Contact us

+ 49 89 9278 0

Email

Request your online meeting

Do you need support with selecting the best power supply for your application? Our team is looking forward to answer your question.

Request your meeting
You are here: / Blog

UPS systems ensure greater reliability in critical infrastructures

Power Supply
Application
Critical Infrastructures
Dc-Ups

In this blog article, you will learn why UPS systems are indispensable for ensuring a reliable and stable power supply in critical infrastructures, which components are needed for this, and which standards they must meet.

In the past 100 years, electricity has always flowed in one direction – from the producer to the consumer. However, new technologies, innovative ways of energy procurement and generation, as well as comprehensive digitalisation, are fundamentally changing the market. The successful integration of innovative components is crucial to actively shaping climate change and ensuring sustainable success.

The infrastructures for electricity, gas, water, and heat extend over vast supply areas and decentralised stations. Their smooth operation is of fundamental importance. Disruptions must be detected and resolved immediately, as they can have significant impacts on all areas of life within a short period. For this reason, these critical areas have been grouped under the term Critical Infrastructures (KRITIS).

KRITIS includes facilities and organisations whose failure or impairment can lead to significant supply shortages or disruptions to public safety. These infrastructures are essential for the functioning of our society and include sectors such as energy, information technology, telecommunications, transport, health, and water.

Ronald Block Regional Sales & Industry Development Manager at PULS

“At PULS, we believe in adding value to our customers’ business. The greatest value for modern electrical grids is stability, and our power supply solutions ensure a high degree of reliability and trust.”

Requirements for power supply systems in critical infrastructures

In this blog article, we examine the requirements for power supplies and DC UPS systems in critical infrastructures, as well as the relevant standards that play a role in this context.

Uninterruptible power supply (UPS) is indispensable in critical infrastructures. Energy supply companies use DC UPS systems in combination with remote control technology to protect the control systems of their power plants and to ensure the integration of renewable energies through transfer stations and distribution networks such as local secondary substations. The focus is on monitoring and controlling spatially remote objects.

Specific requirements for power supplies and UPS systems in critical infrastructures concern reliability, robustness, and security:

  • Avoidance of downtime:
    UPS systems ensure an uninterrupted power supply during power outages and enable an orderly shutdown of systems during prolonged outages.
  • Protection against voltage fluctuations:
    UPS systems protect sensitive equipment from voltage fluctuations and power surges that could cause damage or data loss. This is essential for IT infrastructure and communication systems.
  • Increase in operational safety:
    By providing a stable power supply, UPS systems contribute to overall operational safety and minimize the risk of operational interruptions.
  • Compliance with legal requirements:
    Many critical infrastructures are legally required to take measures to ensure a continuous power supply. UPS systems help meet these requirements and ensure compliance with relevant standards and regulations.

Relevant standards and guidelines for critical infrastructures

The power supply in critical infrastructures is of paramount importance for the safety and well-being of society. By adhering to relevant standards and guidelines, operators can ensure that their systems function reliably and safely. Here are some of the most important ones:

  • §14a EnWG: Regulates the grid-oriented control of controllable consumption devices and controllable grid connections.
  • VDE-AR-N-4105: Technical minimum requirements for the connection and parallel operation of generation plants in the low-voltage network, a national standard for the grid connection of generation plants in low voltage.
  • VDE-AR-N-4110: Forms the technical basis for the connection and operation of customer systems to the medium-voltage network.
  • BSI-Kritisverordnung: This regulation defines which facilities are considered critical infrastructures and what security requirements they must meet.
Electrical grid - Traditional structureElectrical grid - Flexible structure
Traditional gridFlexible grid

Network operators are obligated to ensure a stable and reliable power supply. The grid must adapt to the increasingly flexible energy flow. Uneven consumption situations and generation, higher loads, and the feed-in of decentralised electricity cause voltage fluctuations.

Peak loads with unknown simultaneity factors pose a significant challenge. The following elements have the greatest impact:

  • PV systems
  • Heat pumps
  • Battery storage
  • E-mobility

These requirements from different perspectives, as well as the climate goals of the German federal government, lead to a massive expansion of the energy infrastructure. Experts expect that the energy supply infrastructure will need to be doubled to meet the climate goals.

The constantly growing share of renewable energies also contributes significantly to the strong growth in this sector. Current studies, such as the study by the Hans Böckler Foundation, predict a doubling of the investment volume in the coming years.

In demanding environmental conditions, the right hardware is crucial

The development of UPS systems for critical infrastructures is driven by technological innovations and the integration of new technologies. These trends help improve the reliability, efficiency, and safety of power supply in critical areas.

A significant trend is the introduction of modular UPS systems. These offer flexible and scalable solutions as they consist of several independent modules that can be added or removed as needed. This facilitates adaptation to growing demands and increases redundancy.

Additionally, UPS systems are increasingly being integrated into smart grids. This integration enables better monitoring and control of the power supply, which increases efficiency and reliability. Smart grids can also better incorporate renewable energy sources and improve grid stability.

Another important aspect is the retrofitting of existing infrastructure in local substations with so-called retrofit solutions. These solutions measure the outputs and provide data for extended network planning to take appropriate measures in case of failure. The installation situation of the devices is often challenging, as the standardized form factor of a load switch strip is frequently used as a housing specification.

Finally, there is a growing trend towards the development of environmentally friendly UPS technologies. This includes the use of renewable energies, the reduction of the carbon footprint, and the improvement of energy efficiency.

Retrofit UPS system solution for digitisation of local substations.

Retrofit UPS system solution for digitisation of local substations in critical infrastructures.

High ambient temperatures are the biggest “challenge”

As PULS Group, we support our customers in finding optimal power supply solutions for the aforementioned requirements. We place great emphasis on well-managed project planning and the easy integrability of our systems. The following properties are particularly important to our customers: lifetime, size, and temperature range.

Local substation in the electrical grid.

Power supply solutions for substations in local distribution networks.

There are special requirements, especially regarding operating temperatures and the associated lifetime. The reason for this is the harsh environmental conditions often found in non-air-conditioned outdoor areas.

We consider a “robust” environment with partial direct sunlight in a local substation and use the annual temperature profile of Tönisvorst (a city in North Rhine-Westphalia) from the year 2022. Here, the highest ever recorded outdoor temperature in Germany of 41.2 °C was registered. Such a high outdoor temperature means that temperatures of over 75 °C can occur in active local substations in Germany.

This maximum requirement forms the basis for the offset applied to the temperature profile to simulate the maximum load on the installed components. This means that a permanent load of over 70 °C is not assumed, but rather a temporary peak temperature on several days per year.

This detailed simulation is very useful, as the trend towards warmer years and higher peak values due to climate change is demonstrably present.

Software simulation helps in choosing the right components

To optimally specify our solutions for high temperatures, we conducted a detailed lifetime simulation at the component level using software. Based on the results and the requirement that the devices must achieve stable buffering of full performance for more than 10 years, we selected the components and designed the corresponding circuitry.

To ensure reliable operation, it is crucial that the devices do not shut down even at temperatures above 70 °C. In the event of a necessary safety shutdown, they must also restart independently.

Heat has a negative impact on the lifetime and reliability of DC-UPS and power supplies

The minimum lifetime of DC-UPS and DIN rail power supplies is determined by the lifetime of electrolytic capacitors, which are the most critical element in the devices. Even a temperature increase of +10 °C in the power supply halves the lifetime of the capacitors.

To achieve the longest possible lifetime of DIN rail power supplies and DC-UPS, it is therefore important that the devices are protected from overheating. The cooling concept chosen during the development of the power supply plays a crucial role.

Ideally, the devices are designed to generate as little heat as possible from the outset. This is achieved through high efficiency and correspondingly low power losses. Since losses cannot be completely avoided, it is essential to efficiently dissipate the resulting heated air from the device.

Efficient cooling concept for long-lasting power supplies: The “Cool Design” by PULS

To ensure a long lifetime for power supplies, it is essential to minimise heat generation within the devices. With the “Cool Design” concept, PULS defines the interaction of three key factors that lead to low heat generation: firstly, consistently high efficiency; secondly, optimised dissipation of heat to the device’s surroundings; and thirdly, the thoughtful arrangement of temperature-sensitive components within the device.

In terms of DC-UPS systems, PULS has so far pursued the approach of realising the power supply and the DC-UPS module with separate devices, rather than integrating both functions into one housing. This separates the power supply, as the primary heat source, from the sensitive electrolytic capacitors in the UPS module.

However, PULS’s latest subsidiary Adelsystem – a PULS company has been successfully offering an all-in-one solution for several years, combining a power supply and a DC-UPS in one device. The Italian developers have chosen a smart device concept for this approach, which we will discuss in a separate blog article.

3 principles of “Cool Design” by PULS

3 principles of "Cool Design" by PULS

DC-UPS – with battery or capacitor storage?

Currently, PULS offers two options for an uninterruptible power supply to the load in an emergency: both double-layer capacitors and lead-acid batteries can serve as energy storage in DC-UPS systems for industrial applications.

Double-layer capacitors, also known under trade names such as Ultracaps, Supercaps, or Greencaps, have been available on the market for over 25 years and have developed into reliable and proven components. These initially quite expensive components are suitable as energy storage for DC-UPS systems and can be used in applications such as storing braking energy or providing short peak currents.

Which energy storage solution is suitable for which application cannot be answered in general. Each application is individual and therefore requires a specific analysis to ensure the best possible uninterruptible power supply.

The following questions can help find the ideal backup solution for your system:

  • What output voltage is required?
  • How much current must be available as a reserve?
  • How much backup time is required?
  • Are there loads in this application that do not need backup, and if so, how many?

Based on this information, recommendations can be made for the required output power of the power supply, the backup method, and any additional devices that may be needed. Of course, proven standard combinations that are often used by our customers and are typical for the industry also result from the corresponding requirements of the standard.

Buffering times of DC back-up solutions.

Summary:

Reliable power supply in critical infrastructures is of paramount importance for the safety and well-being of society. By adhering to relevant standards and guidelines, operators can ensure that their systems function safely. The use of modern technologies also allows for the benefits of renewable energies to be harnessed while addressing the associated challenges.

UPS systems are indispensable for ensuring a reliable and stable power supply in critical infrastructures. They protect against outages, voltage fluctuations, and data loss, thereby contributing to the safety and efficiency of operational processes. Implementing UPS systems in critical infrastructures is complex and requires careful planning and good consultation with the manufacturer. Despite these challenges, UPS systems are essential to guarantee the reliability and safety of power supply in critical areas.

Determining which UPS system is suitable for which application cannot be answered in general terms. Each application is unique and therefore requires a specific analysis. However, industry-specific application fields also define proven device combinations. Feel free to contact us, and we will find the right solution for your application.

IO-Link- and EtherCAT-enabled power supplies: How can they help you optimise your system performance?

Power Supply
Application
Industrial communication
IO-Link
EtherCAT

We see a global shift towards a data-driven economy developing at unprecedented speed which heavily affects the future role of data in the manufacturing industry. Therefore smart manufacturing is becoming increasingly important, data-driven insights are crucial for optimising system performance and ensuring operational efficiency. The power supply is placed at a central nodal point in every system and records a significant amount of real-time information that is of particular interest to the operating company as well as the system manufacturer.

A growing line-up of PULS power supplies give you access to this information via IO-Link or EtherCAT. In this blog article you will learn how you can profit from those solutions now and in the future.

What is the condition of the power supply? Do you still have enough power left to supply further modules inside the cabinet? What is the quality of the mains voltage like? And how does the temperature develop inside and outside of the power supply?

Many PULS power supplies are able to answer these questions with real application data. This information can help to tackle the big questions within the application: Is your system running at its optimum and as expected? If not, which adjustments need to be made?

Knowing the answers can help increase system availability and reduce maintenance and operating costs. And last but not least, reliable data is the key to success in smart manufacturing. This means the power supply has the potential – in parallel with its function as a converter – to also act as a sensor and therefore makes a significant contribution to your approaches for predictive maintenance and automation of industrial processes, which leads to a higher output, better performance and lower costs.

Power supplies with a communication interface strengthen availability of the overall system

Power supplies perform a rather more passive role in terms of communication output. Following installation, they need to work reliably in the background and remain as maintenance-free as possible – ideally for many years.

So the question which communication protocols a power supply manufacturer like PULS should support in the long-term is essential and must be well considered. Based on many meetings with various customers and market analysis we decided to go for IO-Link and EtherCAT. The reasons for this decision are explained in this article.

Therefore we are extending our portfolio with IO-Link and EtherCAT versions of our most popular products.

CP20.248-IOL with IO-Link interface and display

For example the reliable and efficient 1-phase 480 W DIN rail power supply CP20 is available as an EtherCAT (CP20.241-ETC, CP20.481-ETC), IO-Link (CP20.242-IOL) version as well as a hybrid version with IO-Link and an integrated power supply condition display (CP20.248-IOL). For the higher power demand, the well-established 3-phase 960 W DIN rail power supply QT40 comes with IO-Link. These devices are ready for a simple integration into existing communication networks. Our robust IP54, IP65 and IP67 Field Power Supplies (FIEPOS) for decentralised applications feature IO-Link as well and another variant supporting EtherCAT is under development.

With all these new tools at hand customers profit from a future-proof solution that alongside a highly efficient and reliable energy supply embedded in a compact housing, also provides completely new insights into the performance requirements and physical processes of their systems or machines. This valuable information can be used to to better understand what is really going on in the application to optimise the availability and capacity utilisation of the system. In addition, the data helps to reduce energy costs, permits needs-oriented, preventative maintenance and provides valuable information for sustainability reports.

Remote diagnostics and automated parameterisation

The connection via IO-Link or EtherCAT also facilitates remote diagnostics and parameterisation via the user software being applied in the automation system. The system engineer can set the output voltage via the configuration software and the devices can be switched on and off remotely assuming remote access is enabled in the user software.

The settings made by the user, as well as critical process values, are saved on the automation system with full resistance to voltage failures and simultaneously on the built-in non-volatile memory in the power supply. If a device exchange becomes necessary, rapid, automated parameterisation of the new device is carried out during ongoing operation – in accordance with the parameters stored on the automation system. Downtime due to maintenance work is therefore avoided in the long term.

The data sent by the power supply also provide information on the cause of the fault and simplify problem-solving. This data is categorised in cyclical data, acyclical data and events.

The output current is included in the process data, for example, and is communicated to the master in a cyclical data telegram. The acyclical signals include device information such as input and output parameters that can be queried at all times.

Special events are also reported by the power supply. These events could be warnings or error messages, such as too low or too high input voltages, an overload or too high temperatures. If an abnormal condition arises, the power supply sends a message to the IO-Link or EtherCAT master and displays to the user the need for action, even before a failure actually occurs. Maintenance is therefore preventative and needs-oriented. This means that rigid cycles of regular servicing work are no longer required. In turn, this saves costs on new purchases and maintenance.

Additionally, events or warnings can trigger application reactions. In the simplest case, this can establish a safe state of the system. Furthermore, it is even possible to completely avoid system downtime based on the communicated events and therefore prevent insufficient product quality.

Now let’s dive deeper into the advantages of IO-Link and EtherCAT.

Benefits of power supply data

Advantages of the IO-Link communication protocol

IO-Link is based on serial, bidirectional point-to-point communication. The system is very robust overall and also has a high level of security – two factors that PULS pays particular attention to in the development of its industrial power supplies. The devices are often exposed to the harsh environments of the lower automation level and at the same time need to be protected against sabotage from outside. Data transmission via IO-Link is tried and tested for this usage.

The component costs for an IO-Link port in the power supply is relatively low in comparison to more complex communication protocols. Due to the low number of additional components, the MTBF value (Mean Time Between Failures) is almost as high as for the products without IO-Link. E.g. the MTBF for the QT40.241 (without IO-Link) is 375,000 h and for the QT40.241-IOL (with IO-Link) 350,000 h. This means that there are no compromises in terms of the reliability of the devices.

The same also applies to the long lifetime of 62,000 hours – at 3AC 480V, continuous full load and +40°C ambient temperature. This makes the IO-Link-compatible power supplies particularly well suited to failure-critical applications, such as in the automotive industry, factory automation and process industries.

In addition, IO-Link has been designed from the ground up as a user-friendly plug and play solution. Installation and operation are simple and can be realised cost-effectively. Standard shielded IO cables are all that are required for the cabling. Integration capability in all standard field bus and automation systems is ensured, offering flexible usage options.

Additional advantages of the EtherCAT communication protocol

The integration of the available PULS power supplies with EtherCAT interface into existing EtherCAT networks is very easy and works without additional gateways, which is a big plus for users who already rely on this field bus solution.

The biggest benefit of EtherCAT is its real-time capabilities, high-speed data transmission and easy integration, which outperforms any other industrial communication. This allows the power supply data to be used within real-time control loops. Based on the data, drives and other high-energy users can be optimally controlled to maintain overall dynamic power needs at their optimum level.

The data enables improved system efficiency as power supplies can be used at the optimal operating point. This leads to increased system throughput, improved product quality, and reduced waste, ultimately benefiting end-users by delivering better results due to the consistent performance and minimal disruptions.

Power supplies with EtherCAT interface are ideal for maintenance, logging and remote control in large-scale systems.

DIN rail power supply with EtherCAT interface

Have you ever heard of ADELBus?

The newest member of the PULS Group, Adelsystem – a PULS company, has developed its own communication network for its DC-UPS solutions, called ADELBus. This network allows the connection of all components in a system using a single communication protocol based on MODbus-RTU or CANbus technology, depending on the application field.

ADELBus enables the remote monitoring and control of all system parameters. It is designed to be simple yet powerful, providing robust and versatile communication capabilities for various industrial applications.

Learn more

AI decisions in the factory based on digital load profiles

The data recorded by power supplies with IO-Link or EtherCAT forms the basis for the technical innovations of the coming years. Above all, PULS is thinking here of the importance of machine learning in combination with the ongoing progress in terms of artificial intelligence (AI). The power supply is already supplying precise measurements of the output current, in other words, the load current. On the basis of these very carefully measured values, it is possible to detect and describe digital load profiles.

Based on information on the output current, for example, it is possible to determine whether or not a load changes across an extended period. This change can be an indication of signs of wear in the machine or plant. As an example, in the case of knocked out profiles, a sinus curve would be detectable in the load profile. As part of computer-aided data analysis based on artificial neural networks, this anomaly would be detected and reported.

Data is also provided by many other system components in parallel. Certain patterns can be recognised in these data sets and linked to operating states. The next step would then be a similarly automated decision-making process on the subsequent procedure using AI. This approach means that the power supply and other components as data sources open up entirely new options in the use of AI in the factory environment.

The use of current as a standardised data source in the production process plays an important role here. As a physical value, current supplies precise, interpretable and reliable data. This means that common big data problems in established company structures, such as incompatibility and inconsistency of data, or difficulties in networking and scaling, can be avoided.

Simplified artificial intelligence (AI) process for power supply data in industrial applications.

Summary: Let power supply data work for you

In conclusion, leveraging your power supply unit as a data source offers significant advantages for both operating companies and system manufacturers. By integrating PULS power supplies with IO-Link or EtherCAT, you gain access to valuable real-time information such as output current, voltage levels, temperature development, and load on the power supply. This data enhances system availability and reduces maintenance costs while supporting predictive maintenance and automation of industrial processes.

With the addition of communication interfaces, power supplies play a more active role in system diagnostics and parameterisation. The integration of IO-Link and EtherCAT into PULS power supplies ensures compatibility with existing networks and provides robust, real-time data transmission. This enables remote diagnostics, automated parameterisation, and efficient maintenance, ultimately leading to improved system efficiency, reduced energy costs, and enhanced overall performance.

Moreover, these systems are ready for an AI-shaped future. The data recorded by power supplies with IO-Link or EtherCAT forms the basis for technical innovations, including machine learning and artificial intelligence applications. This opens up new possibilities for optimising system performance and predictive maintenance.

Explore the benefits of these advanced power supply solutions and discover how they contribute to the success of your smart manufacturing initiatives.

More electric drives, less pneumatics: What does this mean for the power supply?

Application
sustainability
Application
Intralogistics

The shift from pneumatic to electric drives is a well-known development in the industry. However, in recent years, this topic has gained significant momentum. This is due to the continuously increasing cost pressure and the ever-stricter requirements for CO2 reductions. In both areas, the advantages of electric solutions prevail. This blog article illustrates, using the example of OEMs in the automotive industry, how smart industrial power supplies support the transition from pneumatic to electric drives.

Electric and pneumatic drives each have their advantages and disadvantages.

Pneumatic drives are inexpensive to purchase, easy to operate, offer high overload resistance, and are robust against environmental conditions such as temperature fluctuations and increased dust exposure. However, pneumatic drives require a central, continuous compressed air generation, which involves significant effort. It is necessary to distribute and maintain a consistent pressure throughout the entire factory. If there is a loss of compressed air due to a leak in the system, it must be quickly identified and repaired, which entails high maintenance efforts.

Especially in applications with many switching cycles, the high energy losses due to poor efficiency are significant during operation. Even in modern compressed air systems, the majority of energy is lost as waste heat. Additionally, the compressed air system must always be ready for use and therefore in operation, which results in high energy consumption. This leads to generally high operating costs and CO2 emissions.

Electric drives combined with servo motors offer better energy efficiency and enable high speed and precision. Thanks to integrated microprocessors, most electric components have a bigger range of functions and allow access to application data in connection with a central monitoring system. Operating costs are generally lower, and the CO2 footprint can be sustainably reduced. Additionally, electricity can be easily distributed in the factory – almost without losses. The ability to convert and store electricity is another advantage. New technologies, such as wireless energy transmission, also come into play. Electric solutions are also significantly quieter, which reduces noise pollution for the workforce.

However, electric drives are more expensive to purchase. Additionally, the systems are more complex compared to pneumatic solutions and may require retrofitting existing equipment.

OEMs are generally cautious about changes to proven systems. But the economic, political, and social pressure regarding energy efficiency is prompting more and more manufacturers to opt for the purely electric route. Therefore, new industrial plants often omit the installation of a pneumatic system right from the start. As is often the case, the automotive industry and its suppliers are taking a pioneering role in this regard. The numerous projects to switch from pneumatics to electricity that PULS has accompanied in this segment had one thing in common: the right power supply system is crucial for success.

Decentralised power supply of conveyor systems

In the automotive industry, everything from large body parts and heavy engines to components from the small parts warehouse is transported via kilometer-long conveyor belts and driverless transport systems. In the BMW plant in Regensburg, Germany the assembly lines alone have a total length of 5.5 km.

When the stoppers, diverters, as well as lifting and rotating units in conveyor systems are converted from pneumatic to electric drives, a decentralised and protected power supply is ideally suited. In order to realise this, space-saving and powerful power supplies with sufficient power reserves are needed directly in the field. Long, loss-prone supply lines are eliminated, and flexibility is increased.

PULS has developed the product category ‘Field Power Supplies’ for this purpose, which consists of 360 W and 600 W power supplies with high protection classes IP54, IP65 and IP67, as well as many different connector options.

Additional features, such as up to four integrated current-limited outputs, ensure the safety of electrical consumers. With these eFuses integrated into the power supply, it is possible to realise selective power distribution, protection, and monitoring outside the control cabinet.

The Field Power Supplies are very robust both mechanically and electrically, and resistant to harsh environmental conditions such as moisture, dust exposure, and vibrations.

Field mounted power supply solution from PULS

Sufficient power reserves for dynamic motion sequences

For cobots, smaller robots, and decentralised applications in the automotive industry, electric drives have also become the first choice.

A reason for that is also the significant technological advances in electric motors. In recent years, these have contributed to making electric drives a real alternative to pneumatics. The motors generate a lot of power with small dimensions and weight. However, the rapid movements that electric motors enable, for example in robotic applications, require power supplies that can not only handle higher loads in the short term but also process the resulting regenerative energy.

Many PULS power supplies have generous power reserves, known as BonusPower. Numerous DIN rail power supplies from the proven DIMENSION product family provide up to 150 % power for 4 seconds. The FIEPOS field power supplies also achieve 200 % power for 5 seconds thanks to BonusPower. Upcoming product families for DIN rail mounting, currently in development, will even surpass these values in terms of peak performance and dynamics.

Thanks to the generous power reserves, oversizing of the power supply is unnecessary, resulting in cost and space savings.

Wireless charging of autonomous guided vehicles and mobile robots

Loss-prone pneumatic drives are becoming increasingly rare in autonomous guided vehicles (AGVs) and industrial trucks. Instead, manufacturers are also relying on electric solutions here, which are better suited for mobile applications. However, for efficient power supply and battery charging during operation, an appropriate charging infrastructure is needed in the factories first.

Several leading automotive manufacturers are already using the innovative wireless charging technology from the PULS Business Unit Wiferion for charging AGVs and cobots.

Wiferion’s contactless charging technology allows these vehicles to remain continuously in operation without disruptive charging breaks or manual interventions. Wireless charging offers significant advantages over conventional charging systems, such as the elimination of mechanical wear or the risk of tripping hazards from cables or contact strips.

With Wiferion’s etaLINK and CW systems, AGVs and mobile robots can be efficiently and autonomously charged during their normal work cycle, such as during short stops at stations. The elimination of long downtimes for energy intake increases the fleet availability significantly. The energy transfer takes place directly via charging pads, which allow for high positioning tolerance and start the charging process in less than a second.

With the established 3 kW and the new 1 kW systems, Wiferion technology is currently leading in the market. The maintenance-free solutions enable a significant increase in fleet efficiency and operational safety – ideal for 24/7 continuous use in demanding environments such as the automotive and logistics industries.

1
2
3
Available PULS power supply solutions for an automotive factory.
1

Reliable and efficient IP20 DIN rail power supplies for applications inside the control cabinet.

2

Wireless charging solutions for AGVs and CoBots.

3

Field Power Supplies with IP54, IP65 and IP67 for on-machine mounting in decentralised applications.

Increasing system availability through application data

Every minute of system downtime is extremely costly. OEMs in the automotive industry therefore try to minimise the so-called downtime of machines and conveyor systems to an absolute minimum.

With pneumatic drives, there is a risk of a leak in the compressed air system that must first be located. Electric drives are easier to manage in terms of control and preventive maintenance.

PULS offers power supplies with various communication interfaces, including IO-Link, EtherCAT, and power supplies with integrated displays. This allows for easy and quick access to application data and power supply functions.

Based on the power supply data, machine builders and operators can further optimise their machines in terms of efficiency and productivity. EtherCAT (e.g., CP10.241-ETC or CP20.241-ETC) is ideal for monitoring, logging, and remote control of complex systems thanks to real-time data transmission.

Power supply data is particularly advantageous within real-time control loops. Operators can control drives or other energy-intensive consumers optimally to keep the dynamic power demand within the capabilities of the power supply system. This optimal utilisation of the power supplies enable improved system efficiency. In particular, the power supplies, together with other system components, enable automated responses to handle unplanned operating conditions that previously often led to downtime or even damage.

Power supplies with communication overview

For example, the power supply provides precise measurements of the output current – that is, the load current. Using these finely sampled values, it is possible to recognise and describe digital load profiles.

Based on the information about the output current, the operator can determine whether a load, such as an electric motor, changes over a longer period. This change can be an indication of wear. In the case of worn profiles, a sine wave would be recognisable in the load profile. Computer-aided data analysis helps to detect and report this anomaly early. This way, it is easy to replace the wearing component before a failure and system downtime occur.

Increasing efficiency in 24/7 operation and reducing CO2

The decision for an electric drive is only one factor that positively impacts efficiency and the CO2 balance. Power supplies with high efficiency also support this process. The higher the efficiency of a power supply, the lower the power losses and thus the energy waste. PULS now achieves efficiencies of over 96 % with its power supplies.

An example calculation illustrates the importance of this value. With an efficiency of 96.4 % (e.g., with the SP960.241-S), losses of 3.6 % occur. For the corresponding power supply with 960 W output power, the power loss is thus 34.5 W, which is dissipated as heat to the environment.

A thought experiment shows the significance of each percentage point in efficiency. If we reduce the efficiency to 92 %, we see increased losses of 76.8 W, more than double.

Applying this to the total number of power supplies in a factory and considering the additional cooling, it significantly impacts the CO2 balance. The higher the efficiency of a power supply, the lower the energy waste and thus the CO2 emissions.

Summary: Efficient transition from pneumatic to electric drives

Increasing cost pressure and stricter CO2 reduction requirements drive the shift from pneumatic to electric drives in the industry. Electric drives offer better energy efficiency and lower operating costs, although they are more expensive and complex to purchase. Especially in the automotive industry, it is evident that decentralised power supply with powerful power supplies increases flexibility and minimises energy losses. PULS supports the transition from pneumatic to electric drives with suitable industrial power supply solutions. This not only contributes to reducing the CO2 footprint but also makes financial sense for companies.

New headquarters in Munich: Design thinking led to a new working environment

Company
Company
Locations

Developing innovations also requires an appropriate analogue workspace concept. The work environment must give employees the option to work together in interdisciplinary teams, work visually, test ideas, observe intensive phases of concentration, create prototypes, and much more.

This results in future-proof, user-oriented solutions. In short: an innovative work environment must offer genuine space for Design Thinking.


From prototype to an innovative working environment


We use Design Thinking in two completely different ways. On the one hand, we were guided by the Design Thinking approach when the new premises were being developed. The starting point was to understand employee needs and working methods. In addition, the workplace concepts of other companies were analysed both for inspiration and to avoid repeating common mistakes.

Based on these observations, a prototype was developed  and a room in the old office building was rebuilt accordingly. In the prototype room, the employees – as the target group – had the opportunity to test furniture and lighting concepts, evaluate floor coverings, follow sketches from architects and carpenters, and monitor project progress on whiteboards; feedback was explicitly requested at all stages.

The experience gained and suggestions from employees were directly incorporated into the development phase of the new premises. The result is a unique work environment that is currently in the advanced stages of “refinement”.



To activate the external video, please click on the link. By activating embedded videos, data is transmitted to the respective provider. Further information can be found in our privacy policys. Show Content


Award winning concept


The team of the architecture and design studio Evolution Design was honored with the Golden A’Design Award.
They were awarded for their design of the new PULS headquarters in Munich.

Creativity desired

The new world of work is itself the result of a Design Thinking process. It is therefore only logical that the rooms encourage employees to follow this innovative approach themselves.

The environment invites you to engage in creative work. Many walls can be written on or are magnetic. The Project Area is the perfect meeting place for team-working in larger groups. There are also numerous small meeting rooms and break out areas available for 2-3 persons; these are not bookable and can be used at any time.

Innovation needs focus


Attention has also been paid to concentrated individual working and desk sharing has been deliberately avoided. The personal desk or developer workstation, which is also height-adjustable, remains the base station for every employee. Employees can find an even more peaceful environment in the quiet spaces, such as the small library. In these quiet spaces there are no telephones or mobile phone calls, and even loud conversations are a no-no.

A modern nap room allows staff to take time to slow down and relax. Here, employees can get comfortable in a massage or relaxation chair to recharge their batteries with a quick nap.

Naturally, attention has been paid to digital technology across the entire working environment. Employees can connect to their desktop on their workstation via any screen and work together with their colleagues in Munich, and thanks to video conferencing systems work on projects with their global teams.


Form follows function


The great innovative power that drives PULS in developing each power supply is evident in the design elements of the new working environment. Every detail – whether visible or hidden – has received special attention; nothing was left to chance.

Even the lighting concept for the workstations is based on a joint development by our CEO Bernhard Erdl and the designer Tobias Grau. The cabinets and sideboards were also developed in-house.

This consistency of detail runs across both floors. The result is a coherent overall picture of modern shapes and colours featuring the highest level of functionality.

Reaching for the stars: Power supplies for the most accurate telescopes in the world

Company
Application
efficiency
Application

The Cherenkov Telescope Array Project (CTA) is currently one of the most ambitious projects in astrophysics. The result will be the largest and most accurate gamma ray observatory in the world. DIN rail power supplies from PULS play a decisive role in this project.

The CTA observatory consists of more than 100 telescopes of various sizes – with 4, 12, and 23 m mirror diameters – installed in both the northern and southern hemispheres.

These highly sensitive telescopes enable scientists to detect high-energy gamma rays from across the universe. They are about ten times more accurate than existing instruments. As a result, researchers expect groundbreaking new insights into intergalactic and extragalactic objects.

A completely reliable and low-maintenance operation of the telescopes, in various climate zones, is crucial for the success of this project. And here, the right power supply makes all the difference.

PULS DIN rail power supplies are known for their high efficiency, compact design, long service life, and robustness in harsh environments. These features are key requirements for the CTA project, as the power supplies are expected to ensure a constant energy supply for the telescopes for many years to come.

The CTA project consists of over 100 telescopes in various sizes. (Source: CTA Observatory / G. Pérez, IAC, SMM / flickr.com)

Looking for answers using nearly 1800 pixels

The goal of the CTA project is to answer some of the unresolved questions in astrophysics.

For example, the observatory will help scientists to better understand the effects of high-energy particles on the evolution of cosmic systems, and to search for new very high energy (VHE) gamma-ray sources in the future.

Prof. Ulrich Straumann and his team from the Physics Institute of the University of Zurich are also involved in this ambitious project. Together with other international teams, they are working on the development of a camera for the 12 m telescope.

The telescope has a 12 m mirror diameter and a 16 m focal length.

The camera, installed directly in the focal point of the telescope, weighs almost two tons and consists of 147 modules with 12 light-sensitive detectors each. Additionally, the camera contains built-in amplifiers and digitizing electronics, allowing for decentralized data storage.

Altogether, the camera contains nearly 1800 individual pixels. Its field of view is approximately 7°, resulting in a hexagonal sensitive surface with a diameter of 2 m.

Power supplies with high efficiency, compact size and long lifetime are crucial

For a project of this size and scientific scope, selecting the most efficient power supplies is particularly important.

After intensive research, the developers at the University of Zurich decided on the DIN rail power supplies from PULS.

The AC/DC converters CPS20.241 (24V / 20A) and QT40.241 (24V / 40A), as well as the MOSFET redundancy modules YR40.242 and YR80.241, are used in the control cabinet of the camera.

As a precaution, the power supplies are installed in a redundant system. This ensures the availability of the camera at all times – despite the harsh environmental conditions.

The Swiss scientists particularly praised the high efficiency (QT40.241: 95.3%, CPS20.241: 94%), small width (QT40.241: 110 mm, CPS20.241: 65 mm) and long minimum service life (QT40.241: >7.5 years, CPS20.241: >10 years, both at full load and +40 °C ambient temperature) of the PULS DIN rail power supplies.

“With the PULS power supplies, we can easily achieve the required output power of 4.5 kW within the available space,”

explains Dr. Achim Vollhardt, who is involved in the camera project as an Electronics Engineer.

His colleague, Senior Scientist Dr. Arno Gadola adds: “The documentation of the power supplies is very detailed and contains extensive information about their lifetime expectancy. This way we can easily estimate the lifetime of the power supplies under our operating conditions.”

The CTA project is an application that demands everything from power supplies: challenging technical and climatic conditions, the highest demands on efficiency, and a global application with the lowest possible maintenance effort. But it is precisely in this environment that PULS power supplies show their full potential.

For the Swiss PULS Electronic GmbH, the close cooperation with the University of Zurich in conjunction with the CTA gamma-ray observatory is a particularly exciting project.

“If our power supplies can contribute to our understanding of the universe and our existence, then this is not only a technical and economic success, but also a great personal pleasure and satisfaction for me and our company,”

says Heinz Setz, Managing Director of PULS in Switzerland.

Learn more:

The CTA project intends to install over 100 telescopes in various sizes throughout the northern and southern hemispheres. (Source: CTA Observatory / G. Pérez, IAC, SMM / flickr.com)

Twisting toward possibilities: The Rubik’s cube solving machine

Company
Engineering
power supply
CP20.241

Surely everyone has tried to solve a Rubik’s Cube at some point. And most of us know how frustrating that can be: after countless twists and turns, you still end up staring at a chaotic color pattern — even though it feels like you’ve tried every combination.

But do you know how many possible combinations a Rubik’s Cube actually has?
To be precise: 43,252,003,274,489,856,000 — that’s about 43.25 quintillion.

To put this into perspective: if you tried one combination every second, it would take 1.37 trillion years to try them all — that’s about 100 times the age of the universe!

To activate the external video, please click on the link. By activating embedded videos, data is transmitted to the respective provider. Further information can be found in our privacy policys. Show Content

Twisting up mechatronics and automation

At PULS, we are committed to continuous innovation and therefore proudly support young talents on their way to becoming creative engineers and entrepreneurs.

In a world overloaded with information, we believe in focusing on meaningful achievements that showcase real engineering excellence.

Today, we are excited to share an inspiring story:

Four young mechatronics and automation students from Bielefeld University — Tom Töws, Matthias Risse, Jan Ewerszumrode, and Laurids Wetzel — decided to take on the challenge of building an automated Rubik’s Cube solving machine as part of their course on mechatronic systems.

What began as an idea from fellow students — abandoned due to budget limitations — was revived and completed by this determined team.

CP20.241 brings the machine to life


This is where PULS came in to support this innovative project.
We sponsored one of our high-quality DIN-rail power supplies: the CP20.241.

With its 24V / 20A output, compact design, high efficiency, and optimized cooling, the CP20.241 offered the perfect solution to reliably power the machine. Its industrial robustness made it an ideal fit for this high-tech prototype.

If you would like to get some more information on this product please refer to this page.

Bringing solutions to high gear

After three months of hard work, intensive brainstorming, and a lot of teamwork, it was finally done.

Problems, for instance, were things like the recording of the state of the cube via image processing, the control of stepper motors for turning the cube sides, and a complex manual mounting of the cube.

But where there is a will, there is a way. Despite all the obstacles, their dedication and diligence finally paid off.

An extended remake now takes on the shape of the developed machine, which is of excellent quality and meets all necessary requirements to be used at industry fairs.

On top of this, the team has established a high-quality and robust industrial design.

Now this part is where the real magic happens:

The Rubik’s cube can ideally be solved at a speed of 15 moves per second.

The underlying solution algorithm requires between 10 and 35 turns. In the best case, the cube can therefore be solved in less than a second and can compete with professional approaches and solutions.

The Rubik’s cube solving machine is powered by a PULS power supply.

Magic³


We want to congratulate this young team of innovators on their successful project and are happy to have been a small part of it.

We are hoping for many more of these wonderful initiatives, as this topic is predicted to become a big part of the future.

And of course, we are all striving for a magical future characterized by creativity, drive and innovation.

Power for makers: Power supplies for start-ups

Company
Application

MakerSpaces are a dream come true for every inventor. Tools, machines, sparks, iron filings and like-minded people make it such a cool place to be!

But there is much more to the MakerSpace than a workshop for private handicraft: every corner is filled with innovations and technology waiting to be discovered. For example, one team is working energetically on a prototype of a transportation capsule for Elon Musk’s Hyperloop.

Thanks to these committed projects, and especially the creative people behind them, the MakerSpace is one of the most important meeting places of the regional start-up scenes.

Many start-up and maker projects need to power up the electronic components of their inventions. Power supplies are, therefore, quite in demand with the makers. That’s why PULS has displayed some of its DIN rail power supplies in various MakerSpaces and offers free samples for many projects.



To activate the external video, please click on the link. By activating embedded videos, data is transmitted to the respective provider. Further information can be found in our privacy policys. Show Content

Electronics Lab in Munich


The Electronics Lab provides machines and know-how for prototyping.

Experienced trainers pass on their knowledge to makers during regular workshops, starting with the basics, such as soldering and the correct application of measuring equipment to more complex tasks, such as PCB manufacturing and assembly.

The Electronics Lab also houses the PULS Power Bar. Makers can check out samples of the PULS power supplies and request free units for their prototypes by scanning a QR code.

MakerSpace projects

The PULS Power Bar is already very popular. More and more makers are requesting PULS power supplies for their prototypes. Our power supplies are already integrated in the following exciting maker projects.

To activate the external video, please click on the link. By activating embedded videos, data is transmitted to the respective provider. Further information can be found in our privacy policys. Show Content

#1 Variobed


Maker:
Florian Schmid

Integrated PULS power supply:
CS5.241 | 24V, 5A single-phase DIN rail power supply

Application:
“My bed is a self-made construction that I can lift up to the ceiling electrically, so I have more space in my room. So far, I had a Meanwell power supply in use, but it broke recently. Now I am pleased with the PULS CS5. I’m sure that it will last longer.”

#2 Race car


Maker team:
TUfast e. V. Racingteam

Integrated PULS power supply:
CP10.121 | 12V, 16A single-phase DIN rail power supply

Application:
The power supply is being used in the latest TUfast race car. The team will start with this setup in the upcoming Formula Student season.

Power supplies for your prototypes


You are a dedicated maker or a young start-up and need power supplies for your prototypes? No problem!

Get in touch with us and tell us about your project. We will check how we can support you. Of course, this offer also applies to German and Austrian start-ups outside of Munich.


Free Samples

Community, workshops, events


The MakerSpace is all about cooperation, creative exchange, sharing experiences, learning from mistakes and much more. Therefore, the MakerSpace teams provide interesting framework programs. The following activities are currently planned in the MakerSpaces that PULS supports:

UnternehmerTUM MakerSpace in Munich:

Happylab MakerSpace in Vienna:

MakerSpace Amstetten:

  • Events
    Opportunities for collaborative work in a technical environment

MakerSpace HTL Hollabrunn:

  • Website
    Community for makers, upcyclers and tinkerers

What is the meaning of the IP ratings for power supplies?

Power Supply
Application
Design
Ip Rating
Power Supplies

The IP rating indicates to what extent an electrical device is protected against the penetration of foreign objects and moisture. In this blog post, you can find out which IP codes there are, what the differences are between them and what you need to pay attention to when choosing a power supply.

Environmental influences such as dust or moisture can prevent the electrical components in a power supply from functioning correctly. In addition, the interior of the power supply may need to be protected from penetration by foreign objects, such as tools, screws and wires, and from accidental contact by the user. It is important to pay attention to the IP code (international protection code), particularly when power supplies are installed outside a cabinet. The power supply can only be used safely and costly downtime can only be avoided if the IP rating is suitable for the conditions.

What IP codes are there?

The IP code generally consist of the abbreviation IP (international protection or sometimes ingress protection) and two digits (for example, IP20, IP54, IP67 etc.).

The first digit identifies the protection against accidental contact and the penetration of foreign objects, like sand and dust into the device. The second digit indicates the protection against water and moisture.

In the case of industrial power supplies, DIN EN 60529 is the relevant standard for determining the IP rating. The ISO 20653:2013 standard is also frequently used for road vehicles. However, it only applies to electrical components in vehicles that need additional protection against pressure washing, for example with a steam cleaner.

In the context of power supplies, IP codes are occasionally confused with protection classes. While IP codes relate to the penetration of foreign objects and water and to accidental contact, the IEC protection (or appliance) classes determine the structure and insulation of power supplies with the aim of protecting users from electric shocks.

The following table gives an overview of the meaning of the numbers of the different IP ratings:

Foreign objects
o No protection
1 Protected against solid foreign objects with a diameter ≥ 50 mm (e.g. a hand)
2 Protected against solid foreign objects with a diameter ≥ 12 mm (e.g. a finger)
3 Protected against solid foreign objects with a diameter ≥ 2.5 mm (e.g. a tool)
4 Protected against solid foreign objects with a diameter ≥ 1 mm (e.g. wires)
5 Complete protection against contact and dust
6 Complete protection against contact and fully dust-tight
Water
o No protection
1 Protected against vertically dripping water
2 Protected against vertically dripping water when the enclosure is tilted (up to 15°)
3 Protected against water falling as a spray at an angle up to 60° from the vertical on both sides
4 Protected against water splashing from any direction
5 Protected against water jets from any direction
6 Protected against powerful water jets from any direction
7 Protected against temporary immersion
8 Protected against continuous immersion
9 Protected against high-pressure, high-temperature water jets

Which IP ratings are frequently applied to industrial power supplies?

The IP rating required depends on the installation site and the environmental conditions in each case. Power supply manufacturers that supply products to their customers ex stock generally only offer products with selected IP ratings that have become industry standards. The following table gives an overview of the most common IP ratings for industrial power supplies.

IP rating  Foreign objects Water Application
IP20 2 Protected against solid foreign objects with a diameter ≥ 12 mm (e.g. a finger) 0 No protection Use in a protected environment such as a cabinet
IP54 5 Complete protection against contact and dust 4 Protected against water splashing from any direction Use in a decentralised location outside a cabinet
IP65 6 Complete protection against contact and fully dust-tight 5 Protected against water jets from any direction
IP67 6 Complete protection against contact and fully dust-tight 7 Protected against temporary immersion

If different combinations of protection against contact and moisture are needed in special cases, customer-specific power supplies are often the ideal solution.

What do codes such as IPX4 and IP6X mean?

Electronic devices are often tested in relation to only one of the two codes for foreign objects and water.

The “X” indicates that the product has not been subjected to the corresponding tests for this code. Therefore, this is not a variable that can simply be replaced by any of the values from the table of IP ratings.

A power supply with the code IP6X offers full protection against contact and is dust-tight, but has not been tested for water penetration. In a similar way, a power supply with the code IPX4 has undergone the necessary tests for water splashing, but has not been evaluated for the penetration of foreign objects.

Which IP ratings does PULS offer for its power supplies?

PULS offers a variety of power supplies with the IP ratings described above. The products can be divided into two categories:

IP rating Application Product families
IP20 Use in a protected environment such as a cabinet DIMENSION

PIANO

MiniLine
IP54 Use in a decentralised location outside a cabinet FIEPOS
IP65
IP67

In the light of the increasing trend for decentralisation, the IP rating of industrial power supplies now plays a more important role than it did a few years ago. The DC supply is very often installed directly on the machines, outside the protective cabinet. To ensure the safety of employees and the correct functioning of the power supply, IP54 is required as a minimum across all system components (e.g. SPS, HMI, sensors etc.).

For these applications, PULS has developed the field power supplies in the  FIEPOS product family.

Die dezentralen FIEPOS Schaltnetzteile mit hoher Schutzart IP54, IP65 oder IP67 wurden für den flexiblen Einsatz direkt im Feld entwickelt.

Figure 1: The decentralised FIEPOS switch-mode power supplies with a high IP rating – IP54, IP65 or IP67 – have been developed for flexible use directly in the field.

Summary

The IP rating describes how well a device is protected against accidental contact, foreign objects and liquids. The majority of IP codes consist of two digits. The first digit represents the protection against accidental contact and foreign objects, while the second digit indicates the protection against water and moisture. The higher the numbers, the greater the protection. Industrial power supplies that are used inside a cabinet normally have the rating IP20. Power supplies installed outside a protected environment should have a higher rating, e.g. IP54 or IP67.

Analysing backfeeding events with the help of power supply data

Power Supply
Application
Backfeeding

Backfeeding is a physical process that is highly desirable in many applications, such as electric vehicles, for the purpose of energy recovery. However, in an industrial setting, backfeeding can be a problem and lead to costly system downtimes if the power supply units fail. In this blog article you will learn how power supply data can help you to identify those backfeeding events and take measures.

Resistance to backfeeding: why is it important for power supplies?

Rotating machine components, such as drum motors, store kinetic energy which they feed back during braking in the form of voltage to the output of the power supply. On its output side, the power supply can absorb a certain amount of this energy in its output capacitors. At the same time, the output voltage increases accordingly.

The resistance to backfeeding events describes the maximum voltage allowed at the output of the power supply. If this figure is exceeded, the power supply will switch off and the system or machine will shut down.

However, even plant operators are often not aware of the backfeeding figures in real operating conditions. There is a lack of specific data concerning the frequency and the maximum values.

A detailed real-life load profile is helpful when choosing a suitable power supply during the planning phase and when analysing faults in the operating phase. The question is: how can this data be obtained?

The power supply as a data source

The power supply manufacturer PULS has developed the FIEPOS family  of power supplies for decentralised use and has integrated the option of application analysis.The power supply functions like a sensor. It records a variety of application-related parameters (for example, voltage, current, temperature) and makes them available in real-time.

As the decentralised power supply is on the field level, PULS logically uses an IO-Link interface for communicating these data. Therefore, the FIEPOS power supplies function as reliable data sources and make the perfect complement to the existing condition monitoring systems. The following practical example clearly demonstrates the value that these data can add.

Application analysis with the help of the power supply

A manufacturer of intralogistics solutions planned to replace its existing 24 V power supply with a different decentralised solution. The power supply that was currently in use was constantly causing system shutdowns and it had not been possible to identify the cause.

PULS advised the company about the available solutions and made available a sample of the three-phase 360 W FPT300 power supply. With the support of application specialists from PULS, the customer evaluated the initial data after putting the power supply into operation.

The aim was to investigate three different processes:

  1. The parallel operation of the running motors without braking.
  2. The parallel operation of running and braking motors.
  3. The serious case of all the motors stopping abruptly at the same time, for example in the event of an emergency stop.

In all three situations, the output voltage and the current were measured and analysed over a specific period.

Analysis of the load profile in normal operation

Figure 1: Load profile in normal operation

As expected, in situation 1, where the motors were running, there were no noticeable problems (see Figure 1). However, the first load profile for the plant in normal operation was determined, which can help with identifying the correct size of the power supply.

Analysis of the load profile for parallel operation of running and braking motors

Figure 2: Load profile for parallel operation of running and braking motors

In situation 2, the parallel operation of running and braking motors was analysed. In almost all cases, the energy from the braking motors resulting from backfeeding was directly absorbed by the running motors. Only one brief occurrence of a slightly increased output voltage and a negative current spike was observed, which did not present a problem for the power supplies (see Figure 2, marked in red).

Analysis of the load profile for an emergency stop situation

Figure 3: Load profile for an emergency stop situation

Situation 3 was more critical. All the drum motors stopped simultaneously and caused a rapid drop in current and an increase in voltage to 31 V (see Figure 3).

The data analysis showed that this situation led to the system shutdowns that were mentioned initially. The capacity of the output capacitors in the previous power supplies was not sufficient in this case. As a result, the power supplies shut down.

The FIEPOS power supplies are very electrically robust. The highest permitted output voltage during a backfeeding event is 35 V/4.3 J for the FPT300. The output capacity is 18,000 µF.

As a result, the worst figure of 31 V in this example presented no problem for the power supply. As soon as the voltage fell again, the FIEPOS power supply automatically continued working in normal mode. However, it is worth mentioning here that the motor control centres from different manufacturers shut down for self-protection at a voltage of around 32 V.

The detailed inspection by the technical specialists at PULS before the customer made their purchase decision gave the customer the confidence that they were opting for a reliable, future-proof solution.

Decentralised solutions for intralogistics

Alongside its extensive IP20 portfolio, PULS is expanding its range of power supplies in protection classes IP54 and IP65/IP67 for decentralised use outside the cabinet. For system developers that means greater flexibility when planning a plant and more space in the system, together with time and cost savings.

The FIEPOS product family is based on single-phase and three-phase 360 W or 600 W field power supplies. The majority of the systems also function at 200 percent for 5 seconds. This makes them ideal for starting high-current loads and prevents the need for expensive, oversized power supplies. Over the next few months, additional performance classes will be added to the FIEPOS portfolio.

The power supplies are available with a variety of connector configurations, including M12-L/-T/-A, 7/8” and Han Q series. The power supplies from the FIEPOS eFused range have up to four current-limited outputs. These systems allow for selective current distribution, protection and monitoring in the field.

Summary

A reliable and versatile power supply is an essential feature of end-to-end decentralization in intralogistics systems

However, for this goal to become reality, power supply manufacturers must collect as much practical data as possible from the field of intralogistics to be able to offer appropriate solutions. The key is to gather and evaluate real application data.

PULS plays a leading role as an innovator in application analysis on the basis of power supply data. A global team of application engineers advises customers and users on overcoming their technical challenges. The team members can answer questions about complex application situations and identify the best solutions.

The findings from these data are also essential for the development of the decentralised power supply solutions of the future.

Efficient power supplies – An investment in the future

Power Supply
Sustainability
efficiency
Net Present Value
Npv

In the search for a suitable power supply, the costs play a major role, alongside the technical requirements. The focus is often on the initial purchase price, while other potential costs that may be incurred during the operation of the power supply are not taken into consideration. In this blog post, we demonstrate why the decision to purchase a high-quality power supply is a profitable investment for your company, by taking a close look at all the costs involved.

How do I find the right power supply?

Let’s assume for a moment that you have to select a power supply for a new project and the choice is between a  CP20.241  and a power supply from another manufacturer. You already know that from a technical perspective both products are suitable for your purpose.

You have access to the device data in Figure 1 and the application data in Figure 2. Figure 1 shows that both power supplies produce the same power. The efficiency of the CP20.241 from PULS is 1.6 percent higher, which results in power losses that are 8.5 W lower. Figure 2 shows the relevant data for the operation of the plant.

 

Comparison of the power supplies’ basic data

Figure 1: Device data

Specifications based on the application data

Figure 2: Application data

 

Alongside the data from Figures 1 and 2, you also know that the purchase price of the CP20.241 is €20 more than the power supply from supplier A, which is less efficient.

You are a project buyer and you need to keep track of the project costs, so you are tending towards choosing the device with the lower purchase price.

But before you make the decision, you remember that the company has a new CFO who is currently evaluating the profitability of all the projects and who is focusing in particular on projects that are profitable in the long term. You try seeing things through the CFO’s eyes and, alongside the purchase price, you want to check the potential running costs and include them in your decision-making process.

You take a detailed look at the data and, in particular, the differences between the two devices. On the basis of the existing data, you immediately notice the power losses, which are linked to possible savings or additional costs when it comes to the electricity bill. You examine these data more closely.

Your aim is to avoid losses as far as possible. Using the power loss figures and the application data from Figure 2, you calculate the potential energy savings over one year of operation, if you choose the more efficient power supplies:

With a more efficient power supply, this is how much energy you can save per year.

Figure 3: Calculation of the energy savings per year

It emerges that the 100 power supplies you need could give you additional savings of 5355 kWh/year if their efficiency level is 95.6 percent instead of 94 percent. You calculate the potential cost savings on the basis of an electricity price of €0.11/kWh, which will remain the same for the next ten years. You discover that you can make savings of up to €589 per year over the entire operating period:

A lower energy consumption also results in lower electricity costs.

Figure 4: Electricity cost savings per year

Note on electricity costs

Electricity costs fluctuate considerably over time and vary from one region to another. This means that it is not possible to generalise. In the European Union, for example, in the first half of 2022 industrial customers were paying on average €0.18/kWh (Electricity price statistics – Statistics explained (europa.eu)). In our example, we have used a low, fixed electricity cost of €0.11/kWh and disregarded future general and inflationary price increases during the operating period. Of course, higher electricity costs also result in significantly higher savings.

Purchasing a power supply: an investment decision?

You now have the following figures available when you consider the power supplies with 95.6 percent efficiency:

  • Initial investment: additional costs of: 100 items x €20 = €2000
  • Annual saving on electricity costs of: €589

As you have already realised, your new CFO thinks in terms of cash flows, which affect the liquidity and the value of the company. You know that an investment is profitable in the long term if you get a positive figure when you add together the initial investment and all the future cash flows. You can work out the number of years of operation that it will take for an investment to pay for itself.

You calculate the impact that the decision about the 10-year runtime will have on the costs and savings. If you choose the 100 power supplies with 95.6 percent efficiency, the cash flows are as follows:

You can also work out the break-even point, which is the time when the expenses correspond to the savings.

Calculation of the break-even point
Figure 5: Calculation of the break-even point

You discover that the savings are so considerable by the fourth year that they fully compensate for the higher initial investment. With a runtime of ten years, further savings are possible. In this example, up to €3890 can be saved if future savings are taken into consideration alongside the investment costs before the purchase decision.

Linear savings not including the net present value (NPV).

Figure 6: Savings not including the net present value (NPV)

You are very surprised by the results and you realise that focusing only on the purchase price is too simplistic and does not form an adequate basis for decision-making.

In a brief meeting, your CFO gives you the feedback that simply comparing initial investments and future cash flows can be helpful in coming to a quick, straightforward assessment of which investment is better. However, this approach is too simple to provide a reliable basis for decision-making. Your CFO explains that, wherever possible, you should also take into the consideration the change in the value of the future cash flows.

The CFO as the decision-maker on investments?

Following your meeting with the CFO, you receive an e-mail with the following information:

Dear John,
Thank you very much for the information you gave me. I think you need to extend your calculation to take into account the value of the money over time. In periods of high inflation, it is clear that future cash flows are worth less than payments made today. For example, €100 today is worth more than €100 in two years. To take these changes in value into consideration, you must discount all the future cash flows to their current value in your investment calculation. To make a decision about an investment, you need to calculate the net present value, which discounts and adds together all the current and future cash flows. This allows you to decide on an investment on the basis of realistic figures.
I have attached a detailed explanation of net present value.
Best regards
Susanne

What is net present value?

Net present value is one of the most important figures for assessing the value and the cost-effectiveness of an investment. A positive NPV means that an investment is worthwhile and will generate profits in the future.

The relevant factors in the calculation are the initial investment and all the future cash flows (inflows and outflows of funds). It is important to take into consideration the present value. Earlier cash flows have a higher value than later ones. The initial investment is then added to the discounted incoming and outgoing payments in the operating years. Alongside the payment flows, an interest rate must be included in the discount. This covers possible loan interest, the inflation rate and a risk mark-up and is normally decided on by each individual company or for each individual project.

The NPV is calculated as follows:

Formula for calculating the net present value (NPV)

Figure 7: Formula for calculating the NPV

You are very pleased to have had the input from the CFO and you try out the new calculation. To take into account inflation and loan interest, you use a fictitious interest rate of 5 percent. The result is as follows:

Net present value (NPV) taking into account inflation and loan interest.

Possible savings taking into account the NPV

Figure 6: Savings not including the net present value (NPV)

You realise that the future cash flows discounted against the current value are much lower than in the previous calculation. However, it is clear that using this approach the investment will also start to pay for itself in the fourth year and that additional savings of more than €2500 are possible over ten years of operation.

You have now completely rejected your original idea of choosing the cheaper option with the lower level of efficiency. Despite the higher initial investment, you opt for the more efficient power supplies, which means that your company is making an investment that is profitable in the long term.

Efficient power supplies increase sustainability

It is obvious that alongside the financial considerations, the efficient power supplies also contribute to increased sustainability. In our example, in addition to the financial benefit over the 10-year operating period, there is also a reduction in CO2 emissions of around 19.6 tonnes (5355 kWh/year x 10 years x 0.366 kg CO2/kWh). Would you like to find out more about this? Then take a look at our blog post “How do efficient power supplies contribute to CO2reduction?”

This explains how highly efficient power supplies can make a valuable contribution to more climate-friendly and sustainable industrial production by reducing energy wastage and therefore also CO2 emissions.

Summary

This simple example makes it clear that from a financial perspective the choice of a power supply should not be based solely on the initial purchase price. A calculation of this kind is too simplistic and, in many cases, will result in significantly higher costs in the future.

Our sales specialists will be happy to advise you on your choice of power supply. They will also help with investment calculations and take your specific cost factors and regional requirements into consideration. You are welcome to contact us.