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Increased System Availability due to Modern Power Supplies

2 March 2023

Throughput instead of Downtimes

Form and function in perfect harmony: automobile chassis provide cars with their distinct characters and also contribute decisively to passenger safety and vehicle efficiency. Stamping, bending, drawing and shaping the exterior skin parts take place in a stamping plant, where enormous tools shape sheet metal using several thousand pounds of compressive forces. When compared to these giants, the activities of the attached sensors appear rather unremarkable. And yet they are the hidden heroes in the stamping process: they ensure safety, precise positioning, and high levels of product quality. Their work is crucial and depends on reliable power supplies.

Stamping plants in automotive production are one of the most impressive manufacturing segment: it is loud, the floor vibrates constantly, and powerful stamps crash together every three seconds, on average, using up to 8000 tons of compressive force to turn the so-called plates into shaped sheet metal parts. At the beginning of this process are the coils – roll sheets of steel or aluminum weighing several tons. At the end, after multiple linked servo transfer presses have carried out their violent work, there are individual shaped parts, like doors, roofs or engine hoods, that can already be distinguished by model.

This requires both enormous forces and also the highest levels of precision: the exact feeding of the plates, their positioning in the stamping tools, and monitoring their removal dictate the speed of throughput. Stamping remnants in a tool or an incorrectly fed sheet of metal mean post-treatments, scrapped parts, equipment stoppages or even, in the worst case scenario, damage to the stamp.

To prevent this, numerous pressure sensors, inductive and infrared sensors, cameras, etc. ensure that the stamping process is monitored and controlled. They are supplemented by a myriad of safety sensors or light barriers, as worker safety is at extraordinary risk in the face of these forces. Dozens of 24 V power supply units are used to reliably supply this equipment and the sensors with direct current.

Stable Power Supply

Power supply units form the heart of every control cabinet: no controller functions without the appropriate electrical supply, regardless of its performance level. The same applies to the sensors mentioned in regards to the stamping plants. In these cases, the quality of the supplied voltage is also decisive for seamless functioning. At the moment, however, the energy markets around the world are in upheaval and thus much more subject to fluctuations.

An example for this is Brazil, a country that currently uses around 85% renewable energy supplies for electrical production. The majority is hydropower, which is currently being replaced by other forms of energy due to the resulting environmental issues and uncertainties caused by increasing periods of drought. There are thus many reasons for a reduced grid stability in Brazil, which can cause enormous difficulties in the automotive sector, for example.

“Current fluctuations lead to large idle times for our automotive customers, starting at the stamping plant,” explains Eduardo de Marchi, customer service manager and interface specialist at WAGO Brazil. “The most problematic part of this is troubleshooting to find the fault: Is it linked to poor grid stability? At the power supply? At one of the sensors? Troubleshooting can lead to hours in which the entire production line in the stamping plant is idled.”

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Knowing instead of Searching

What customers need most, in addition to a high-quality supply of power, is detailed information about the status of the power supply and the consumers connected to it. The WAGO Power Supply Pro 2 can provide both. It is not only one of the most efficient power supply units on the market, it is also highly communicative. An attachable communication module connects the Pro 2 to a controller or IoT gateway, and provides valuable information. The connection can be established via IO-Link, Modbus TCP/IP, Modbus RTU or EtherNet/IP™. This allows the power supply to optimally link into the existing automation and network landscape and enables consistent real-time monitoring. The Pro 2 thereby transmits both its own status data and also enables a detailed monitoring of all consumers that are connected.

“Previously, our customers only received the ‘DC-OK’ response from the power supply unit,” explains de Marchi. “The fact that they can now visualize the total load behavior, overvoltage or short circuit events in their DC consumers at any time changes everything: troubleshooting has been reduced from hours to mere minutes.”

In addition, previously unimagined potentials relating to maintenance measures are still opening up. On the software side, the Pro 2 allows customers to establish warning thresholds. While a simple DC OK function only switches off when currents are far outside of the nominal range due to drops in the output voltage, the Pro 2 can be set to report any current limit violation, even within the nominal current range – without switching off or interrupting the supply of power. In practical terms, this permits predictive maintenance that is no longer dependent on faults: the gradual increase in current consumption is indicative of wear in specific, individual consumers. This allows corresponding service measures to be carried out before malfunctions actually occur.

Customer Satisfaction is Number One

“Thanks to the Pro 2, idle times can be drastically reduced,” reads the primary response from the customer side, as de Marchi reports. The customer service manager from WAGO Brazil then lists other specific features, like “additional benefits arise from the smart load management, the high efficiency of 96.3% and the robust service life of WAGO power supply units,” and concludes that, “the service availability and flexibility delight our customers, and this is aside from the benefits they gain from the hardware.”

For example, a classic product presentation on site at the customer’s location had to be canceled due to the strict restrictions on contact during the Covid 19 pandemic. Therefore, the WAGO sales team organized a series of online presentations that were oriented 100% to the customer requirements. The interactions of hardware and software and the effects on the demonstration consumers were depicted using tailored videos, often with multiple, split screen overlays. This allowed the customer to learn how their future challenges could also be solved by the Pro 2.

de Marchi’s team also provided additional support regarding in-house justifications for the solution: “Our contact is responsible for automation; therefore, we initially offered the Pro 2 Power Supply with a Modbus TCP communication module. However, when the customer proposed this solution to other departments, their internal IT division rejected the concept because that would have required many additional IP addresses in the system. We understood the situation and helped the customer solve this challenge by replacing the communication module with Modbus RTU, which could communicate with the controller already present in the control cabinet.” Due to the serial interface of this communication module, no additional IP addresses had to be reserved. This also facilitated the connection into the IT landscape.

Now, when idle times occur in the stamping plant due to voltage fluctuations, they can be drastically shortened due to the comprehensive status reports about the 24 V consumers transmitted by the WAGO Power Supply Pro 2, as the high level of information density enables extensive fault isolation. At the same time, the data is used for predictive maintenance for many of the connected consumers, which also increases system efficiency.

About the Author

Eduardo de Marchi is a customer service manager and interface specialist at WAGO Brazil, located in Sao Paulo, Brazil. He began his career at WAGO in 2009 as an intern, where he has worked ever since, rising in the ranks to achieve the role of interface specialist in 2013. This is because, as he remains convinced, WAGO interface products are simply fantastic! He particularly values the respectful approach that his colleagues have for one another, and views WAGO as an employer that places a great deal of value of personal development and also supports this at the individual level.

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