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In extreme environments, such as metallurgical high-temperature workshops, wind power bases in cold regions, outdoor communication base stations, etc., violent temperature fluctuations have always been the "fatal injury" of filter performance attenuation. Recently, Shanghai Fengchuang Industrial Co., Ltd., a national high-tech enterprise, launched a wide temperature series filter, which successfully broke through environmental restrictions with an ultra-wide working temperature range of-25℃~+85℃ and a stable performance of "zero temperature drift", providing all-weather reliable electromagnetic protection solutions for industrial automation, new energy, communication and other fields, and redefining the performance standards of filters in extreme environments.

As a leading enterprise that has been deeply involved in power supply and filter technology for more than ten years, Shanghai Fengchuang's wide-temperature filter is a masterpiece in material science, structural design and temperature compensation technology. "When the temperature of the traditional filter exceeds-10℃~+60℃, the center frequency will shift more than 50ppm/℃, which will lead to the failure of the filter and the false triggering of the equipment." The R&D director of the company said that the temperature drift coefficient of the new product was controlled within 5 ppm/℃ by integrating three core patented technologies, and the filtering performance was consistent in the whole temperature range, which completely solved the application pain point in extreme environment.

Innovating material system and building the core foundation of wide temperature operation. Fengchuang abandoned the traditional ferrite core and adopted a self-developed nanocrystalline alloy composite core. After vacuum annealing at 1050℃, a uniform nano-grain structure was formed, and the change rate of permeability in a wide temperature range was less than 3%. At the same time, the key capacitor element is made of metallized polypropylene film, and its equivalent series resistance (ESR) is controlled within 18% in the range of-25℃~+85℃, which is far better than the industry average of 35%. In the limit test of Songjiang laboratory, the filter runs continuously for 500 hours at 85℃, and the insertion loss is still above 45dB. In the low temperature environment of-25℃, the startup response time is only 0.3 seconds, and there is no performance degradation.

Intelligent temperature compensation technology realizes "zero temperature drift" breakthrough. Drawing lessons from the principle of temperature compensation in the field of satellite communication, Fengchuang innovatively designed a compensation structure of "bimetal+digital algorithm", monitored the ambient temperature in real time through a built-in high-precision temperature sensor, and automatically adjusted the filter parameters within 20 milliseconds. The test data show that when the temperature suddenly rises from-25℃ to 85℃, the center frequency offset of the filter is only 3ppm, which is far below the industry standard limit of 25ppm, ensuring that the signal transmission error rate is controlled at 10-9. This dynamic compensation ability enables it to stably suppress the harmonic interference generated by the inverter in a desert photovoltaic power station with a temperature difference of 60℃ between day and night.

The sealed protective structure strengthens the adaptability to extreme environment. The product adopts IP65-grade fully sealed metal shell, and is filled with high-temperature resistant insulating material through special potting process, which effectively resists dust, humidity and salt spray erosion. In the high temperature and high dust test of simulated metallurgical workshop, the filter runs continuously for 1000 hours at 85℃ and dust concentration of 10 mg/m without failure; In the simulation of marine climate with salt spray concentration of 8 mg/m, the protective performance reached the standard of 1200 hours without corrosion. In addition, the optimized cooling air duct design ensures that the temperature rise of the shell does not exceed 20℃ when the equipment is running at full load, which further ensures the stability in a wide temperature range.

Multi-industry practical cases prove the hard-core strength of products. In a cold wind power base at-25℃ in Northeast China, the filter provides harmonic suppression for wind turbine converter, which reduces the failure rate of converter from twice a month to zero and increases the annual power generation by about 1200kWh；. In the 85℃ steelmaking workshop of a metallurgical plant in the south, its stable operation has reduced the number of false alarms of PLC control system by 90%, and the production line downtime rate has dropped from 3.2% to 0.7%. After the application of a new energy vehicle charging pile enterprise, the EMI test margin of the filter in outdoor extreme temperature increased from 2dB to 8dB, and it passed the CISPR 32 Class B certification successfully, and the charging efficiency increased by 8%.

Strict quality control and authoritative certification build market trust. Each filter must pass 18 limit tests, including-25℃ to 85℃ wide temperature cyclic aging, 10kV lightning surge impact, 500-hour salt spray corrosion, etc., and fully pass CE, UL and CQC certification, in line with international standards such as EN 61800-3. Relying on the modular customization ability, the delivery cycle of wide temperature solutions in special fields such as medical care and military industry can be shortened to 15 days.

"Extreme environment is the touchstone for testing technical strength." Yu Pingfeng, the founder of the company, revealed that this series of filters have been supplied in batches to European wind power projects, tropical power stations in Southeast Asia and communication base stations in cold regions in China. In the fourth quarter of 2025, orders increased by 230% year-on-year. Fengchuang is continuing to tackle the problem of ultra-wide temperature technology at-40℃~+100℃, and plans to expand its application scenarios to satellite communication, polar scientific research equipment and other fields, and continue to lead the industry in technological upgrading.

http://www.fonchuang.com
Shanghai Fonchuang Industrial Co.,Ltd.

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