sector, power conversion plays a major role in ensuring the safe, efficient, and reliable operation of trains. It involves converting electrical power from the grid to the appropriate form and voltage for traction systems, signaling, and station infrastructure.
Mersen's solutions for railways power conversion address the unique challenges of this industry, including the need for high power output, robustness against environmental stresses and vibrations, plus adherence to stringent safety standards.
Power conversion for solar energy
Power conversion is a strategic element in the utilization of solar energy, enabling the transformation of direct current (DC) generated by solar panels into alternating current (AC) that can be fed into the electrical grid or used by AC-powered devices.
Our solutions are designed to cater to the specific requirements of commercial, and utility-scale solar installations, optimizing energy harvest and contributing to the grid's stability. With Mersen's advanced power conversion components, we're helping to drive forward the adoption of solar energy, supporting a cleaner, more sustainable energy future.
Power conversion for wind energy
In the wind energy sector, power conversion transforms the mechanical energy captured by wind turbines into electrical energy that can be distributed and used. This process involves converting the variable frequency and voltage output from the turbine's generator into a stable frequency and voltage that align with grid specifications.
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High Speed fuses for power conversion
Mersen offers a comprehensive line of high-speed fuses specifically designed to safeguard power electronics and power circuits within your conversion equipment. These fuses function by interrupting extremely high fault currents in a very short time, thereby limiting the thermal energy (I²t) and peak let-through current that can damage sensitive components.
Mersen enhances the protection of your power conversion systems with:
- Semiconductor protection: They act as a critical line of defense for various power electronics components, including IGBTs, silicon carbide (SiC) semiconductors, GaN devices, thyristors, triacs, diodes, and more.
- Ultra-fast acting: Their rapid response time minimizes fault duration, significantly reducing stress on protected components.
- Reduced I²t: By limiting the thermal energy let-through during a fault, high-speed fuses help prevent overheating and consequent damage to sensitive electronics.
- Transient overload tolerance: These fuses are designed to withstand normal surges in current without compromising protection during actual fault conditions.
- Durability: Mersen's high-speed fuses are built to endure heavy-duty operation and multiple switching cycles.
Mersen caters to a wide range of applications within the power conversion industry, with high-speed fuse solutions ideal for:
- Power inverters, converters, and rectifiers
- AC and DC drives
- Direct current (DC) common bus protection
- Reduced voltage motor starters
- Uninterruptible power supply (UPS) systems
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Laminated bus bars for power conversion
Mersen's expertise in bus bar technology is showcased through our innovative Bus Bars Value Add Assembly, which allows the integration of various components into a single, compact solution. This approach not only enhances the efficiency of the bus bar itself but also optimizes the entire power conversion assembly by incorporating features like cooling functions and monitoring sensors directly into the bus bar design.
Benefits of integrated bus bar assemblies include :
- Enhanced thermal management: By integrating cooling solutions directly into the bus bars, we reduce the temperature of the bus bar and associated capacitors, decreasing the overall thermal stress on the system.
- Reduced size and weight: Our design allows for a more compact assembly, minimizing the size and weight of bus bars and thereby optimizing space and enhancing performance in power conversion applications.
- Increased component lifespan: The reduction in operating temperature and improved efficiency contribute to a longer lifespan for semiconductors and other critical components.
- Improved electrical performance: Integration minimizes equivalent resistance and serial inductance, enhancing overall electrical efficiency.
- Cost and time efficiency: Our integrated approach streamlines the manufacturing and assembly process, significantly reducing time and production costs, which is crucial for high-volume applications in EV/HEV, industrial, and renewable energy sectors.
Mersen uses advanced brazing, soldering, and mechanical assembly techniques to incorporate fuses and cooling solutions directly into our bus bars, enhancing efficiency and functionality. Our custom capacitor designs are precisely tailored to integrate seamlessly with bus bars, ensuring optimal performance for specific applications.
We also embed monitoring sensors to provide crucial real-time data for system integrity and performance.
In designing our bus bars, we consider all associated components like PCBs, resistors, and circuit breakers from the start, aiming for a comprehensive integration that maximizes performance while reducing production footprints, aligning with the specific needs of power conversion applications. This streamlined approach reflects Mersen's commitment to delivering efficient and tailored solutions.
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Capacitors for power conversion
Mersen's capacitors are designed to provide stability and improve the performance of power conversion systems. They are essential for energy storage, filtering, and providing the necessary reactive power to optimize the conversion process.
Key features of our capacitors include:
- Innovative designs: Mersen capacitors are designed to offer low inductance and high capacity, making them ideal for a wide range of applications, including industrial, renewable energy, and electric vehicle markets.
- Integration capabilities: Mersen capacitors can be integrated into complete modules based on customer specifications, enhancing the efficiency and performance of power conversion systems. Features like extremely low inductance, increased capacity volume, and ease of mounting and exchange highlight their advanced design and functionality.
- Longevity and reliability: Designed for stability and safety, Mersen capacitors ensure a very long life due to innovations like direct contact between the capacitor and bus bar, which prevents contact corrosion of terminals and enhances the overall durability of the assembly.
- German quality manufacturing: By maintaining production entirely in Germany, Mersen ensures top-tier quality and reliability in all its capacitor offerings. This proximity between development and production not only enhances quality but also facilitates quick adaptability to customer needs and technology changes.
- Customization and versatility: Whether for standard needs in small to medium quantities or complex, custom-made products for demanding applications, Mersen works closely with customers to deliver precisely what is needed.
Mersen’s approach to capacitor technology reflects our broader commitment to providing robust and customized solutions across various applications. With a strong focus on individual customer needs and a proven track record of innovation, our capacitors are instrumental in advancing power conversion technologies, driving efficiency, and supporting the dynamic needs of modern electrical systems.
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Cooling solutions for power conversion
Efficient cooling helps maintain the performance and reliability of power conversion equipment. Mersen's advanced cooling solutions, including heat sink technologies and extensive cooling expertise, are designed to effectively dissipate heat, preventing thermal overload and enhancing system efficiency.
Innovative cooling technologies and services:
- High-performance air cooled heat sinks: Mersen offers an array of air cooled heat sinks that vary in size and are made from different materials. Utilizing our patented Fabfin® design, these heat sinks feature fins that are mechanically secured to the base plate using our unique swaging technology. This method provides a robust connection that eliminates the need for less efficient bonding agents, ensuring optimal thermal management.
- Embedded heat pipe air cooled heat sinks: By embedding heat pipes into the surface of air cooled heat sinks, Mersen can rapidly disperse heat over a larger area. This technology is particularly effective in applications involving high heat concentrations from power electronics like SiC and Power Amplifiers, significantly enhancing cooling efficiency.
- Heat pipe assembly heat sinks: For applications requiring more advanced cooling, Mersen employs Heat Pipe Technology. This robust, long-lasting solution is ideal for managing the high heat loads typical in power electronics, providing superior cooling performance.
- Liquid cooled cold plates: Mastering vacuum brazing technology, Mersen produces leak-proof liquid cooled cold plates known for their robustness and superior thermal performance. These cold plates, available in both embedded tube and vacuum brazed designs, are corrosion-resistant and designed to offer enhanced cooling for high-performance applications.
Mersen's engineering team collaborates closely with clients to design and simulate customized cooling solutions, pushing the performance boundaries of heat sink technology. Whether through air, phase change, or liquid cooling, Mersen is equipped to provide the right thermal protection solutions to meet the demanding requirements of modern power conversion applications.
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Contact
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