Reliable High-Voltage DC Monitoring in Metals Processing

Key facts about the application

Sector

Metals Processing

Application

High-voltage DC measurement in Electric Arc Furnaces and Drive Systems

Measured Parameters

Voltage and Current measurement in 4.8 kV environments

Main Requirements

Reliable isolation under extreme electrical stress
High accuracy for process optimization
Fast response times for system stability
Noise immunity in harsh industrial environments

Precision and safety in extreme industrial environments

Metals processing plants, especially those using Electric Arc Furnaces (EAFs), operate under extreme conditions, relying on high currents and voltages to melt and refine metals such as steel. These parameters are critical for monitoring efficiency, ensuring process stability, and protecting valuable equipment. However, the extreme electrical stress and harsh conditions present in steelmaking environments creates a problem for transducers. To meet these challenges, Knick Interface provides high-isolation measurement solutions tailored for the metals industry, enabling accurate data acquisition and secure operation even at voltage levels reaching up to 4,800 V DC.

Description and requirements

In metals processing, especially in steelmaking with Electric Arc Furnaces (EAFs), large amounts of electrical energy are required to melt scrap and refine metal. These systems often operate with high DC voltages and currents in the tens of kiloamps, which must be measured reliably to optimize performance, control energy usage, and prevent equipment failures.

The challenge lies in the extreme electrical and physical environment. High-voltage busbars and shunt connections expose measurement equipment to continuous isolation demands of several kilovolts. At the same time, harsh ambient conditions with pollution, vibration, and heat require devices capable of operating without degradation. It is imperative that measurement devices meet the isolation capability to safely withstand these voltages, or risk critical gaps in monitoring and safety.

Customers in this sector require transducers that not only provide precise and fast response measurements but also ensure long-term electrical safety with high test voltages and reinforced isolation. These requirements are essential both for protecting control systems and for meeting industry standards in one of the most demanding industrial applications.

Why Knick ?
Knick’s P41000 and P42000 high-voltage transducers were developed specifically for demanding industrial environments like metals processing. With continuous measurement and isolation up to 3.6 kV and 30 kA DC (via shunts), they provide the robustness required in EAF and drive applications. Fast response times in the microsecond range ensure reliable detection of load changes, while reinforced isolation protects equipment and personnel. Moreover, the devices feature a high common mode rejection ratio, extracting the true measurement data vs noise in the system. By combining accuracy, safety, and durability, Knick transducers offer a proven, industry-specific solution for reliable high-voltage DC measurement.

Conclusion

By integrating Knick’s P41000 and P42000 transducers, metals processing plants gain precise, safe, and reliable high-voltage DC measurements essential for efficient furnace and plant operation. The combination of high isolation, fast response times, and proven performance ensures both operational safety and improved process control. Customers benefit from reduced downtime, streamlined maintenance, and efficient equipment operation. With Knick’s measurement solutions, operators can confidently manage the extreme demands of electric arc furnace environments, optimizing both performance and safety in their production process.

Matching Products

P41000 High Voltage Transducer / Transmitter | Calibrated and Switchable

Product number:

P41000

P42000 High Voltage Transducer / Transmitter | Calibrated and Switchable

Product number:

P42000

Associated industries and applications

Heavy Industry and Processing Industry

When it comes to reliably measuring high direct voltages and currents under harsh conditions, the high-isolation transducers from Knick are the top choice.