Ceramic Industry Solutions and Cases

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Core Industry Pain Points

(1) Extremely Harsh Grid Environment Ceramic production sites are densely populated with high-power nonlinear loads such as kilns, presses, and ball mills, which start and stop frequently. Grid harmonics (THDi) exceed 20%, and voltage fluctuations are significant. This easily causes PLCs, temperature controllers, and variable frequency control systems to crash, leading to loss of kiln temperature control. This directly results in the scrapping of ceramic bodies and a sharp decline in batch production pass rates.

(2) Poor Adaptability to High-Temperature, High-Dust Environments Temperatures around kilns in production workshops remain above 60°C year-round, while powder processing areas have high dust concentrations and corrosive gases from ceramic glazes and chemical raw materials. Ordinary UPS components age rapidly, cooling systems fail, and dust accumulation on circuit boards causes short circuits. The failure rate is 80% higher than in conventional scenarios, and the average equipment lifespan is less than 2 years.

(3) Insufficient Tolerance for Heavy Load Impacts The starting current of presses, ball mills, and large fans reaches 6-8 times the rated current, classifying them as highly impulsive loads. Ordinary UPS systems cannot withstand instantaneous high current impacts, frequently triggering overload protection shutdowns. In the event of a power outage to the kiln, ceramic bodies are prone to cracking and deformation, resulting in losses of tens of thousands of yuan per batch.

(4) High Requirements for Continuous Operation and Passive Maintenance Ceramic production is a continuous assembly line operation. Once a kiln shuts down, restarting and reheating require several hours, often leading to the scrapping of an entire kiln load. Traditional UPS systems lack early fault warning capabilities; after a fault occurs, manual on-site troubleshooting is required, resulting in downtime of 4-6 hours and significant production losses.

(5) Decentralized Deployment Across Multiple Workshops 

Corresponding Solutions
(1) Ultra-strong Power Grid Purification Solution Adop/12/18-pulse rectification active filtering technology, with input THDi < 3% and power factor ≥ 0.99. It effectively filters out higher harmonics generated b-power loads, stabilizes grid voltage fluctuations within ±5%, prevents malfunctions in temperature control, variable frequency, and control equipment, ensures precise kiln temperature control, and improves produpass rate.

(2) Specialized Protection Solution for High Temperature and High Dust Features high IP protection rating design, paired with fully enclosed dust-proof cooling channels and high-temperature resistantponents. The body is coated with anti-corrosion three-proof coating, suitable for ultra-wide temperature environments from -10℃ to 50℃. It resists high tempee, high dust, and corrosive gas erosion, reduces component aging rate by 85%, and extends equipment service life to over 10 years.

(3) Heavy Load and Shocnce Solution Optimizes the power frequency transformer winding design to enhance instantaneous overload capacity. It can withstand 150% rated load impact for 10 minutes, easilyng the start-up requirements of strong impact loads such as presses and ball mills. It eliminates shutdowns caused by overloads and ensures continuous operation of core equipment like

(4) Production Line-level Zero Interruption Guarantee Solution Adopts N 1 redundant parallel design with a maintenance bypass, allowing simple faults to be replaced online without power interruption, achieving zero rruption for UPS self-maintenance. It is equipped with a large-capacity battery pack, with extendable runtime of 4-8 hours to cope with long-term utility pooutages, reserving sufficient time for kiln normal cooling and safe production line shutdown, avoiding mass scrap of ceramic blanks.

(5) Factory-wide Centralized Intelligent O&M Solution Eipped with a monitoring platform to achieve centralized management of UPS equipment across all workshops in the factory, real-time monitoring of core parameters suc

Scope of Application
Covers various ceramic manufacturing enterprises, adapting to core production scenarios throughout the entire process, including raw material crushing workshops, forming and pressinorkshops, glazing and printing workshops, firing kiln workshops, polishing and edging workshops, testing laboratories, and finished product storage control areas. It meets the uninterrupted power supply requirements for varc production and supporting loads, such as kiln temperature control systems, hydraulic presses, ball mills, polishing machines, glazing equipment, inkjet printers, variable frequency conveying systems,trol systems, ceramic composition testing instruments, and intelligent warehousing equipment.

Success Cases：