modular anode control (mac) for paint rectifiers

PUBLIC

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 1

Modular Anode Control (MAC)for Paint Rectifiers

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 2PUBLIC

Agenda

Rockwell Automation MAC Benefits

Rockwell Automation MAC Solution – Overview, Sample System HMI screens, One Line

Modular Anode Control (MAC) Advantages


Modular Anode Control (MAC) Advantages

Ability to run multiple body styles through a common ElectroCoat Tank simultaneously with unique and independent voltage (current) profiles

Reduced energy consumption Improved quality control – Uniform Film Thickness & Surface Finish Increased uptime - Fault Ride Through Reduced material usage Common global design Global support


Rockwell AutomationModular Anode Control (MAC) Rectifier PowerFlex 75x AC drive-based design with patented transformer

MAC current ratings both Greater/Less than 200A possible Standard, patented adjustable voltage – adjustable frequency (AVAF) feature

18 Pulse Design Ability to adjust and tune percentage of ripple on output DC from drive Use of Standard UL Certified bus bar option (both MCC & NEMA12 designs) Power isolating AC Input safety contactors & DC output disconnect (per section)

Ability to isolate & service during production Use of standard Rockwell Automation control & power components

MAC PowerFlex 75x drive and control assets are common with those throughout entire Paint Shop Troubleshooting & maintenance techniques are common with entire Paint Shop & Plant

Choice of EtherNet/IP or DeviceNet communication Compliant LOTO hardware & design (System & Section) Touch-Safe Design HMI control and expanded system monitoring & diagnostics Rated Environment – NEMA 1 MCC or IP54 (NEMA12) enclosure design Flexible system layout (Back to Back for MCC, or Group/In-Line/Individual for MCC & IP54) Smaller, more efficient footprint & lighter weight (1/4 to 1/3 the weight)

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 5PUBLIC Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Rockwell Automation MAC Version 2.0PF753 Drive in Rittal/Hoffman IP-54 enclosure

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 6PUBLIC Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

Rockwell Automation MAC Version 2.0PF753 Drive in Rittal/Hoffman IP-54 enclosure


E-Coat Tank Overview


MAC Rectifier Voltage (Current) Profile


Rectifier 1 Status Screen


Rockwell Automation MAC Version 2.0PF753 Rectifier MAC One Line


1) Material Savings (uniform film thickness across all body styles)

2) Reduced Installation Costs Material (no Bus Duct & less cabling required) Labor (60 Man Days less) Improved Time to Market-one shift @60JPH-2 wks ($1k to $10k profit per vehicle)

3) Ability to maintain with in-house maintenance resources (no service PO’s to rectifier manufacturer)

4) Ability to isolate, repair, and maintain sections individually during production - no planned downtime required (Typically 2 days production loss per incident)

Savings / Opportunity$1-1.5M USD/yr

$35-75k USD$25-50k USD

$58-288M USD

$50-100k USD

$960k-9.6M USD

Rockwell Automation Rectifier MACBenefits - Potential Savings


5) Reduced cost of assets and spares (Use of common Control & Power components throughout Paint, Body, & Final) – no requirement for N+1

6) Energy Savings (Reduced energy usage + reduced charge for poor power factor)

Estimated One Time Savings – Improved Start-up:

Estimated Operational Savings (OpEx) – Per Year:

Estimated Savings – Per Downtime Incident:

Savings / Opportunity$150-250k USD

$100-150k USD/yr

$58M USD

$1.1 to 1.65M USD / yr

$1 to 9.5M / incident

Rockwell Automation Rectifier MACBenefits - Potential Savings (cont’d)

modular anode control (mac) for paint rectifiers

Technology