151 Richmond St. S.W., PO Box 519, Hensall, ON, N0M 1X0 A Solution Company 151 Richmond St. S.W., PO Box 519, Hensall, ON, N0M 1X0 Ph: 519-262-2822 Fax: 519-262-2310

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.

Manufacturing Competitive Profitability Product Cost Automation resolve inconsistencies electrical power quality

Automation Solid state technology Based on static power conversion Number of devices operating on same production line

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

Most Common Areas Welding operations Mis-indexing problems of robots Other areas

Case Background The welders involved are 2.2KVA high frequency welders Previous process used gas flame welder Output of about 6-7 pieces a minute

Improving Efficiency A new high frequency welder was introduced Much faster producing about 25-30 pieces per minute Scrap rate at 33%

Part A Part B A & B Welded Together The Finished Product

Good Welds

Bad Welds

Close-up Over Heated Under Heated

Finished Products

Trying to improve Quality Modifications on the new Welders From single phase to three phase More welders were added Situation deteriorated even more

Investigations Quality analysis performed Require individual filter on each welder because the short circuit capacity was 1-4 at best Proposal was uneconomical

Move To New Facility Special attention was given to the powering Isolation transformer was installed to serve only the welders Distribution panel was dedicated to welders Slight improvement

Different Problems In the new facility The 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

New Investigation Inrush current when welders fired Voltage drop Depleted power to the next welder at random

Mitigation Resolution 50 Amp Aim Active Filter Possibility of mitigating problem for all welders from one central location with one filter

Results No Filter Welding approximately 25 pieces of product per minute, scrap rate of 16%

Results With Filter Welding approximately 25 pieces of product per minute, scrap rate of 0.7%

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

Phase A Filter OFF

Phase A Filter ON

Phase B Filter OFF

Phase B Filter ON

Phase C Filter OFF

Phase C Filter ON

Questions?