Uninterruptible power supply cuts manufacturer’s downtime

The modern manufacturing floor typically includes networked computers, PLCs, robots, and other power-sensitive microprocessor-based electronics that must operate reliably from utility power. At one major airline manufacturer, an unexpected power problem resulted in the scrapping of thousands of dollars worth of parts.

10/01/2008


The modern manufacturing floor typically includes networked computers, PLCs, robots, and other power-sensitive microprocessor-based electronics that must operate reliably from utility power.

At one major airline manufacturer, an unexpected power problem resulted in the scrapping of thousands of dollars worth of parts. The micro-controller responsible for monitoring a key stage in the parts manufacturing process had been plugged into a low-cost, line-interactive type uninterruptable power supply (UPS) that “provided basic battery backup and minimal power conditioning. It was designed to protect computers in a home or office,” according to Rob Ayala, a CNC engineer at the plant.


An airline manufacturer switched to a Falcon Electric online SSG Industrial-Grade UPS for improved manufacturing quality.

“The line-interactive UPS would let transients and dirty utility power directly through to the micro-controller. This would frequently result in the loss of critical data communications, requiring the process to be shut down prior to completion,” Ayala says.

“After we had solved the process power problem by deploying on-line UPSs in that cell,” Ayala explains, “we moved the line-interactive UPSs to backup non-critical computers. We then noticed that the batteries inside the on-line UPSs would last for several years, typically two to three times longer than the one to two year life we would get from the line-interactive systems.

“In my support role, I would frequently receive calls about malfunctioning line-interactive UPSs, and it was almost always the result of weak or dead batteries that had failed prematurely.”

This led Ayala to reconsider the plant’s UPS designs. He selected the Falcon Electric SSG Industrial-Grade On-line UPS, with several SSG 1.5 kVA units. The line is rated to withstand environments with temperatures up to 55 °C.

When looking to perform a similar analysis at your plant, Ayala offers the following UPS suggestions:

  • Evaluate the UPS provider Website for product selection;

  • Check for industrial-grade ratings and designs;

  • Call to gauge the knowledge and helpfulness of sales and technical staff; and

  • Select an on-line UPS to ensure reliable operations for any industrial setting using microprocessor-based equipment on the production floor.

www.falconups.com





No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Sensor-to-cloud interoperability; PID and digital control efficiency; Alarm management system design; Automotive industry advances
Make Big Data and Industrial Internet of Things work for you, 2017 Engineers' Choice Finalists, Avoid control design pitfalls, Managing IIoT processes
Engineering Leaders Under 40; System integration improving packaging operation; Process sensing; PID velocity; Cybersecurity and functional safety
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
click me