Hwashin, located in Chennai, India, manufactures sheet metal parts such as floors, hoots, trunk lids, brake pedals and cowl bars for Hyundai cars. Because the plant is dusty, Hwashin experienced frequent breakdown of its servo stabilizers, frequent burn-out of robot controller cards and frequent stoppage of welding lines which caused production loss. This was especially prevalent during power outages, because of power fluctuations caused by the backup power supplied by the diesel gas generator.
Hwashin had been using servo stabilizers to protect its equipment against power fluctuations. The manufacturer turned to TSi Elecpower Ltd, TSi Power’s subsidiary in India, for a better solution. TSi Elecpower recommended the TSi line of VRP with PWM continuous seamless correction, explaining the technology and its many advantages over servo stabilizers. To prove the product’s efficacy, TSi Elecpower offered Hwashin a trial VRP unit to try out for five weeks on one of its robot controllers.
The trial was a success and the manufacturer saw a marked improvement in the performance of its welding lines. Hwashin realized that the TSi-VRP was superior technology compared to the servo stabilizer. It began the process of rolling out the TSi-VRP throughout the plant for complete power conditioning.
Since 2013, Hwashin has installed 139 VRPs, a mix of 6 kVA and 10 kVA in their 2 plants. Currently in Plant-1, 101 VRPs are powering 101 robot controllers. This plant still has an additional 99 servo stabilizers powering 99 robots still in use.
“The welding lines powered by servo stabilizers incur an average annual expense of INR 2 million on burnt cards of robot controllers. But, there is no burnt card in the welding lines powered by VRP. In short, Hwashin have benefitted enormously by installing the VRPs to power the robot controllers.”
—Mr. Rajakumar, Hwashin’s Plant-1 Sr. Engineer (Projects)