The automotive manufacturing industry has adopted a large number of impact and non-linear loads in the main production processes, such as motor and laser welding machines in the body shop; presses in the press shop; inverters in the paint shop; automatic production lines in the assembly shop, etc. Impingement and non-linear loads all have a common feature, that is, the load fluctuation is very large and the harmonic generation is very large. At the same time, with the continuous demand for energy-saving and energy-saving in the country, the use of energy-saving lamps has been largely used, and conventional motors have gradually been replaced by variable frequency drives. These new non-linear loads have exacerbated the power quality problems of automotive manufacturers.
At present, many OEMs and parts factories have gradually begun to do energy monitoring and management of equipment, and tested the power consumption curve of their own key energy-consuming equipment, matching the production curve, and finding that energy is wasted to achieve the effect of energy saving. Here are some typical automotive application examples:
I. Chongqing Baosteel Auto Parts Press Shop
Chongqing Baosteel Automotive is mainly engaged in the production of automotive door panels and support members. The usual process includes a large number of stamping links. The currently used Schuler automatic press integration equipment.
Problems encountered: During the work of the stamping equipment of Shule, irregular currents caused the entire power supply system to trip, seriously affecting continuous production and normal operation of other peripheral equipment. The initial suspicion was caused by the inrush current during the operation of the Shule punch. The Schuler presses have a rated operating current of 1700A and a protective limit of 5000A.
Test plan: The customer uses Fluke 435-II power quality analyzer, through the inrush current test function, real-time monitoring of the current fluctuations of the stamping equipment.
Test results: After Fluke 435-II power quality analyzer test found, Shule punch press maximum operating current of 3240 A, far higher than the rated operating current of 1700 A, of which more than 2000 A duration is more than 5 s
Inrush current trend waveform under one working condition
Reason confirmation / solution:
It is found that the pressure current of Shulehong is too high, and the peak current reaches the trip limit in the case of multiple load operation. This causes the system to be powered off and communicates with Shule manufacturers. The maximum current of the press system is adjusted to 2300A under the condition of ensuring the process. Left and right, reduce the punch current to avoid tripping. It has been running for two months or so, and there is no phenomenon of tripping, which ensures the continuous production of customers and brings benefits to customers. Stamping of automobile bodies and parts is an important part of automobile production. A large number of large-scale equipment such as CNC punch presses and stamping machine tools are used in the system. These devices not only cause inrush currents, but also have impact on system operation. They are also typical harmonics. Sources and impact loads, harmonics generated not only cause the bus voltage fluctuations, the equipment can not run, but also to reduce the system power factor, voltage and current waveforms seriously distorted, increase the reactive power system losses, affecting the entire power supply system.
II. Changan Suzuki Automotive Painting Workshop
The Changan Suzuki automotive paint shop discovered that due to the failure of the power supply converter, the power supply of the trailing-rail power motor was cut off and there was no fault in pulling the body-in-white from the plating bath, resulting in the white-body scrapping, with a single loss of about 30,000. The reason for this may be Due to voltage problems. A one-week inspection at the customer site through the power quality analyzer Fluke 435-II found a drop in customer voltage from the point.
Problem: Incorrect operation of the power supply inverter causes the motor to lose power
Severity: The body in white cannot pull out from the plating bath, causing the body in white to be scrapped
Fault reason judgment: B phase voltage falls, causing the inverter to malfunction
Test Equipment: Fluke 435-II Power Quality Analyzer
Test Data:
Voltage drop trend chart
Voltage drop event waveform
The harmonic problem is also a prominent power quality problem in the painting process. The main load of the coating process is power electronic devices and large-capacity heating devices. These devices are manufactured using the principles of rectification and frequency conversion. During this process, harmonics are generated, while heating devices use more resistive devices. The power quality of the paint shop is characterized by large inductive and reactive power, low overall power factor, large and complex harmonic currents, severe system bus voltage drop, high heat generation, and low utilization.
Harmonics will increase the equipment loss in the paint shop, increase the iron loss, copper loss, dielectric loss and voltage peak of the main transformer, increase the transformer noise, and reduce the transformer load capacity. Harmonics can cause misuse of equipment such as painting, painting, and transportation, resulting in non-uniform paint spraying and poor transportation. In the coating surface, defects such as air bubbles, paint leakage, poor polishing, and repeated paintings are seriously detrimental to the coating of products. Quality. As the reactive power consumption of the system increases, the voltage of the busbar drops and the voltage deviation occurs. However, the voltage of the heating equipment may be too low to reach the surface coating temperature standard of the baking vehicle within the prescribed time and the baking quality problem will occur.
Voltage harmonics
Current harmonics
Changan Suzuki automotive paint harmonic test chart
Improving power quality is one of the important tasks for the company's power supply and distribution management, and it should be particularly valued in the automotive industry. The improvement of power quality can increase production efficiency, reduce energy costs, reduce defective rates, and increase production efficiency to ensure continuous production.
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