Rectifiers and Controllers Update on the Latest!

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Kathlyn O’Connor’
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1 Rectifiers and Controllers Update on the Latest! Event: IHAA Bi-annual conference Date: 2018/09/2018 Place: Seattle, WA, USA Presented by: Frank Munk

3 Why this presentation? 1. When it comes to new technologies I am often asking myself: - Never heard about it Did I miss something? - What it this new technology about? - Is this new technology suitable for my application? - Industrial environment - Robustness - Services 2. What could be our benefit? - Will we save on operation cost (Energy, Maintenance)? - Will we become more productive? - How can we make use of this new technology in the company?

4 Drivers of developments 1. Making available - Inventions lead to new products which make new applications available and spin off to other industries 2. Making it more robust - A new product needs to be reliable to keep operating costs low 3. Improving function - Getting control to adjust it to the dynamics of the application 4. Improving performance - Increasing power density to lower costs 5. Searching for new solutions to improve 2, 3, or 4 or changing needs - Exploring new ideas to adapt to changing demands

5 One of the first Making DC power available sources using the Dynamo principle Driver: We need light Source: Frank Munk Edison summer estate Fort Myers, Florida

generator, right hand side three phase motor Source:

6 Ward Improving - Leonard function converter First controllable DC power source Converter: Left hand side DC generator, right hand side three phase motor Source:

Solid state or diode rectifiers Semiconductor material for conversion instead of tubes Tap switch, reactors or

Thyristors or SCR (silicon controlled rectifier) Semiconductor for conversion and control Improving the performance

7 Improving performance and function 1. Tube based rectifiers Power conversion by electronics instead of a mechanical system 2. Solid state or diode rectifiers Semiconductor material for conversion instead of tubes Tap switch, reactors or Variac transformer for control 3. Thyristors or SCR (silicon controlled rectifier) Semiconductor for conversion and control Improving the performance of rectifiers by introducing new more powerful components to reduce the number of components. Combing functions to reduce the number of components Increasing power by using liquid cooling at the component instead of an indirect air or oil cooling around the component Source: Google Photos Tubes, Solid state, SCR

8 Driving factors which sparked the development of a new power conversion technology years ago: - Better process control by controlling process conditions for each part instead of a bulk of parts (Reactor design instead of tank design) - Less space to include a new line into the same building - Less weight to ease installation work and reduce installation cost - Predictive maintenance to reduce or avoid non-productive time (Interface) - Reducing operation cost by reducing energy cost and improving efficiency Reducing size and weight by using a Switch Mode Power Supply design to convert AC into DC power

9 Is the SMPS design ready for my application? We opened up a SMPS design and manufacturing center almost 30 years ago. We have been supplying SMPS rectifiers since then to various industries, in particular the plating industry.

Design comparison Traditional versus SMPS SCR - Thyristor (Option) Ripple filter AC DC Input: 3 x 380-480 V/ 50 60 Hz Trafo

10 Design comparison Traditional versus SMPS SCR - Thyristor (Option) Ripple filter AC DC Input: 3 x V/ Hz Trafo Primary Secondary Output: DC current SMPS design Source:

11 SMPS IGBT based Cooling of components Solid state rectifier SCR control Cooling of components Solid state rectifier Variac control Cooling of componets

backbone of the SMPS, also called IGBT technology, is a single power module which

12 SMPS - Modular design to get more power Function block diagram - SMPS Air cooling C o o l i n g o f c o m p o n e n t s Note: For all rectifier suppliers the backbone of the SMPS, also called IGBT technology, is a single power module which is put in parallel or series to get to the required output power Water or air cooling

13 Solutions now achievable by SMPS Better process control by controlling process condition for each part instead of a bulk of parts (Reactor design instead of tank design) Modules are placed in one cabinet 6 x 25 V/1000 A in one cabinet individual controlled and independent from each other

14 Solutions now achievable by SMPS Less space required to include a new line into the same building Less than ¼ of the volume and less than ½ of the foot print

15 Solutions now achievable by SMPS Less weight to ease installation work and reduce installation cost Less than 1 /3 of the weight 25 V/ > 5000 A Power upgrade became an option now

16 Where there is light there is shadow - Complexity Components required for a traditional 1,000 10,000 A rectifier Components needed for an SMPS IGBT based rectifier module A rectifier module

Electronic components also follow a life cycle and don t last forever Life cycle graph of an electronic component Sudden failure which happens randomly End of life: Failures happen more regular Early

17 Electronic components also follow a life cycle and don t last forever Life cycle graph of an electronic component Sudden failure which happens randomly End of life: Failures happen more regular Early failure during burn in or testing Time Conclusion: The risk of a failure is increased for SMPS versus traditional rectifiers because more components and power modules are needed to achieve the same power.

System reliability Productivity, operation cost are influenced by the number of modules Presumption: System consist of n elements of the same, with the same reliability R i = R ->

18 System reliability Productivity, operation cost are influenced by the number of modules Presumption: System consist of n elements of the same, with the same reliability R i = R -> R S = R n n: Number of modules System reliability R S average component reliability R Conclusion: The risk of failure is increased by the power of n, n being the number of modules

19 SMPS - higher efficiency Energy cost saving makes your ROI Are you sure? Efficiency graph shown in a rectifier leaflet of an SMPS supplier

20 SMPS and SCR can both offer a high efficiency The SCR design makes the difference Same efficiency graph updated by us

21 SMPS and SCR efficiency is ranging between % for anodizing rectifiers already Don t get mislead Graph updated by by a us graph 80 % 30 %

to reduce your operation cost Old school: Achtung!

22 Summary Yes SMPS rectifiers offer new alternative ways to improve your process productivity but space and energy cost saving might not help you to reduce your operation cost Old school: Achtung! New school: Multiple modules together to get to the same output power level of a traditional rectifier.

23 Trends in control systems 1. PLC system on process level become more and more affordable - Complex algorithm can be stored in the controller - IoT ready interface on board 2. Touch panel systems became more robust and can now simplify operation - Mobile phone generation has different needs 3. Enter your destination, the goal you like to achieve, and let the controller do the job to give you extra time for other work 4. Know what you did to find the root cause of a problem if needed 5. Interface with the IT world of your company Make process information available - IoT also means that data become more easily available - Big data analysis algorithm allow you to do better next time 6. Online information and remote access for a better service

Dedicated process controllers are used in manual

Making process data available and using expert

productivity, improve quality in manual lines --

24 Dedicated process controllers are used in manual lines or integrated into fully automated lines Making process data available and using expert know how in automated lines Increase productivity, improve quality in manual lines -- Expert know how is made available for other tasks in production

4 th generation of process controllers for aluminum anodizing and coloring applications 1. More versatility to be able to do more than just one alloy 2.

25 4 th generation of process controllers for aluminum anodizing and coloring applications 1. More versatility to be able to do more than just one alloy 2. More process information to allow online-monitoring (trend lines) 3. Simplifying complex programming to design a treatment program to the alloy needs 4. Remote monitoring, remote access offering IoT ready interfaces

26 Touch panel display simplifies operation 1 st step: Select a mode: Manual or automatic (complex program) 2 nd step: Select a program using the program library 3 rd step: Start and monitor the process

27 Know what you are doing or what happen A graph can help Process overview Program overview What happen? Online -screen Live data and history data

28 Industry 4.0 / Internet of Things Smart network on process level Remote access manager Office IT network Operational Technology (OT) network Process level network Hardware and software which changes the physical process through direct monitoring and/or control of physical devices such as pumps and rectifiers

29 IT and OT start to collaborate The new process controller should be IoT ready which means that they can be integrated into an OT network structure to make process data and system status information data available to other levels in the network and the company

30 Summary SMPS rectifiers are not new to the industry they are available for about 30 years but due to the given capacity they are commonly just in the plating industry Energy efficiency was not the driver for the SMPS development. It was space and control of rather a part than a batch which drove the development. Traditional rectifier designs can reach efficiency levels of % as well SMPS have an excellent power factor but create high harmonics and can trigger oscillations in the factory due to the none linear load current Watch out for impedance limits by the rectifier supplier SMPS have side effects (Lifetime, System reliability, Harmonics) New process controllers can do complex recipes and become easier to handle IT and OT world start to collaborate to improve the productivity

31 Congratulations - You made it! If you have any questions or comments please approach us fm@munk.de -

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