techcompass.sanyodenki.com Open in urlscan Pro
143.204.98.30  Public Scan

Form analysis
1 forms found in the DOM

Name: search_form — GET https://search.sanyodenki.com/

<form name="search_form" action="https://search.sanyodenki.com/" method="GET" onsubmit="return mysearch(this);" data-hs-cf-bound="true">
  <input type="text" name="kw" value="" class="iSearchAssist">
  <input type="hidden" name="ie" value="u">
  <input type="hidden" name="site" value="tech_en">
  <button type="submit" name="" value="send">Search</button>
</form>

Text Content

We use cookies to offer you a better browsing experience, analyze site traffic,
and personalize content.

If you decline, your information won’t be tracked when you visit this website. A
single cookie will be used in your browser to remember your preference not to be
tracked.

Cookies settings
Accept All Decline All

Find technologies that solve on-site problems
 * Enter Keyword
   Search
   Product Site
 * Contacts
 * 


 * Home
 * Case Study
   * Motor / Driver
   * Fan
   * UPS / Renewable Energy Inverter
 * Column
 * Training
   
 * Contacts
 * Conditions of Use
   Privacy Statement
   Privacy Notice (GDPR)

閉じる
Case Study
Data of a control device was lost even with a UPS... Why?


A UPS WITH LI-ION BATTERY SOLVED A LONG-UNSOLVED PROBLEM!

Food Manufacturer Company A (500 Employees)
 * Home
 * Case Study
 * UPS Case Study

Problem
 * Company A had a problem of a control device restarting over and over for
   unknown reasons even though a UPS was installed.
 * It was unlikely a power problem as a UPS was used, so they assumed the
   problem was caused by noise and took countermeasures, which did not improve
   the situation.
 * The operation panel was hard to see, and alarms were often overlooked.

Solution and Results
 * SANYO DENKI helped them measure the voltage in the factory, and identified
   the cause to be a momentary interruption in their standby UPS and its
   deteriorated lead-acid batteries.
 * The problem was solved by switching to a UPS with a power-quality mode.
 * The use of a UPS equipped with lithium-ion batteries greatly reduced the
   frequency of maintenance.

Tens of millions of tons of food is wasted annually in Japan. The government has
enacted a law to promote the reduction of food loss, requiring consumers, food
manufacturers and retailers, and food service providers to reduce food loss.


PROBLEM



FOOD WASTE OCCURRED EVERY FEW MONTHS DUE TO UNEXPLAINED LOSS OF CONTROL DEVICE
DATA.

Traceability, quality control, and process control are essential for the
management and control of food manufacturing.
Company A, which manufactures and sells food products, had cared to protect
management information by using uninterruptible power supplies (UPS) as power
backup for the control devices of their manufacturing equipment in case of
emergency. However, despite the UPS, the company had repeatedly suffered data
loss and food waste due to faulty control. Mr. K, a manufacturing engineer,
explained:

"In the food manufacturing process, if any part of the data such as temperature,
time, flow rate, etc. is lost, it affects the quality of food, so we had no
choice but to dispose of the food. For some reason, these control devices would
stop and restart, without anyone making them so, causing data to be lost,
resulting in food waste." A power supply problem would be a reasonable cause of
this problem, but Mr. K could not reach the conclusion yet.

"It was a serious problem, but it didn't occur frequently, so we had dealt with
them by wasting food for many years. However, the frequency increased year by
year and the Act on Promotion of Food Waste Reduction was issued a few years
ago, so we started investigating this issue with more priority. Since a UPS was
used, we had eliminated the possibility of power outage. Then we assumed that
noise was the cause, and we took various measures for it, which never improved
the situation."


SOLUTION AND RESULTS



THE CAUSE WAS A "STANDBY" UPS? SANYO DENKI PROPOSED A HYPOTHESIS AT THE HEARING

When Mr. K consulted a distributor about his problem, he was introduced to SANYO
DENKI. After hearing about the problem, a sales representative of SANYO DENKI
guessed that the cause of the problem was the use of a "standby" UPS.

SANYO DENKI's hypothesis:

(1) Power supply factor

• When a motor starts up in the factory, there occurs a temporary voltage drop,
causing the UPS to switch to battery operation.
• An interruption of 5 ms occurs during transfer to battery operation.

(2) Manufacturing equipment factor

• With the capacitor of the DC power supply in the equipment aged, the
electrolytic solution volatilizes, causing its ability to store electricity to
deteriorate.
• A voltage drop also occurs in the DC power, causing the control device to
restart.

"He guessed these factors might have caused the data losses, even though the UPS
was used. He also pointed out that lead-acid batteries deteriorate under high
temperatures, so the backup time might be shorter than the rated value," said
Mr. K.


USE OF A UPS WITH A POWER-QUALITY MODE IMPROVED THE MANUFACTURING TROUBLE

In response to these suggestions, Company A carried out measurements in the
factory with the support of SANYO DENKI. As a result, these hypotheses were
proven.

"First of all, we detected frequent voltage drops of about 10%, which was just
large enough to cause a UPS transfer to battery power. This means that transfers
were about to happen at any moment! We also found one of our UPSs was raising a
battery alarm, even though it had only been two years from the last battery
replacement. It seemed that the UPS was installed in a way that the alarm
indicator was hidden due to its size, causing the alarm to be overlooked," he
explained.

SANYO DENKI's representative suggested they use SANUPS E11A-Li, a UPS with
lithium-ion batteries, in the power-quality mode (Double Conversion mode).

What is the Double Conversion mode?

In this mode, the UPS supplies power through its inverter. Even in the event of
an outage, the UPS keeps supplying power through the inverter, and transfer to
battery never occurs. This is why this type of UPS is said to have the highest
reliability.






USE OF THE LI-ION UPS HAS ELIMINATED BATTERY REPLACEMENT

Based on the measurement results, Company A decided to adopt the SANUPS E11A-Li
UPS to replace their UPS in the factory. Mr. K described the effect of the new
UPS as follows.

"It was more compact than the previous one, so it neatly fitted in the power
distribution panel. Also, since the battery is now long-life lithium-ion
battery, we don't have to do the periodic inspections or replacement anymore,
unlike lead-acid batteries, which saves time and costs. Most importantly, we
were able to identify the cause of the loss of data and solve the problem.
Manufacturing process problems not only result in food loss, but also require
time-consuming settings and adjustments for restarting operations. We are very
grateful to SANYO DENKI for helping us improve work efficiency and reduce
overtime work. We would like to consult them anothertime."

Date of publication: May 28, 2021

Learn more about
SANUPS E11A-Li　＞


CASE STUDY

UPS / Renewable Energy Inverter
Are lithium-ion batteries really not worth the cost?
Comparing UPSs by battery life
UPS / Renewable Energy Inverter
Unhappy with the support system and battery replacement costs
SANUPS A11K-Li eliminates the need for battery replacement in regional bank ATMs
for 10 years
UPS / Renewable Energy Inverter
In Southeast Asia, increased voltage dips and interruptions reduced factory
productivity.
Voltage dip compensator that eliminated downtime due to voltage dips and
interruptions
 * Home
 * Case Study
 * Column
 * Training
 * Conditions of Use
 * Privacy Statement
 * Privacy Notice (GDPR)
 * Contacts

© SANYO DENKI CO., LTD. All Rights Reserved.