Technical Information

Case 1.

For example, if a panel stops working, even if it is only for 10 to 20 minutes, because the production line is an integrated system from the front-end to the back-end, not only the stopped panel but also the lines before and after it will be interlocked and the machines will stop.
Furthermore, if a furnace or other equipment stops, it will take 1-2 hours to restore operation. In other words, if the failure of one panel is taken into account, a loss of around 2 hours will occur.

Case 2.

For example, if your inverter stops working, replacing it will naturally require the cost of purchasing a new inverter. Just replacing the circuit board will likely cost several tens of thousands of yen.
If spare parts are not available, it may take several days, or even weeks, in some cases. If the inverter is old, it may no longer be manufactured. In the case of a long distance or an emergency, additional charter fees are required. Furthermore, if you keep inventory in case of an emergency, your inventory assets will increase. If you need to hire more maintenance staff for preventive maintenance and regular inspections, this will lead to higher labor costs, and you must be prepared for significant expenses.

The above-mentioned incidents occur every day at production sites. In the next section, we will introduce the effects of heat and humidity, which are common causes of sudden shutdowns of machines and panel.

(3) Effects of heat on equipment

Data has proven that heat significantly accelerates the failure rate of semiconductors and electronic components and shortens their lifespan. Graph 1 shows the temperature changes inside and outside panel of a certain automobile manufacturer. There is a temperature difference of approximately 15 to 20 degrees Celsius throughout the test.

In panels where the temperature inside the panel reaches 55°C or 60°C, the lifespan of the capacitors used in electronic devices is significantly shortened, as shown in Graph ②.
Graph ② shows the relationship between the lifespan of an electrolytic capacitor and ambient temperature, known as the "10°C doubling rule." At a temperature of 30°C, the lifespan of an electrolytic capacitor is approximately 80,000 hours, but at a temperature of 40°C, it is 40,000 hours. In other words, it is halved. At a temperature of 60°C, it is one-quarter of that, or about 10,000 hours. The lifespan of semiconductors and electronic components is also significantly shortened by heat.

For every 10°C increase in temperature, the lifespan is halved

10℃ doubling rule
The graph on the right shows the relationship between the lifespan of electrolytic capacitors used in electronic devices and ambient temperature.
If the ambient temperature rises by 10°C, the life of an electrolytic capacitor will be halved.
As electronic devices become smaller and high-performance, the amount of heat they generate is on the rise, and panel that house them are also becoming smaller, so it is expected that temperatures inside panel that are not properly addressed will become even higher than before.

Furthermore, Graph 3 shows the relationship between the failure rate of semiconductors and ambient temperature, known as the "Arrhenius Law." According to this, the failure rate is very low at temperatures below 30°C, but at 40°C the failure rate is 1. At 60°C, this increases to between 10 and 30 times, and at 80°C it increases to between 100 and 300 times. This clearly shows how the failure rate of semiconductors and electronic components increases dramatically as the temperature rises.

As the ambient temperature rises, the failure rate increases exponentially.

Arrhenius's law
The graph on the right shows the relationship between the ambient temperature of a semiconductor and its failure rate.
If the relative failure rate at 40°C is assumed to be "1," it increases exponentially to "10" at 60°C and "100" at 80°C.
It is clear that permanent cooling of control equipment will continue to be an important factor in ensuring the continued stable operation of production lines.










 

1) Cooling effect

On the previous page, we mentioned that spot cooler have a low discharge temperature, but some may be wondering if the same is true for control panel cooling unit. A typical spot cooler is said to have a discharge temperature difference (the temperature difference between drawing control panel cooling unit and it is used under the typical temperature and humidity conditions of Japan's summer, there is a possibility of condensation. (Graph ⑤)

For this reason, Apiste has focused on its unique "mild cooling design" that prevents condensation by keeping the discharge temperature difference within 8°C, taking into account Japan's average summer humidity of 60%. By cooling slowly while dehumidifying, condensation is prevented. Every single component that makes up freezing cycle has been reviewed and the design of the unique refrigeration circuit has been adjusted. This has resulted in cooling that is gentle on electronic devices.





 

2) Dustproof effect

Because of the structure that completely separates the internal and external air, the panel with the cooler installed is spatially independent and sealed, and unlike board fans or outside air intake, it has a dustproof effect. This is why control panel cooling unit is introduced in oil mist and dusty environment.




 

3) Dehumidifying effect

When humid air passes through a cooling coil cooled by refrigerant, condensation occurs due to the temperature difference on the surface of the panel coil, and the water that is generated is discharged outside. This is dehumidification. This product improves the panel environment by preventing not only heat problems but also problems caused by moisture and dust.

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