1 151 Richmond St. S.W., PO Box 519, Hensall, ON, N0M 1X0A Solution Company 151 Richmond St. S.W., PO Box 519, Hensall, ON, N0M 1X0 Ph: Fax:
2 Presented by: Peter Kratochvil Cos Phi Inc.The Effect of Power Quality on Product Quality in Manufacturing A Case Study Presented by: Peter Kratochvil Cos Phi Inc.
3 Manufacturing Competitive Profitability Product Cost Automationresolve inconsistencies electrical power quality
4 Automation Solid state technology Based on static power conversionNumber of devices operating on same production line
5 Solid State Devices Characteristic behavior of these solid state devices Draw electric current in spurts or pulses Distort the sine-wave Impact the electrical power within the whole facility Equipment reliability means consistent product
6 Most Common Areas Welding operations Mis-indexing problems of robotsOther areas
7 Case Background The welders involved are 2.2KVA high frequency weldersPrevious process used gas flame welder Output of about 6-7 pieces a minute
8 Improving Efficiency A new high frequency welder was introducedMuch faster producing about pieces per minute Scrap rate at 33%
9 Part A Part B A & B Welded Together The Finished Product
10 Good Welds
11 Bad Welds
12 Close-up Over Heated Under Heated
13 Finished Products
14 Trying to improve QualityModifications on the new Welders From single phase to three phase More welders were added Situation deteriorated even more
15 Investigations Quality analysis performedRequire individual filter on each welder because the short circuit capacity was 1-4 at best Proposal was uneconomical
16 Move To New Facility Special attention was given to the poweringIsolation transformer was installed to serve only the welders Distribution panel was dedicated to welders Slight improvement
17 Different Problems In the new facilityThe distortion was less than half of the distortion in the old premises Welders fired coincidentally at the same time The more Welders the more frequent were the coincidences
18 New Investigation Inrush current when welders fired Voltage dropDepleted power to the next welder at random
19 Mitigation Resolution50 Amp Aim Active Filter Possibility of mitigating problem for all welders from one central location with one filter
20 Results No Filter Welding approximately 25 pieces of product per minute, scrap rate of 16%
21 Results With Filter Welding approximately 25 pieces of product per minute, scrap rate of 0.7%
22 Conclusion Power quality or lack of power quality can impact not only the electrical distribution system but also impacts: The final product of a process The profitability of the company
23 Phase A Filter OFF
24 Phase A Filter ON
25 Phase B Filter OFF
26 Phase B Filter ON
27 Phase C Filter OFF
28 Phase C Filter ON
29 Questions?