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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