In automobile production workshops such as pressing, welding, and assembly workshops, the use of numerous non-linear loads — including electric welding machines, laser welding machines, and large-capacity motors — results in significant power quality issues.

The transformer load currents in these workshops exhibit severe harmonic distortion, primarily in the 3rd, 5th, 7th, 9th, and 11th orders. On the 400 V low-voltage bus, the total voltage distortion rate exceeds 5%, while the total current distortion rate (THD) reaches nearly 40%, far beyond acceptable standards.

This leads to:

• Excessive harmonic power losses in electrical equipment and transformers

• Increased transformer heating and efficiency losses

• Average transformer power factor as low as 0.6, causing serious power loss and reduced output active power capacity

• Harmonic interference disrupting the automatic Fieldbus control system, preventing normal production operations

Adopted Solution

To resolve these issues, Elcosine Power recommends deploying a combination of Intelligent Power Quality Comprehensive Management Devices (SVG/APFC) along with Active Power Filters (APF). These solutions provide:

• Reactive Power Compensation: Rapid and accurate compensation, improving average power factor to 0.98 and above

• Harmonic Mitigation: Effective filtering of harmonic currents in compliance with national and international standards

• Energy Savings: Reduced transformer and line losses, lowering overall power consumption

• System Reliability: Improved transformer utilization, reduced overheating, and extended lifespan of electrical components

• Operational Stability: Eliminating harmonic interference ensures uninterrupted operation of automated production systems

With Elcosine’s advanced solutions, automobile manufacturing workshops achieve higher energy efficiency, reduced operational costs, and enhanced production reliability.