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发布于: April 3, 2025 cURL Too many subrequests. cURL Too many subrequests. Mattress Machine Blog

Unexpected power failures often catch factory managers off guard, causing machines to stop mid-process and production plans to fall apart.

To minimize machinery downtime during power outages, we must prepare with risk assessments, UPS backup, emergency planning, and generator support.

Without a strategy, even a 10-minute power cut can cause hours of delay. Let’s explore how I approach this common but solvable challenge.

How do I conduct a proper power outage risk assessment?

Many factories wait until it’s too late to think about power risk—by then, it’s already costly.

A good risk assessment identifies which machines are most vulnerable, and what losses a shutdown would cause.

Start by ranking machines by how critical they are to your workflow. For example, our pocket spring bagging machine is essential—if it stops, nothing moves forward.

Risk Prioritization Table

Equipment	Downtime Impact	Power Sensitivity	Priority
Glue Line	cURL Too many subrequests.	Medium	cURL Too many subrequests.
Spring Bagging Machine	Very High	cURL Too many subrequests.	Very High
Compressor	Medium	cURL Too many subrequests.	Medium

Once we listed our top 3 failure risks, we were able to plan targeted protections—starting with UPS support.

Should I invest in Uninterruptible Power Supplies (UPS)?

During short blackouts or voltage dips, damage often comes from the sudden stop, not the duration.

UPS systems give sensitive equipment stable power for a short time—enough to shut down safely or wait until the generator kicks in.

We installed UPS units on our PLC systems and servo controllers—those are costly to replace and often suffer when power flickers.

UPS System Essentials

Match UPS capacity to machine load (Watt/hour)
Test monthly: especially battery health and alarms
Use surge filtering: to handle power "bounce-back"

We avoided a servo system reset—and 3 hours of downtime—thanks to a simple 3-minute UPS buffer.

Do I really need backup generators for power outages?

Short-term backup is great, but what if the grid fails for hours?

Backup generators keep your main machines running long enough to complete batches, protect materials, and reduce delays.

We use a 60kVA diesel generator to power our main line during outages. It’s fitted with an automatic transfer switch (ATS), so it starts in under 8 seconds.

Generator Readiness Checklist

Monthly test runs
Full fuel tank + backup drums
Filter/oil checked every 3 months
Simulated power-cut drills every 6 months

Without our generator, we’d lose not only time—but also half-done glue assemblies, which can’t be reused.