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Intelligent Power Supply, Intelligent Customer Service

8 July 2022

Always Exceeding Expectations

When looking for an adequate replacement for a discontinued device, the first step is searching for objective criteria – technical performance data, dimensions, etc. are what count. If you can find something that meets these requirements, that’s the end of the story. But when you find not just a first-rate product, but also a first-rate sales and support strategy, that’s where true success stories begin.

Even in the automotive industry and its associated suppliers, products are sometimes discontinued, despite frequent modernization of production lines, making it necessary to find an adequate replacement on short notice. That’s what happened in the US Midwest, where a major supplier wanted to replace more than thirty 24 V power supply units without undertaking extensive restructuring. One of the most important basic requirements was that the new power supply could not be larger than the one it was replacing – that would have required a complete redesign of over two dozen control cabinets. An international comparison identified only three suitable devices; one was the WAGO Power Supply Pro 2. “I was already familiar with the customer, and I was pleased that our compact design got us on the shortlist,” recalls Bradley Sedoris, Regional Sales Manager at WAGO USA. “When they told us that our Pro 2 Power Supply, unlike the other two devices, had passed all tests perfectly, that’s where my job got started.” Like all other WAGO Sales employees, he works very closely with customers, is familiar with their processes and knows the challenges they face every day.

Passed with Flying Colors

For the customer, the key challenges included not only reliability and high availability, but above all, the need for very short review times: “The automotive industry hates experimentation,“ explains Sedoris. “Components need to fulfill their purpose reliably and should be as easy to integrate as possible.” This is exactly what the Pro 2 Power Supply was able to offer. Even during the first test run, all the loads – from the PLC, sensors and I/O devices, to touch screens and RFID systems in the sheet metal press area – were reliably supplied with power. Where the other two candidates failed, the WAGO device passed with flying colors. Even during load peaks, all the loads started up reliably thanks to the PowerBoost function since the power supply can provide up to 150% of the output power for up to five seconds.

The device is ideal for use in sheet metal punching and forming, as well as in welding equipment, due to its broad application temperature range up to +70°C and high vibration resistance. The 24 V power supply also made a positive impression when it came to integration because, thanks to the function keys and interface configuration software, installation required very few steps.

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Ideal Power Supply and Protection

After the first power supply units were replaced, it was time to receive feedback. “Particularly when working with new customers, or when existing customers are using previously unfamiliar hardware, we regularly solicit feedback. This enables us to support our customers even better,” reports Sedoris. “When I dug deeper into where they saw potential for optimization in the application, the lack of protection on the load side came up. They were very pleased that our power supply includes an electronic circuit breaker.”

The ECB function can be flexibly set up to the nominal current. The user can freely specify how long it should take for the protection function to trip, between 100 ms and 5 seconds. If, for the amount of time corresponding to that setting, the current exceeds the ECB trip value – which is also configurable – the output is switched off. This protects connected loads against overcurrent and possible damage. That is particularly advantageous for the powered controllers and RFID systems since these are comparatively high-priced devices.

The Key to Versatile Optimization

Solutions can be found for more than just specific requirements:

“Of course, we first point out the features of our innovative products that are of primary importance to our customer’s application,” reports the Regional Sales Manager. “In this process, I often present features that previously used products couldn’t offer. Where it gets interesting is when this process uncovers optimization potential that either couldn’t be exploited previously or had not even been on the radar.” For example, the communication capability of the Pro 2 Power Supply in customer applications opened up a whole range of previously unimagined possibilities. The intelligent power supply can be connected to a PLC or an IoT gateway via a communication module. The Pro 2 then continuously sends service and operating data via IO-Link, Modbus RTU or ETHERNET-based protocols.

This extensive monitoring and communication via standardized protocols can revolutionize operation and maintenance: With current data on the power supply and connected load, targeted troubleshooting can locate the cause of a fault quickly and reliably. “Especially in the automotive sector, downtime costs a lot of money – tracking down the cause of a fault in minutes rather than hours is a dream come true for many customers,” explains Sedoris. State-of-the-art Big Data analytics opens up even more possibilities. Continuous monitoring of all load conditions, coupled with appropriate algorithms and machine learning, allows very accurate predictions about the state of the power supply and – what is far more valuable – the state of connected loads.

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In the Name of Environmental Protection

Energy efficiency and reducing CO₂ emissions have become increasingly central concerns in recent years. If you’re looking to optimize energy use, every contribution to energy savings is welcome. “One aspect of the Pro 2 I should mention is its high efficiency: up to 96.3%,” explains the Regional Sales Manager, adding: “Power supply monitoring data can also be used for energy optimization. In addition, smart load management and the configurable standby mode also contribute to the savings. Together with the customer, we always uncover further opportunities for optimization.”

The added value that can be achieved by using the intelligent WAGO Power Supply Pro 2 is multi-layered. Because many of the advantages cannot be grasped at first glance, WAGO sales employees like Bradley Sedoris see their task as supporting customers over the long term: “The better we get to know our customers, the better we can support them. We show them how tailored use of our products can help them meet their day-to-day challenges, but we also help them uncover previously untapped potential they can exploit.”

About the Author

Bradley Sedoris has worked in the industrial sector for over 30 years. Since 2017, he has worked as a Regional Sales Manager for WAGO in the US Midwest. From Kentucky, he supports OEMs and end users in many sectors, mainly the automotive and conveyor technology industries. He is convinced that WAGO’s innovative, reliable products, combined with first-class customer support, provide the perfect basis for successful sales.