Industrial power supplies, power converters, and supplementary power components used for automated operations include electrical and electronic components. They...
• Accept power from utility company main power or intermediate power components • Use transformers to change voltage-and DC output rectifiers (if applicable) • Regulate power-and solve voltage surges and electromagnetic interference or EMI issues • Regulation through Any changes in the voltage of the main power source or load • Still sending power (now at a more available current, frequency and voltage) to the different settings and machines they serve • In some cases, uninterruptible power supplies (UPS) store power in In the event of a power outage in the utility grid • If there is a failure, be ready to cut off the power at any time
Power supplies and power quality components abound in industrial environments.
Power requirements for industrial applications vary widely. The use of AC power is everywhere, but most industrial equipment and hardware use DC power. Of course, the utility power for operating automation facilities is generated and provided as AC. Therefore, this alternating current is received by a component called a power supply, which converts the power to direct current... and then reshapes it for use by other industrial components in the installation.
The three main power types include unregulated, linear, and switching-they use different operating principles. But switching power supplies are most common in industrial applications; other power supply types are rare or (for many applications) outdated. Switching (switch mode) power supplies or SMPS are favored for their small size and high efficiency, even as high as 80% and higher. Their formats abound...Although the most widely used is DIN rail mounting.
Modern power generation involving turbine generators rotates the rotor electromagnetic coils (in positive and negative states) in the stator. When passing through the rods on the stator, the rotor magnetic field induces current in one of two directions. In the United States, such generators on the electric utility grid have copper strip trio and rpms settings to output standard three-phase 60 Hz utility power. Hydro generator image from Dreamstime
Although countless industrial automation components use DC power supplies, AC is the first choice for power distribution because it has the highest transmission efficiency... and its voltage is the easiest to increase and decrease through a transformer.
Linear power supplies perform voltage regulation by using a transformer to convert input AC power into a voltage useful for another component or machine. Then, the power supply uses rectifiers and filters to achieve the final AC to DC conversion and smoothing function-usually at some voltage slightly higher than the target output to prevent undervoltage faults. Controlling heat dissipation through variable shunts or series resistors provides basic voltage regulation... albeit at the cost of reduced efficiency.
The industrial power supplies and other electrical components they serve are usually installed on DIN rails on cabinets and panels.
Compared with linear power supplies, switching power supplies are our focus. They use rectifiers and (for AC output) inverter electronics to convert the input AC power into a higher frequency power source (up to several kHz). Then they quickly switch power between the load and the on-board inductors and capacitors. Voltage conversion through a transformer (because of the high frequency involved) can be very compact.
Only the diode rectifier allows current to pass in only one direction...so it converts AC power (changing direction) to DC power, and the current stays in that direction. The problem is that this simple device without other electronic devices can produce output that exhibits problematic fluctuations.
Most DIN rail-mounted industrial power supplies can effectively convert line power and other potentially damaged input AC voltages into regulated DC power supplies. This DC power supply is reshaped and used by connected industrial automation components to realize monitoring, automation, control, assembly and testing functions. Switching power supplies are known for their high efficiency, low weight and highly compact design.
WAGO's 12-Vdc COMPACT power supply is efficient and economical for standard applications. They have the same space-saving compact housing and pluggable picoMAX connectors, which complement WAGO's extensive 24 Vdc power supply product portfolio. The 787-1201, 787-1211, and 787-1221 shown here have fast and shock-proof push-in cage clamp connections. DIN-35 rail or chassis mounting options abound. Each power supply has passed global certification, including UL 508 and EN 60335-1.
The switching power supply for DIN rail installation is installed on the control cabinet and panel, and is designed for the robustness of the automated factory settings. The most common DIN rail is a standardized 35 mm high metal mounting rail that can install electrical and electronic industry components, such as circuit breakers, distributors, power supplies, and control components. Such DIN rails in control panels and electrical cabinets help ensure safe, neat wiring and organization of components.
Industrial power can be found in all industrial control cabinets.
As explained in detail later in this design guide, the DIN name is derived from the Deutsches Institut für Normung (German Standards Association), which published the original geometric specifications of the rails. The standard width of the DIN rail is 7.5 mm or 15 mm, and the standard thickness is 1 mm, which is specified by the EN 60715 standard. The back of the DIN rail-mounted industrial power supply is designed to be locked to the DIN rail.
There are countless power supply brands and models to meet the specific requirements of the market and design. The following are some factors that design engineers should consider when choosing an industrial power supply.
Power phase: The required number of phases and input type (DC or AC), as well as the output voltage, current, and number of ports must be specified, as these vary by power supply model.
AC power can be provided as a single-phase, two-phase, or three-phase power supply. Industrial power supplies have corresponding single-phase, two-phase and three-phase devices. The single-phase power supply will have a single input port for ground, live and neutral. In contrast, three-phase equipment has three live ports in addition to the neutral and ground ports. It is also possible to use a DC-to-DC converter to convert a DC power supply from one voltage to another. In fact, industrial power supplies can provide a variety of outputs-usually 5, 12, 24, and 48 Vdc can be provided in series. The current ratings are also everywhere.
The power phase and the number of output ports are the first two parameters, which determine which power supplies are suitable for a given application.
Number of power output ports: Some DIN rail-mounted industrial power supplies allow designers to directly connect multiple DC-powered devices. These units have multiple output ports.
Size: All industrial power supplies are very small, but some are designed to be more compact. Before making a final choice, the design engineer should pay careful attention to the space allocated to a given power supply. The installation direction, airflow in the designated area, and nearby equipment also need to be considered.
Power supply regulations, approvals, ratings and certifications: DIN rail mounted power supplies can work in a variety of environments. Particularly challenging or bizarre ambient temperature, humidity, vibration, dust levels, and electromagnetic activity must be recorded in advance-and the power supply can withstand these conditions (and meet specified safety regulations). After all, security is paramount in all applications and must not be ignored or compromised. This is why it is recommended that engineers conduct a second verification to ensure that all purchased power supplies have all the necessary safety approvals and certifications for a given market, environment and application.
Consider a standardized measurement standard for industrial power safety—IEC's hazard-based safety engineering (HBSE) classification standard. HBSE quantifies the dangers of power supplies and the need for safety measures. HBSE level 1 conditions refer to those that are not painful when exposed to power... and the possibility of electric ignition is very small. The HBSE category 2 situation refers to the situation where contact with the power source will cause pain but not cause harm... and there is some possibility of electric ignition, but the potential spread of the fire is limited. The HBSE Class 3 situation refers to the situation where human contact with the power source will indeed cause injury... and it is likely to cause electric ignition and spread of fire.
Additional power function: Some applications may require special power functions. For example, certain installations that place power supplies in difficult-to-access locations may benefit from remote control capabilities. Other non-standard power features include integrated IO-Link ports, hot-swappable plug connectors, and output voltage adjustment functions.
DIN rail-mounted switching power supplies are indispensable in various industrial and manufacturing operations. The efficiency of a switching power supply is usually much higher than its unregulated linear power supply, with an efficiency of 90% or higher. How do they consume the least power under no-load conditions, thereby further improving their energy efficiency.
The installation and operation of the switching power supply is also very simple. Those products built specifically for DIN rail mounting can be quickly and safely connected to DIN rails with little or no tools. Most of these devices have spring clips, clips, or push-in terminals that can be installed manually. Connecting to mains and loads is as easy as most devices have screw or alligator terminals compatible with ring terminals, connectors, and wire stripping.
Reliability is another benefit. Most DIN rail-mounted switching power supplies currently available do not contain mechanical parts. (This significantly reduces the risk of failure and maintenance requirements-extending the life of the equipment.) In addition, such power supplies usually include safety circuits that protect internal sub-components and connected industrial components.
Other benefits include physical compactness and versatility. DIN rail-mounted power supplies are very small, light and compact, so they can be installed in small spaces. Due to the DIN rail installation method, they can be used in conjunction with other equipment in the electrical cabinet and control panel. Industrial power supplies sometimes charge for general-purpose power supplies that can also accept voltage input ranges. For example, some switching power supplies can work with grid voltages from all over the world...whether it is 120 V or 230 V in the United States or Europe. ⚙️ Etiido Uko's contribution• Mechanical engineer
Lisa Eitel has been working in the sports industry since 2001. Her areas of focus include motors, drives, motion control, power transmission, linear motion, and sensing and feedback technologies. She holds a bachelor's degree in mechanical engineering and is a member of the Tau Beta Pi Engineering Honor Society; a member of the Society of Women Engineers; and a judge of FIRST Robotics Buckeye Regionals. In addition to her contribution on motioncontroltips.com, she also leads the production of quarterly motion problems in the design world.
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