Retrofit of a metal spraying system for capacitors
In a challenging retrofit project, we modernised the control technology of a metal spraying system for capacitor production at our customer KBR EnergyManagement GmbH. In addition to increasing the test voltage to 2 kV, safety functions were expanded, hardware components replaced and the operating concept optimised - all with minimal intervention in the existing system structure. The result: more process reliability, greater user-friendliness and a future-proof solution for production.
Realisation
First, a detailed specification with a risk analysis was drawn up, which served as the basis for the modernisation. The existing control technology was replaced by an advanced control system from Siemens and the connection of the sensors and actuators as well as the safety technology were brought up to date. Overall, the project team took care to limit the changes to what was absolutely necessary.
The test voltage was increased from 1.5 kV to 2 kV in accordance with the customer's wishes, which required a redesign of the control cabinet panels in order to install the additional hardware required, such as new transformers, coils, contactors and compensating chokes. The overall structure of the system remained the same. Our team fitted the mounting plates with the components, while the control cabinet itself, with the necessary reinforcements, was built according to our precise specifications and customised by an in-house department at KBR.
The previously stationary HMI was replaced by a new comfort panel on a swivelling support arm system. This means that the operating personnel always have the system in view. The parameter sets have been supplemented and the visualisation revised so that an appealing look, more operating functions and additional alarm messages are now available. "The look and feel of the visualisation and the selection of images were closely coordinated with the customer.
The technical specifications and services were documented in detail and precise operating instructions were drawn up.
After completion of the mechanical installation and finalisation of the electrical system as well as a test phase, the system was commissioned on site at the customer's premises just three weeks after the start of the modernisation measures. Finally, HEITEC also provided staff training and start-up support.
Customer benefits
- State-of-the-art metal spraying system for capacitors with error-proof and future-proof control technology
- Improved product quality thanks to customised solution with increased test voltage
- Reliable safety thanks to new safety functions and modern safety technology
- Ergonomic operation and clear visualisation
- Investment security thanks to operational readiness for the next 15 years
- Guaranteed component availability and transparent spare parts management including obsolescence management.
- All services from a single source thanks to a dedicated project team