WLK Motor Excitation Series
PRODUCT ADVANTAGEADVANTAGE
Outstanding Capabilities of Hengda Industrial Control's Excitation Products in System Operational Performance and Reliability
● Unmatched Stability and Control Precision:All product series utilize a 32-bit DSP-based digital control system, delivering high sampling accuracy, rapid operational response, and industry-leading control precision. For instance, the WLKF generator excitation systems achieve a voltage control accuracy of ±0.1%. This ensures extremely stable operation for both motors and generators, even under dynamic load changes or grid fluctuations. This level of precision minimizes operational deviations and maximizes system efficiency.
● Adaptive Intelligence for Optimized Performance
Integrated adaptive control functionality allows the system to intelligently analyze real-time motor/generator operating conditions and automatically select the optimal control strategy. This significantly reduces the need for manual adjustment during both commissioning and continuous operation, accelerating deployment and sustaining peak performance.
● Excellent System Reliability and Uptime
Redundancy as a Core Design Principle: For critical applications, the WLK-S3 and WLK-WS3 models feature an advanced dual-processor control system with a hot standby function. This design enables a disturbance-free automatic switchover in under 6 milliseconds upon fault detection, virtually eliminating unplanned downtime.
● Hot-Swappable Components for Continuous Service: The physical isolation of critical components in dual-system models—such as power supplies, analog sampling modules, and touchscreens—allows for the hot replacement of failed parts without interrupting system operation. This significantly boosts operational uptime and simplifies maintenance procedures.
● Comprehensive Self-Diagnosis and Automated Recovery: The integrated self-diagnosis function provides real-time fault localization. Coupled with the automated seamless switchover to the backup system, this capability minimizes manual troubleshooting and intervention, thus enhancing the system's overall resilience.
● Decades of Proven Longevity: The company's products demonstrate exceptional durability and reliability in the field, with documented cases of brush excitation systems operating flawlessly for 29 years and brushless systems for 15 years. This extensive operational history underscores the robust design and long-term reliability of the entire product portfolio.
● Fast Response and Dynamic Stability:
The excitation system's extremely low response delay of ≤0.02 seconds allows for rapid adjustments to changes in load or grid conditions. This delivers superior dynamic stability and prevents operational deviations.
● Robust Electromagnetic Compatibility (EMC): Designed in compliance with stringent IEC standards, the system achieves outstanding EMC performance, ensuring reliable operation, minimized interference, and enhanced data integrity.
Product Introduction in the Series
WLK-T3 Excitation System
The WLK-T3 is a microprocessor-controlled single-system excitation cabinet for synchronous machines, serving as the foundational model in the WLK Motor Excitation Series.
It is primarily used for the standalone excitation of synchronous motors ranging from 200 kW to 10,000 kW. Its applications are widespread, covering the drive for various industrial equipment such as compressors, ball mills, blowers, water pumps, and refrigeration systems.
The system is focused on delivering straightforward, reliable performance for applications that don't require the highest level of redundancy. A single-system configuration typically means a lower initial acquisition cost and simpler integration, making it an ideal choice for standard industrial applications that need proven, stable control without the added complexity and expense of a redundant system.
WLK-S3 Excitation Control System
The WLK-S3 is a microprocessor-based dual-system excitation control cabinet designed for synchronous motors. It is ideally suited for mission-critical applications requiring extreme operational continuity, effectively preventing significant economic loss or safety risks caused by unexpected interruptions.
This system supports synchronous motors from 200 kW to 10,000 kW, driving essential industrial equipment such as compressors, ball mills, blowers, water pumps, and refrigerators.
The WLK-S3' s dual-system architecture enables disturbance-free automatic switching and allows hot replacement of faulty components—including controllers and touchscreens—without shutdown, owing to its fully isolated design of critical parts. These features are central to minimizing downtime and ensuring high operational reliability.
WLK-WS3 Excitation Control System
The WLK-WS3 is an increased safety-type, microprocessor-based dual-system excitation control cabinet for synchronous motors. It uniquely integrates both static and rotating excitation systems, making it suitable for brushless synchronous motors of various capacities and loads in explosion-hazardous zones of type IIC T3, as well as in standard industrial environments.
A standout feature of the WLK-WS3 is its "Increased Safety" (Exe) design, with explicit explosion-proof certifications—including Ex e II Gc, Ex e II T3 Gc, and Ex e mb II T3 Gc—particularly applied to its rotating control module. This specialized capability allows it to serve highly compliant niche markets such as chemical plants, mining operations, and environments with combustible dust. The inclusion of both static and rotating excitation systems further underscores its versatility and comprehensive performance in demanding high-safety applications.
Core Technical Features Shared Across WLK and WLKF Series
● Digital Signal Processing (DSP): All models employ a 32-bit DSP for digital sampling and control, ensuring high sampling accuracy, rapid processing speed,and precise control tracking.
● Adaptive Control: The controller intelligently selects the optimal control strategy based on real-time motor/generator operation and sample data,optimizing performance and reducing commissioning time.
● Human-Machine Interface (HMI): Features a 10-inch TFT true-color LCD touchscreen (dual screens for S3/WS3 models) for comprehensive monitoring, parameter configuration, and fault information display,supporting both Chinese and English menus.
● Communication Capability: Includes RS485 and Modbus interfaces for seamless interacting with DCS,supporting remote monitoring and control.
● Flexible Control Modes: Supports multiple operating modes such as constant power factor, constant excitation current, constant excitation voltage, or constant firing angle operation, enabling automatic tracking of operating conditions and disturbance-free switching.
● Forced Excitation Function (Optional): Enhances system stability by activating forced excitation during grid voltage dips.
● Comprehensive Protection & Limiting Functions: Provides limits for max/min excitation current/angle,various out-of-step protection functions(e.g.,excitation loss, de-excitation, excitation failure,tec.), PT/CT disconnection protection, and self-diagnostics (e.g., pulse abnormalities, software/hardware errors, overtemperature, and thyristor faults),all with alarm logging and display.
WLK CASE
● Case: Excitation System for a Synchronous Motor in an Air Compressor, Sichuan Jinbei Chemical's Synthetic Ammonia Production Line
● Challenge: In 1996, the customer needed a customized excitation system for an air compressor in a new synthetic ammonia production line. At that time, very few excitation products offered microprocessor-based intelligent control, and standard solutions could not meet their precise and varied operational requirements.
● Solution: Hengda Industrial Control provided a brush-type microprocessor-controlled excitation system, which was already commercially available in 1996. The system was precisely tailored to meet the customer's specific needs.
● Result: Through close collaboration, Hengda Industrial Control successfully delivered a customized excitation control system. This solution has ensured the safe and continuous operation of the synchronous motor for 29 years and remains in service without a single failure. As a result, Sichuan Jinbei Chemical has since become a key long-term partner of Hengda Industrial Control.
USE cases
Case Study: High-Voltage Liquid-Resistance Soft Starter System Upgrade
1. Project Background
The high-voltage motor system at Shaanxi Yangxian Yuhu Chemical Co., Ltd. had been operating with liquid-resistance soft starters for more than a decade. As the existing equipment aged, several pain points became evident:
The liquid-resistance cabinets were bulky and occupied excessive floor space.
Their complex design demanded frequent maintenance of electrolytes, electrodes, and mechanical parts, resulting in significant O&M workload and high costs.
Startup performance was limited—low accuracy and the inability to support frequent restarts within short intervals—constraining production scheduling flexibility. The customer urgently required a high-efficiency, low-maintenance, and intelligent high-voltage soft-start solution.
2. Hengda's Solution：
Having reliably used Hengda’s excitation systems for more than a decade, the customer had full confidence in our product quality and service support. Based on this established trust, the customer directly selected the HDGR solid-state soft starter cabinet for this critical upgrade.
The solution delivered transformative results:
Lower O&M Costs & Space Optimization: The fully solid-state, modular design occupies significantly less space than the former liquid-resistance cabinet. Eliminating the need for electrolytes and mechanical upkeep, the maintenance frequency and costs were drastically reduced, achieving truly “low-maintenance or maintenance-free” operation.
Improved Startup Performance & Productivity: Leveraging high-precision thyristor control technology (as HDGR is solid-state), the system ensures smooth starting, completely eliminating mechanical and electrical shock during startup. It also supports rapid, repetitive starts and stops, significantly increasing the operational efficiency of the production process. The system's integration enables remote monitoring and condition diagnostics, further aligning with the customer's requirements for a digitalized and intelligent factory upgrade.
3. Client Feedback
The Operations and Maintenance (O&M) Department spoke highly of the benefits of the HDGR's minimal maintenance needs and high starting accuracy. They reported that the new equipment's performance stability and reliability significantly exceeded expectations, effectively guaranteeing the full life-cycle operation of critical assets. This retrofit not only addressed the client's core O&M pain points but also—via advanced solid-state technology—achieved a dual enhancement in production efficiency and reliability in a critical industrial segment.
Hubei Sanning Group: Eliminating Recurrent Failures in Synthesis Reactor Electric Heating with WDTJ
● Customer Challenge
The original temperature control system for Hubei Sanning Group's synthesis reactor relied on analog, non-microprocessor-based circuitry (using resistors and capacitors) to adjust the thyristor firing angle. This caused significant three-phase output imbalance. The resulting uneven heating of three-phase resistor elements led to frequent filament cracking, breakage, and short circuits, repeatedly forcing production line stoppages.
● Our Solution
Since 1997, we have supplied the first-generation WDTJ AC voltage and power regulation cabinet to address this issue. By implementing high-performance industrial control chips and digital synchronous phase-shifting technology, we entirely replaced the unstable analog control, achieving precise digital regulation of the firing angle.
● Long-Term Results
After the upgrade, the system immediately delivered accurate three-phase voltage triggering and stable output current. This completely eliminated unplanned downtime caused by three-phase imbalance at Hubei Sanning Group, ensuring continuous production.
● Built on this long-term trust and proven operational performance,Hubei Sanning Group has since adopted nearly 20 sets of our latest WDTJ AC voltage and power regulation cabinet across five newly built chemical plants. All WDTJ cabinets have been maintaining precise control and stable operation, consistently supporting the development of Hubei Sanning Group's chemical industry.
Case Study:Electrostatic Precipitator Upgrade at Hubei Sanning Chemical
● Customer Challenges
Hubei Sanning Chemical’s electrostatic precipitator (ESP) system had been operating for years with increasing failures and declining dust collection efficiency. Key issues included:
-Failure to reach target high-voltage levels
-Poor voltage control accuracy
-Inability to effectively limit discharge spark frequency
These shortcomings not only risked non-compliance with environmental standards but also undermined production stability.
● Our Solution
We delivered a customized WGT-series high-voltage control power supply featuring:
-Highly precise voltage regulation and improved step-up characteristics
-Microprocessor-controlled monitoring and limitation of spark rate (sparks per minute)
● Results Achieved
-Operating voltage increased by 10%, significantly improving dust removal efficiency
-Stable and accurate voltage output with tightly controlled sparking
-Markedly improved system reliability and reduced failure rate
-The system has now operated flawlessly for three years, earning consistent positive feedback from the custome
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