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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.”