With BLOCK Solutions, we are your partner for customized, all-in-one technical solutions from a single source. Thanks to our comprehensive development expertise, we can bring your visions of integrated system solutions to life in close collaboration with you. We combine electrical and mechanical components from our portfolio – whether standard or customized – as well as components from selected third-party suppliers.
Upon request, we integrate your ‘electrical life’ into a custom-designed enclosure that is precisely tailored to your environmental conditions. The result is a closed system that can be easily integrated into your application.
Our goal is to create the perfect solution for your requirements and to support you throughout the entire project cycle – from development to production of your individual system solution.
At our development center with directly integrated manufacturing, your system solutions are calculated, designed, simulated, optimized, and produced. This creates a closed-loop process based on our proven CoCreation development philosophy established over decades: together with our customers, we develop solutions that meet individual requirements and needs. With a strong focus on practical application and the highest quality standards, we create systems in which every parameter is precisely coordinated.
BLOCK stands for technologically advanced development combined with a high level of vertical integration. Expanded over decades, our manufacturing processes cover all product groups produced at our headquarters, at international production sites, and with external manufacturing partners. Our proprietary technologies – particularly in the field of winding technology – have made us an indispensable innovation driver for power electronics components in more than 50 industries.
VERTICAL INTEGRATION AS A GUARANTEE OF FLEXIBILITY
Our autonomy and independence in manufacturing create the flexibility required in development. Demand-oriented production and a level of automation defined by consistent quality provide the ideal conditions for developing BLOCK Power Solutions comprehensively together with our customers. Our high level of vertical integration enables us to realize complex system solutions tailored to customer requirements – at the component level as well as in connection technology and final assembly.
CUSTOM SOLUTIONS AS A CORE BUSINESS
- More than 25 years of experience in Power Solutions
- High level of vertical integration across all product areas
- A wide range of existing plug-in solutions designed for industry-specific requirements and certified accordingly
- Strong expertise in custom equipment design through interdisciplinary teams
For one of our customers, this system solution ensures reliable power supply for sensitive radio communication equipment. It is a DC distribution system for 19" racks with 21 individually protected supply circuits. Thanks to the practical rack design and pre-wiring, the system is ready to connect and can be installed with just a few simple steps.
The load circuits feature different current ratings, including 15 A, 25 A or 60 A. Through automatic power shutdown, the system is protected by individual short-circuit and overload protection for each circuit. Cooling is ensured by temperature-controlled fans with aluminum filters. The overall robust design is particularly suitable for industrial applications, as clearly separated connectors for each load circuit allow for easy assignment.
This custom system solution combines high reliability, IP65 protection, and complete pre-assembly in a single enclosure. The redundant 24 Vdc/20 A power supply is provided by two separate switched-mode power supplies connected via a redundancy module, ensuring maximum availability. An integrated capacitive UPS based on supercapacitors secures the 24 Vdc supply in the event of a main power failure, preventing system downtime. The individual load circuits are monitored and protected by an 8-channel electronic circuit breaker. All connections are implemented using high-quality IP65 connectors integrated into the enclosure. An optional interface for condition monitoring and power supply diagnostics is available. The solution is robust, low-maintenance, and designed for use in demanding, decentralized industrial environments.
Used in the field of power quality, this product solution serves as a power supply for blade pitch control in wind turbines. The drive system allows the rotor blades to be adjusted to the optimal angle relative to wind direction. As a result, overall system efficiency is maximized while mechanical stress is reduced. By integrating this system solution, our customer has achieved precise control of its renewable energy system, increased energy output, and reduced maintenance requirements.
Together with the customer, a plug-and-play solution was developed. Thanks to pre-assembled cables and connectors, the system can be installed easily and quickly and is ready for operation.
PROJECT STEPS BLOCK DEVELOPMENT
- Development and design of the system solution, including overall assembly concept
- Parallel development, design, and production of the application-specific 43 A line reactor – specification and dimensioning, as well as definition of required input, output, and control cables with customer-defined third-party connectors/couplings
- Manufacturing of the standard autotransformer (Made in Germany)
- Robotic welding processes for the enclosure
- Assembly of components within the powder-coated enclosure
- Internal wiring of specified components (contactors, motor protection circuit breakers, surge protection devices)
This custom, ready-to-connect solution includes a three-phase transformer with enclosure, protection, and a main switch for supplying up to three machines worldwide. The circuit breakers and the main switch are externally accessible, ensuring easy maintenance and convenient operation.
TECHNICAL DATA
- Input voltage (primary): 3 x 208 Vac, 220 Vac, 415 Vac, 440 Vac, 480 Vac
- Output voltage (secondary): 3 x 400 V, 5-pole
- Galvanic isolation
- Power: 35000 VA
- Output via 3 CEE outlets
- Protected by 3 x 16 A circuit breakers
In close cooperation with our customer STABL, we developed an innovative grid connection box featuring an EMI filter and reactor – customized within a specially adapted enclosure. This solution is used in large-scale energy storage systems. STABL’s inverter technology sets new benchmarks in future-ready performance and offers clear advantages over conventional solutions. Together, we are advancing renewable energy and creating sustainable, future-proof storage solutions.
The grid connection box has a power range of 75 kW. Due to the modular design of the storage system, multiple boxes can be integrated into a single battery storage unit. The reactor and EMI filter ensure reliable and interference-free grid connection.
COORDINATED COMPONENTS AND MAXIMUM LINE PROTECTION TO PREVENT POWER DISTURBANCES
Thanks to its design and attenuation characteristics, the BLOCK EMI filter is specifically adapted to the system requirements and therefore ensures reliable reduction of high-frequency interference. The reactor further reduces line feedback and increases overall system stability.
Our customer STABL receives a customized system solution consisting of a jointly developed sheet metal enclosure with an integrated EMI filter and a reactor. The powder-coated front panel highlights the high manufacturing quality and the appealing design.
THE STABL SOLUTION AT A GLANCE
- Customer-specific development of a 19" rack with integrated BLOCK reactor and a BLOCK EMI filter
- The grid connection box ensures compliance with EMC limits and smooths the voltage
- Modular multilevel converters for battery storage systems replace conventional battery inverters
Together with one of our customers, we developed a precisely controllable 330 kVA autotransformer integrated into an enclosure. The single-phase autotransformer converts a primary voltage of 110 Vac at 3022 A to the required voltage. Via remote control using a PLC or a key switch, different voltages can be selectively applied to the output busbars. Integrated into a robust IP23 enclosure with a total weight of 2.4 tons, this product is one of the largest in our portfolio and is engineered for demanding test applications.
TECHNICAL DATA
- Input voltage (primary): 110 Vac (3000 A)
- Output voltage (secondary): Switchable from 150 Vac to 180 Vac
- Switchable via remote control using PLC or key switch
- Integrated into a custom IP23 enclosure
