Preventive module forming ensures operational safety! of CNC, PLC and ROBOT automation technology

  • Electrical status analysis of the intermediate circuit capacitors

  • Condition-based forming pursuant to DIN EN 60384-4

  • Protective process

  • Continuous monitoring during the forming process

  • Immediate disconnection of the module in emergencies, as well as automatic shutdown

  • BVS seal of approval and log of all forming work carried out as part of the operation

Have your bearing assemblies regularly formed on-site before use!

Forming converters has always been an integral part of our cleaning and inspection work. This can now be done on your stored converters on your site, with our newly-developed forming case!

formierungskoffer bvs cnc

Inverters in storage (such as frequency converters, rectifiers, inverters and power converters, etc.) are considered critical spare parts. They are often stored for several years, and must be fully functional when needed.

The problem: Degeneration of the oxide layer

The oxide layer, which acts as an insulating layer (dielectric material) in the intermediate circuit capacitors, degrades over time without permanently applied voltage. The oxide degeneration reduces the insulation voltage, and defects can occur in the dielectric material. If such converters are put back into operation, short-circuiting may occur at these points. In the worst case, this may lead to the capacitor bursting or exploding. The resulting damage is often immense, and ranges from defects in neighbouring parts to completely destroyed modules. This can lead to prolonged system downtime.

A: Oxide layer thickness, B: Time disconnected (in years), C: Probability of default

The solution: Regular forming!

With conventional forming, the applied voltage is increased in stages. With the BVS protective process, the voltage is adjusted in relation to the continuous status analysis of the characteristic values of the intermediate circuit capacitors. In doing so, we ensure that forming only ceases when the specifications are within their tolerances. We therefore comply with DIN EN 60384-4.

Conventional forming

In the conventional forming process, an initially rapidly increasing voltage is applied to the module. This gradually flattens out before the operating voltage (600 V in this example) is reached. As a result, the current flow shoots up at the beginning of the process. The load on the capacitors is too high if there is already an overlaid insulation layer.

Conventional forming – BVS Industrie-Elektronik

BVS protective process

With the BVS protective process, the voltage is increased in slowly rising and flattening waves. This is done so carefully that even overlaid insulation layers can regenerate, as the electric load only increases slowly. Only after forming has been completed do we apply a full load to the module, to test the resilience of the capacitors.

BVS protective process – BVS Industrie-Elektronik

A: Capacitor load, B: Time, C: Power

Forming on your site in two steps:

➊ Your converters are formed with the help of a forming case, and using a protective process, both of which have been developed by BVS. Up to 2 devices can be formed at the same time.

➋ Each formed converter is given the BVS seal of approval, on which the latest forming date is noted, along with the expected date of the next forming operation. You will also be given a log of all the forming work that has been carried out as part of the operation.

Seal of approval – BVS Industrie-Elektronik