Robotic welding in Auto IndustryCase study: Honda cars
Brief layout
• Power Quality issues in Auto Industry
• Problems faced by the industry
• Graphical representation of power
quality paramaters for Robotic welding
• Traditional solutions and its issues
Solutions and Case study
• IGBT based Hybrid PFC and its advantages
• Implementation in Honda cars
• Results achieved
• Conclusion
Power Quality is a major concern in the Auto Industry. With increasing automation, the need for good power quality is increasing drastically.
Introduction
Auto industry has the following major
loads:
• Robotic welding
• Stamping
• Paint section
• Assembly
Issues faced by Auto industry
• Excessive failure of electronic cards in welding robots
• Excessive overheating of cables results in insulation breakdown
• Reduced utilization of transformers due to highle unbalanced load
• Poor voltage profile results in poor weld quality
• Increased losses due to improper utilisation of sources
• Production downtime due to random failures
• Unwanted tripping in robotic welding due to voltage dips
Welding robots represent all major PQ issues in a single load:
• fast fluctuating
• jerky and demand sudden reactive power
• rich in current harmonics
• highly unbalanced
PQ Issues... Fast Fluctuating ProfileL1
(A)
2000
1600
1200
800
400
0
L2 (A
)
2000
1600
1200
800
400
0
16:5116:5016:4916:4816:4716:4616:4516:4416:4316:4216:4116:4016:3916:3816:3716:3616:3516:3416:3316:3216:3116:3016:2916:28
L3 (A
)
2000
1600
1200
800
400
0
Load Current (A)Load Current (A)
• Arms varying between 400 to 1000 Amps
• Fast fluctuating in nature• Less than 100 ms jerks
Low Displacement Power FactorPQ Issues... Low Displacement Power Factor
• Net reactive demand continuously varies between 100 and 700 kVAR
• Fast fluctuating reactive power requirement
• Traditional solutions are ineffective due to fast fluctuations
• DPF varying between 0.4 and 0.8• Due to high reactive demand,
extremely low displacement power factor
• Results in inflated peak demand
High Load UnbalancePQ Issues... High Load Unbalance
16:4416:4316:4216:4116:4016:3916:3816:3716:3616:3516:3416:3316:3216:3116:3016:2916:2816:2716:2616:2516:2416:2316:2216:2116:2016:1916:1816:1716:1616:15
Unb
alan
ce (A
)
1600
1240
880
520
160
-200
Unbalance Apos and Aneg (A)
• High negative sequence component of current is high due to two phase welding loads
• Results in unbalanced loading on transformer and increased losses
PQ Issues... High Harmonic Distortion%
H1
L1N
(A)
100
78
56
34
12
-10
%H
1 L2
N (A
)
100
78
56
34
12
-10
16:4516:4416:4316:4216:4116:4016:3916:3816:3716:3616:3516:3416:3316:3216:3116:3016:2916:2816:2716:2616:2516:2416:2316:2216:2116:2016:1916:1816:1716:16
%H
1 L3
N (A
)
100
78
56
34
12
-10
Current Harmonic Distortion (%)
• High level of current harmonic distortion: I THD is around 35-70%
• This reults in high voltage harmonic distortion at the transformer incomer which is a major cause of most electronic card failure in robotic welding
PQ Issues... High Harmonic Distortion
Voltage Harmonic Distortion (%)
Individual Harmonic profile (%)
High current harmonics leads to high voltage harmonic distortion in the range of 5% to 8%
Predominantly high order individual harmonics are 3rd, 5th and 7th
Traditional solutions: IssuesTraditional solutions like APFC panels and Thyristor based detuned power factor correction panels have their own set of issues. Some of them have been mentioned below:• Slow response time • Premature failure of capacitors • Premature failure of thyristors / contactors• Cannot perform load balancing• Does not reduce harmonic content• Does not reduce voltage distortion• Requires high maintenance
Robotic welding requires a better and more advanced solution which can take
care of all the above concerns with increased reliability
P2 Power Hybrid PFC combines the performance of Active Filter with the affordability of traditional Passive Solutions
1. Compact Dimension2. Easy Maintenance
3. Cost Effective
1. Reaction time < 200 micro sec.2. Stepless & Instantaneous3. Compatible with DGs4. Harmonic compensation5. Load Balancing6. Neutral compensation 7. Long life8. No voltage transients
Hybrid Power Factor correction
Hybrid Power factor correction
IGBT based P2 Power Hybrid PFC :
Combination of Active Power Filter & Passive system (APP heavy duty
detuned capacitor banks) 1
Working :
Switching of detuned capacitors is controlled by the Active Filter's
Advanced digital signal processor
2
Advantage : Base load is catered by the passive
banks whereas fine correction is achieved by utilizing the ultra fast
and step-less response of the Active Power Filter 3
Special Feature : Together, the solution becomes
extremely cost effective and provides the benefits of harmonic,
unbalance and neutral compensation with ultra fast
response 4
Hybrid PFC can take care of all power quality issues under a single unit at an extremely competitive price
Hybrid Power Factor correction
A complete solutions in itself to take care of Power Factor, Harmonics, Load Balancing & Neutral issues
P2 Power Active
Power Filter
Hybrid PFC has an Active Power Filter along with heavy duty APP
type detuned capacitor banks
HyPFC can be programmed for• Reactive compensation• Harmonic mitigation• Load unbalance
Heavy Duty Capacitor
with detuned reactors
Hybrid Power factor correction
HPFC: Brief overview
IGBT based P2 Power Hybrid Power Factor Correction system has following advantages over conventional system (detunedAPFC/ RTPFC)
True PF compensation up to unity1
Step less reactive compensation2
Reaction time in micro seconds3
Leading/Lagging both compensation4
Harmonics compensation as per IEEE-519 standards 5
Load balancing 10
Runs on DG as well as Grid9
Optimum utilization of source8
Maintenance free6
Compact size7
HPFC: Advantages against traditional
Case study: Honda carsP2 Power Solutions recommends : • P2 Power Hybrid Power Factor Correction System for reactive compensation and
harmonic and load balancing on second priority• P2 Power Active Power Filter for harmonic mitigation• P2 Power Active Power Filter for balancing load
welding loads
other loads
P2 Power HyPFC (reactive)
P2 Power APF (harmonics)P2 Power APF (Load Balancer)
TR-1 TR - 2
Overview of connection scheme in typical facility of Welding
Application
CTs
Performance Analysis
18:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
To
tal (D
PF
)
1.2
0.96
0.72
0.48
0.24
0
391.007377.264395.76395.796391.467395.28392.228394.628390.744394.759390.041393.422394.505383.797394.128 392.102392.626394.048375.55395.301 389.776 395.921 393.058393.533
18:4518:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
To
tal (D
PF
)
1.2
0.96
0.72
0.48
0.24
0
392.56386.354393.821388.991377.858395.374395.116393.935391.125393.869395.24394.339393.947395.582395.245394.2391.549395.661393.914393.41390.381 391.084395.963394.493395.854393.799392.598393.331383.248392.393395.035395.995389.163395.787393.022388.746394.784387.064382.768395.005391.04392.416382.551388.947392.228382.52388.301395.152386.61392.59385.542393.875391.476
Improved from ~0.60 to > 0.99
With HPFCWithout HPFC
Displacement Power Factor (dPF) – Trend
Reactive Performance
With APFWithout APF
Current Demand Distortion (%iTDD) - Trend
%H
1 L
1N
(A
)
40
32
24
16
8
0
%H
1 L
2N
(A
)
40
32
24
16
8
0
18:4518:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
%H
1 L
3N
(A
)
40
32
24
16
8
0%
H1
L1
N (
A)
40
32
24
16
8
0
%H
1 L
2N
(A
)
40
32
24
16
8
0
18:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
%H
1 L
3N
(A
)
40
32
24
16
8
0
Performance Analysis
Improved from > 22%
to < 7%
Harmonic Performance
Performance AnalysisVoltage Harmonic Distortion (%vTHD) - Trend
%H
1 L
12
(V
)
10
8
6
4
2
0
%H
1 L
23
(V
)
10
8
6
4
2
0
18:4518:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
%H
1 L
31
(V
)
10
8
6
4
2
0%
H1
L1
2 (
V)
10
8
6
4
2
0
%H
1 L
23
(V
)
10
8
6
4
2
0
18:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
%H
1 L
31
(V
)
10
8
6
4
2
0
Improved from > 5% to
< 2.5%
With APFWithout APF
Harmonic Performance
Current Unbalance (%Aunb) - Trend
18:4518:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
Un
ba
lan
ce
(%)
150
120
90
60
30
0
18:3018:1518:0017:4517:3017:1517:0016:4516:3016:1516:00
Un
ba
lan
ce
(%)
150
120
90
60
30
0
Performance Analysis
With APFWithout APF
Reduced from > 60% to < 8%
Balancing Performance
Conclusion: Benefits for the customer
• Reduced risk of Failures• Reduced Reactive Losses• Reduced Maximum Demand charges• No Overcompensation• Improved Voltage profile• Better weld quality• Virtually maintenance free• No more cable insulation breakdown• Better transformer and DG utilisation
Expceptional savings, improved product quality and high uptime.
ROI less than 9 months for Honda cars!
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