Antecedentes del proyecto:

Located in the Dhaka Industrial Park, Bangladesh, a CNC printing processing system required a reliable and stable power supply to overcome frequent power outages. The industrial park faces persistent power supply issues, with intermittent power outages occurring 3-4 times daily. These outages lead to significant operational disruptions, especially for sensitive equipment like CNC machines that are part of the client’s integrated production line. The client needed a solution that could ensure a stable power supply during outages and help minimize losses caused by downtime and equipment wear due to unreliable power.

Requisitos del proyecto:

The client’s CNC printing processing system consists of a printing unit and a drying unit. Every power failure results in material waste, which increases operational costs. Additionally, restarting the equipment after a power outage requires a lengthy preheating time for the drying unit, causing further downtime. Given the frequency of power outages and the instability of the backup generator, the client had the following specific requirements for the UPS solution:

1. Quick Power Switch: Ensure power transition time is under 10ms during an outage, and maintain stable power supply when using the backup generator.
2. Battery Backup Time: Provide at least 15 minutes of backup time under full load.
3. Redundancy and Easy Maintenance: The system should have redundancy features for quick maintenance and reliable operation.
4. Fault Diagnosis and Monitoring: The system should provide real-time diagnostics and monitoring to allow the client to keep track of UPS performance.

Solución:

After analyzing the client’s needs and system requirements, Gottogpower provided the following solution:

1. Main UPS Configuration:
   • A 6-slot, 30kVA-based GTM180/30 UPS, with a maximum power output of 180 kVA and a power factor of 0.9.
   • The UPS system was configured with 5 power modules in a 4+1 redundancy mode, leaving an extra module for future expansion.
2. Battery Configuration:
   • The solution included 40 units of 150Ah, 12V batteries, which fully met the client’s backup time requirement while ensuring the batteries’ longevity even with frequent shallow discharges.
3. Monitoring and Diagnostics:
   • An SNMP card was included to allow the client to monitor the UPS performance remotely via a web interface, enabling real-time status updates and fault diagnostics.
4. Environmental Adaptations:
   • A dust filter net was installed as an optional feature to adapt to the dust-prone environment of the industrial park.

Resultado:

The modular UPS system was successfully installed and commissioned, providing a stable power supply and meeting all the client’s requirements:

• Seamless Power Transition: The UPS system successfully ensured seamless power switching during power outages, with no interruption to the production line.
• Reliable Backup: The battery backup time met the required 15 minutes under full load, ensuring continuity during power outages.
• Remote Monitoring: The SNMP card allowed the client to monitor the UPS status from the control room, providing full visibility into the system’s performance.
• Zero Faults: After one year of operation, the system ran reliably with zero faults, eliminating the losses caused by power failures and improving overall efficiency.

The installation significantly reduced downtime and improved operational efficiency, ultimately creating substantial economic value for the client. The client also praised the 10 user-friendly LCD interface, which made it easy to manage and monitor the system.

Due to the successful performance, the client is set to place an order for an additional modular UPS system this month, affirming the effectiveness of Gottogpower’s solution for industrial CNC applications.