1. 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
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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 Automation
resolve inconsistencies
electrical power quality

4. Automation Solid state technology Based on static power conversion
Number 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 robots
Other areas

7. 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

8. Improving Efficiency A new high frequency welder was introduced
Much 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 Quality
Modifications on the new Welders
From single phase to three phase
More welders were added
Situation deteriorated even more

15. Investigations Quality analysis performed
Require 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 powering
Isolation transformer was installed to serve only the welders
Distribution panel was dedicated to welders
Slight improvement

17. 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

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

19. Mitigation Resolution
50 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?