Barcelona, Spain – October 2024 – A major Spanish automotive manufacturer has reported a 22% reduction in energy costs and 40% fewer production line shutdowns after upgrading to the ABB SD812F power module series at its electric vehicle (EV) component factory in Barcelona. The upgrade, completed in Q2 2024, addressed unstable power delivery issues that were plaguing the plant’s robotic assembly lines and increasing operational costs.
The Challenge: Unstable Power Derails EV Component Production
Prior to the SD812F deployment, the plant relied on generic power modules to supply electricity to its 50+ robotic arms, welding stations, and precision machining tools. The outdated system caused three critical problems:
- Voltage Fluctuations: Inconsistent power delivery led to frequent robotic arm misalignments, resulting in 300+ defective EV battery trays monthly. Each defective tray cost €120 to replace, totaling €432,000 yearly.
- Production Shutdowns: The old modules overheated during peak production hours (8 AM–6 PM), triggering 2–3 unplanned shutdowns per week. Each shutdown lasted 2 hours, delaying production of 800 EV components and costing €16,000 per incident.
- High Energy Waste: With an efficiency rating of just 90%, the modules wasted significant energy, pushing the plant’s monthly electricity bill to €85,000—well above industry averages for similar facilities.
As the plant ramped up production to meet demand for EV components from European automakers, the power instability became a critical bottleneck. “We couldn’t afford to have robots failing or lines shutting down when we’re trying to scale,” said Carlos Ruiz, the plant’s operations manager. “Our old modules were a liability, not an asset.”
ABB SD812F: The Stable Power Core for Smart Manufacturing
After a three-month trial, the plant selected the ABB SD812F power module series for its stability, energy efficiency, and compatibility with industrial automation systems:
- Ultra-Stable Output: The SD812F delivers a consistent DC voltage (±0.1% tolerance) even during peak load, eliminating robotic misalignments caused by voltage fluctuations.
- 98.5% Energy Efficiency: The module’s SiC technology reduces energy waste by 85% compared to the old 90% efficient modules, cutting electricity costs significantly.
- Thermal Management: Advanced heat sinks and active cooling systems prevent overheating, even during 12-hour production shifts. The SD812F operates reliably at up to 70°C without performance degradation.
- Seamless Automation Integration: The modules connect directly to the plant’s ABB AC 800M controller and MES (Manufacturing Execution System) via Modbus TCP/IP, enabling real-time power monitoring and integration with production schedules.
Results: Defects Drop, Costs Plummet
Six months post-upgrade, the Barcelona plant’s performance metrics are impressive:
- Energy costs down 22%: Monthly electricity bills fell from €85,000 to €66,300, saving €224,400 annually.
- Production shutdowns cut by 40%: Unplanned downtime dropped from 8–12 hours weekly to 5–7 hours, increasing monthly component output by 3,200 units.
- Defect rate reduced by 38%: Robotic misalignments decreased, cutting defective battery trays from 300 to 186 monthly and saving €136,800 in replacement costs.
“The SD812F has been a game-changer for our production line stability,” Ruiz said. “We no longer worry about voltage dips ruining batches or modules overheating during peak hours. It’s given us the consistency we need to scale EV component production.”
Javier Morales, ABB’s industrial automation sales director for Southern Europe, noted the SD812F’s relevance to automotive manufacturing. “EV plants require power solutions that can keep up with precise, 24/7 operations,” he said. “The SD812F series delivers the stability and efficiency that modern factories demand—directly translating to lower costs and higher quality.”
The manufacturer plans to roll out the SD812F series to its two other plants in Madrid and Valencia by Q1 2025.
