Fluke Power Quality Testing and Application


The automobile manufacturing industry uses a large number of impact and non-linear loads in the main production processes, such as motors in the body shop, laser welding machines, presses in the press shop, frequency conversion devices in the paint shop, and automatic production lines in the assembly shop. Both impact and non-linear loads have a common feature, that is, the load fluctuation is very large, and the amount of harmonics is very large. At the same time, with the continuous demand of national energy-saving and energy-saving, the use of energy-saving lamps, the traditional motor, is gradually replaced by variable frequency drag. These new non-linear loads exacerbate power quality problems in automotive manufacturers.

At present, many automakers and accessory factories are gradually starting to do equipment energy monitoring and management, testing the power consumption curve of their key energy-consuming equipment, matching with the production curve, and discovering energy waste points to achieve energy-saving effects. Here are a few typical application examples for the automotive industry:

1. Chongqing Baosteel Auto Parts Stamping Workshop

Chongqing Baosteel Automobile is mainly engaged in the production of automobile door panels and supports. The usual process contains a large number of stamping links. The German Schuler automatic stamping integrated equipment is currently used.

Problems encountered: In the work of Shule's stamping equipment, irregular currents cause the entire power supply system to trip, which seriously affects the continuous production and normal operation of other surrounding equipment. The initial suspected problem was caused by the inrush current during the operation of the Shule press. The Shule press has a rated operating current of 1700A and a protective end limit of 5000A.

Fluke Power Quality Testing and Application



Test plan: The customer uses the Fluke 435-II power quality analyzer to monitor the current fluctuations of the stamping equipment in real time through the inrush current test function.

Test results: After testing by Fluke 435-II power quality analyzer, the maximum working current of Shure press is 3240 A, which is much higher than the rated working current of 1700 A, and the duration of 2000 A or more is more than 5 s.

Fluke Power Quality Testing and Application


Inrush current trend waveform under one operating condition

Reason confirmation / solution:

It is found that the pressure current is too high for Shule, and the peak current reaches the trip limit under multi-load operation, causing the system to be powered off. Communicate with Shule manufacturers, and adjust the maximum current of the stamping system to 2300A under the condition of ensuring the process. Left and right, reduce the punch current to achieve the purpose of avoiding tripping. At present, it has been running for about two months, and there is no tripping phenomenon, which guarantees the continuous production of customers and brings benefits to customers. The stamping and forming of automobile body and parts is an important part of automobile production. The system uses a large number of large-scale equipment such as CNC punching machines and punching machine tools. These devices not only cause inrush current, but also impact on system operation, and are also typical harmonics. Source and impact load, the generated harmonics not only cause the bus voltage fluctuation, so that the equipment can not run, but also reduce the system power factor, the voltage and current waveforms are severely distorted, increase the reactive power loss of the system, affecting the entire power supply system.

2. Changan Suzuki Automobile Painting Workshop

Changan Suzuki Automobile Painting Workshop found that the power of the towed power motor was cut off due to the failure of the power supply inverter. The failure of the body-in-white to pull out the body-in-white from the plating solution caused the body-in-white to be scrapped. The single loss was about 30,000. The reason may be Due to voltage problems. The power quality analyzer Fluke 435-II was tested at the customer site for one week and found that the customer dropped from the point voltage.

Problem: The power supply inverter is malfunctioning, causing the motor to be powered off.

Severity: The body-in-white failed to pull out of the plating solution, causing the body-in-white to scrap

Fault cause judgment: Phase B voltage drops, causing the inverter to malfunction

Test Equipment: Fluke 435-II Power Quality Analyzer

Test Data:

Fluke Power Quality Testing and Application


Fluke Power Quality Testing and Application


Voltage drop trend chart

Fluke Power Quality Testing and Application


Fluke Power Quality Testing and Application


Voltage drop event waveform

The harmonic problem is also a prominent power quality problem in the painting process. The main load of the coating process is power electronics and large-capacity heating equipment. These devices are manufactured using rectification and frequency conversion principles. Harmonics are generated during this process, while heating devices use devices with higher resistance. The power quality of the painting workshop is characterized by large inductive reactive power, low overall power factor, large and complex harmonic current, serious voltage drop at the busbar end of the system, high heat generation and low utilization rate.

Harmonics will increase the equipment loss in the paint shop, causing the main transformer's iron loss, copper loss, dielectric loss, voltage peak, transformer noise, and transformer load capacity. Harmonics can cause mishandling of painting, painting, transportation and other equipment, resulting in uneven painting, poor transportation, defects such as air bubbles, missing coating, incomplete grinding, repeated painting, etc. on the surface of the coating, which seriously affects the coating of the product. Packing quality. As the reactive power consumption of the system increases, the bus voltage drops and the voltage deviates, and the heating device may not reach the baking surface temperature standard of baking in the specified time due to the low voltage, and the baking quality problem occurs.

Fluke Power Quality Testing and Application


Voltage harmonic

Fluke Power Quality Testing and Application


Current harmonic

Fluke Power Quality Testing and Application


Changan Suzuki Automobile Painting Harmonic Test Chart

Improving power quality is one of the important tasks for enterprise power supply and distribution management, and it should be especially valued in the automotive industry. Improve power quality, improve production efficiency, reduce energy costs, reduce defective products, and improve production efficiency to ensure continuous production.


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