GAOHUI Plasma Electrolytic Oxidation Power Source 750V 200A

Engineered for the precise physics of micro-arc discharge, this GAOHUI 150kW system delivers the demanding voltage ceiling and current stability required for Plasma Electrolytic Oxidation (PEO) of lightweight alloys. Unlike standard anodizing supplies, this unit provides a programmable pulsed DC output designed to sustain the critical micro-arc regime between 250V and 750V, enabling the growth of advanced ceramic layers on magnesium, aluminum, and titanium substrates. As a dedicated industrial high frequency rectifier factory, we have optimized the waveform for fast rise and fall times to control discharge energy, ensuring dense, uniform coatings without thermal damage to the substrate. This system outputs a stable DC electrical supply between the cathode and anode, utilizing a closed-loop control architecture to maintain precise voltage and current parameters throughout the oxidation cycle.
PART 1 KEY FEATURES & ENGINEERING HIGHLIGHTS
HIGH VOLTAGE SPARK SUSTAINMENT: The power stage is designed for the high-voltage discharge regime inherent to PEO, operating reliably from 95V up to the full 750V ceiling. This robust output is critical for initiating and maintaining the plasma micro-arcs necessary for converting the surface into an MgO or Al2O3 based coating.
FAST SWITCHING PULSE MODULATION: An IGBT-based inverter provides steep pulse edges with adjustable on/off timing. This waveform control prevents continuous arcing and temperature spikes, delivering the energy in controlled bursts that promote a homogeneous, dense ceramic layer over the entire workpiece area.
HIGH EFFICIENCY AND HEAVY-DUTY DESIGN: Built for continuous production line operation, the system exceeds 92% efficiency at full load. All high-current busbars and transformer windings are overrated, minimizing thermal drift and extending the service life of the power stage. We invite you to verify our competitive heavy-duty DC power supply price against units with lower thermal margins.
TOUCHSCREEN PROCESS CONTROL: A programmable logic controller with an HMI provides direct control over all process variables. Operators can instantly adjust voltage, current, and pulse parameters (frequency, duty cycle, and pulse sequence) using pre-saved recipe profiles.
PART 2 TECHNICAL SPECIFICATIONS TABLE
| Parameter | Specification | Notes |
|———–|—————|——-|
| Rated Output Voltage | 750 V DC | Operational range: 95V – 750V DC |
| Rated Output Current | 200 A DC | Adjustable from 0 to 100% rated value |
| Maximum Output Power | 150 kW | Continuous duty (24/7 rated) |
| Input Voltage | 3-Phase, 380V / 480V AC (50/60 Hz) | Custom input available upon request |
| Efficiency | > 92% (at full load) | Measured at nominal operating point |
| Output Type | Programmable Pulsed DC | Fast rise/fall time, IGBT switching |
| Pulse Frequency Range | 1 Hz – 3000 Hz | Independent adjustable frequency |
| Duty Cycle | 10% – 90% | Adjustable on-time per cycle |
| Cooling Method | Forced Air / Deionized Water | Environment dependent; heavy duty rated |
| Control Interface | RS485 Modbus RTU, Ethernet, 4-20mA | Additional optional Profibus/Profinet |
PART 3 ADVANCED BUILT-IN PROTECTION SYSTEMS
Process reliability is non-negotiable. This unit integrates a multi-layer protection suite that actively monitors the unique load characteristics of the electrolytic bath.
SOFT-START AND ARC DETECTION: A programmable soft-start ramp prevents initial current inrush. In the event of a sustained short or localized high-energy arc, the system’s rapid trip detection (under 1 millisecond) shuts down the output, protecting both the workpiece and the power modules.
UNDER-VOLTAGE AND OVER-CURRENT SAFEGUARDS: Dedicated digital comparators monitor the critical spark voltage window. If the bath voltage falls below the micro-arc threshold or current exceeds the programmed limit, a safe-state shutdown is initiated, communicating the fault via the HMI and remote interface.
THERMAL RUNAWAY PREVENTION: Redundant temperature sensors on the main IGBT banks and rectifier diodes monitor internal heat buildup. If coolant flow is compromised or ambient temperature spikes, an audible alarm triggers and the controller linearly reduces output to prevent component damage.
PART 4 TARGET INDUSTRIAL APPLICATIONS
PLASMA ELECTROLYTIC OXIDATION (PEO): The core application for this power supply. It provides the high electric field strength (voltage) required to break down the dielectric layer on anodes. This creates micro-discharges that sinter a ceramic oxide layer (e.g., MgO, Al2O3) into the metal surface.
LIGHTWEIGHT ALLOY PASSIVATION: Ideal for the surface treatment of magnesium, aluminum, and titanium alloys used in the automotive and aerospace sectors. The controlled pulsed DC output produces a fatigue-resistant ceramic coating that dramatically improves corrosion and wear resistance.
ADVANCED CERAMIC LAYER FORMATION: The precise modulation of pulse frequency and duty cycle allows operators to tailor the phase composition and porosity of the resulting coating. This is critical for producing functional layers with specific dielectric or thermal barrier properties.
HIGH VOLTAGE SPARK ANODIZING: For specialized anodizing processes that require voltages well above the conventional 100V-200V range. The unit handles the micro-arc region associated with hard ceramic coating techniques on non-standard aluminium alloys.
PART 5 CUSTOMIZATION AND TAILORED ENGINEERING SERVICES
As a leading IGBT rectifier manufacturer, we provide complete factory-level customization of this PEO power source to match your exact bath chemistry and workpiece geometry.
FACTORY CUSTOM CAPABILITY: Over 20 years of experience allows us to adjust any parameter. Output voltage can be customized within 1V to 1000V DC. Output current custom ranges from 1A to 100,000A DC. Input voltage can accommodate most international 3-phase mains (AC only). Output is strictly pure, filtered DC.
MODULAR ADD-ONS FOR PROCESS CONTROL: Include specialized modules such as a Process Timer for batch termination, a Multi-Stage Profile Control for ramping voltage and current throughout the coating cycle, and an Ampere-Minute Integrator to calculate total charge transfer for consistent coating thickness. An Automatic Reverse Polarity module can assist in cleaning cycles or specialized cathode etching.
ADVANCED INTERFACING: Standard interfaces include RS485 Modbus RTU and Ethernet (TCP/IP) for MES or SCADA integration. Analog control is supported via 4-20mA input/output signals for external PLC control. For pulse optimization, we offer Pulse Functions with independently adjustable frequency from 1Hz to 3000Hz, enabling fine-tuning of the spark duration.
Request your factory consultation for a custom current voltage rectifier designed to match your specific plasma electrolytic oxidation line. Contact our engineering team to review your bath parameters and production throughput requirements.