Voltage sag mitigation refers to the technical and management measures taken to address power quality issues such as voltage sags or short interruptions. Voltage sags are usually caused by grid faults (e.g., lightning strikes, short circuits), start-up/shutdown of large-capacity equipment, fluctuations in new energy sources, etc. They last from a few milliseconds to several seconds and may cause severe damage or production interruptions to sensitive equipment (e.g., industrial production lines, precision instruments, data centers).
Microsecond-level response for "zero-delay" voltage sag detection
Supercapacitors store energy directly through electrostatic fields, with no chemical reactions involved in charging and discharging, enabling energy release at the microsecond level. Combined with a high-speed voltage detection module (sampling frequency ≥ 20kHz), the system can identify voltage abnormalities (e.g., voltage dropping below 70% of the rated value) within 30-50 microseconds and simultaneously trigger supercapacitor discharge. It completes voltage compensation before devices like contactors and motors act due to insufficient voltage (typically requiring 10-50 milliseconds), truly achieving "voltage sag suppression at occurrence" and preventing equipment shutdown.
Short-term high-power output, perfectly matching voltage sag duration
Industrial voltage sags usually last 0.05-1 second, while supercapacitors have a power density of 1000-5000W/kg. A single system can output tens to hundreds of kilowatts in a short time, ensuring the load-side voltage remains above 90% of the rated value. For example, when the grid voltage drops sharply to 50%, the system can inject the missing voltage within 0.1 seconds, supporting motors, PLCs, and other equipment through the voltage sag period without switching to backup power, thus avoiding instantaneous interruptions during switching.
Million-cycle lifespan, suitable for high-frequency voltage sag scenarios
Industrial grids (e.g., steel, chemical parks) may experience voltage sags several to dozens of times a day. Traditional battery-based mitigation systems (e.g., lead-acid batteries, lithium batteries) suffer rapid lifespan degradation under high-frequency charging and discharging (usually needing replacement every 1-3 years). In contrast, supercapacitors have a cycle life of over 1 million times. With an average of 10 daily voltage sags, they can operate stably for over 270 years, requiring no replacement of core energy storage components throughout their lifecycle. The operation and maintenance cost is only 1/10 of that of battery solutions.
Stable operation in a wide temperature range, adapting to harsh industrial environments
Supercapacitors operate within a temperature range of -40℃ to 70℃. The system, featuring three-proof design (dustproof, waterproof, corrosion-proof) and passive heat dissipation, can be directly deployed in high-temperature workshops (e.g., steel mills), outdoor pump stations, high-humidity chemical workshops, etc., without constant temperature facilities. Even in extremely cold environments of -30℃, the capacitance attenuation rate is less than 5%, solving the problem of lithium batteries' performance degradation at low temperatures.
Intrinsic safety, eliminating safety hazards in industrial scenarios
Supercapacitors use carbon-based electrode materials and inert electrolytes, with no flammable or explosive risks during charging and discharging. Under extreme conditions such as overcharging, short circuits, or mechanical impacts, the system may only experience performance degradation without combustion, explosion, or toxic gas leakage. It can be directly installed in explosion-proof workshops (e.g., oil and gas processing plants), dusty environments (e.g., cement factories), and other places with strict safety requirements, without the need for additional safety distances.
Continuous production lines (e.g., automotive welding, semiconductor manufacturing)
Pain points: Production lines rely on robots, conveyors, and precision welding equipment. Even a 0.1-second voltage sag may cause robot derailment and welding point deviation, requiring 2-4 hours of shutdown for inspection, with a single loss reaching hundreds of thousands of yuan.
Application value: The system compensates for voltage instantly during sag, ensuring stable voltage for robot servo motors and PLC control systems. For example, after deployment in an automotive welding workshop, the number of shutdowns caused by voltage sags dropped from 3-5 times per month to zero, reducing annual losses by over 10 million yuan.
High-power motor clusters (e.g., chemical plant pump sets, steel mill rolling mills)
Pain points: Large centrifugal pumps and rolling mill motors have high starting currents, which easily cause grid voltage sags. Meanwhile, motors are sensitive to voltage sags; when voltage drops below 70%, windings may burn due to locked rotor, resulting in high maintenance costs.
Application value: During voltage sags, supercapacitors discharge quickly to maintain motor voltage, preventing motor stoppage. For example, after deployment in a chemical plant's circulating water pump set, 12 voltage sags were successfully withstood without any motor burnout, saving hundreds of thousands of yuan in annual maintenance costs.
Explosion-proof/harsh environments (e.g., oilfield pumping units, coal mine ventilation systems)
Pain points: Power grids in oilfields and coal mines are prone to frequent voltage sags due to equipment start-up/shutdown. Additionally, these areas have flammable and explosive gases, posing safety risks for traditional battery systems.
Application value: The intrinsic safety of supercapacitors adapts to explosion-proof scenarios, while withstanding temperature differences from -30℃ to 60℃, ensuring pumping units and ventilators do not shut down during sags. For example, after deployment in oilfield wellhead equipment, downtime of pumping units caused by voltage sags decreased by 95%, and crude oil production increased by 3%.
Cold chain logistics and food processing
Pain points: Cold storage compressors and food sterilization equipment are sensitive to voltage. Voltage sags may cause compressor shutdown, leading to temperature rise in cold storage and food spoilage; interruptions in sterilization equipment may result in unqualified batch products.
Application value: The system maintains power supply to compressor motors and sterilization lamps during sags. For example, after deployment in a meat processing plant, 3 cold storage temperature rises caused by voltage sags were successfully avoided, reducing a single loss by over 500,000 yuan.
