Delta DIAView SCADA System Enhances Efficiency for Automatic Capacitor Aging and Sorting

A capacitor is an electrical component that is widely used in electric and electrical systems. It consists of two conductors separated by a non-conductive region. Capacitors are used to store electrical energy temporarily in an electric field, or applied to harmonics filtering, signal processing, power factor enhancement and interference suppression. In the manufacturing of capacitors, the process of identifying defects in the capacitor to reduce current leakage through temperature, time, and voltage control in an aging oven is called capacitor aging and sorting.

The operation process is as follows: Capacitors pass through the feeding machine and conveyor into the aging oven. After polarity and open circuit detection, the aging power supply sets different voltage levels to charge the capacitor being tested. The capacitors undergo short-circuit detection and discharge. In the final inspection process, capacitor parameter detection is finished and the aging and sorting machine starts to remove defective products.

Around 30,000 to 50,000 capacitors per batch are inspected. In the inspection process, new data is produced every 500ms on average. All the data is displayed on the screen, which causes two major difficulties:

1. Observing the results with so many points displayed on the curve is difficult.
2. Customers need to frequently export inspection results since a human machine interface cannot handle such large amounts of data, and expansion memory cards cannot store such a large amount of data.

Delta Industrial Automation recently helped an electrical component equipment supplier enhance the inspection efficiency of capacitor aging and sorting. Delta installed its DIAView SCADA System on the automatic capacitor aging and sorting machine for online real-time monitoring. The inspection results of four parameters: equivalent series resistance (ESR), capacitance (CAP), LC circuit (LC), dissipation factor (DF) are stored and the number of unqualified products recorded. Customers can find the cause of unqualified products and the corresponding solutions through data analysis.

Through the Delta DIAView SCADA system, the customer can always acquire any data at any time for effective analysis. The system also provides an interval curve function: set a data range as an interval, calculate the average or maximum value and show the result as one point on the curve to avoid confusion. To show complete data for further analysis, the customer just needs to click to display inspection results on the sub screen. The curves for the parameters are displayed on the main screen and others on the sub screen. Without switching screens during the whole inspection process, the DIAView SCADA system can ensure complete inspection data collocation.

Delta provides a complete solution for a capacitor aging and sorting machine: for the drive and control system, the solution integrates the programmable logic controllers AH500 Series, the human machine interface DOP-B Series and the AC servo system ASDA-A2 Series; for the monitoring system, the DIAView SCADA system offers real-time monitoring, data collection and search with a variety of data visualization tools to help customers significantly improve the efficiency of their inspection results analysis and save on labor costs.