Recovery events set the real ceiling
A power supply sized only for repeated nominal moves will often dip right when operators need the machine to recover. That is why recovery should be a first-class test state.
We calculate headroom using both average demand and the short recovery burst after a forced stop or jam clear.
- Check recovery current separately from production average current.
- Validate cable drop on the actual installation distance.
- Review PSU thermal margin at the same ambient used for machine FAT.
Supply review matrix
The matrix used before PSU approval.
| State | What to log | Reason |
|---|---|---|
| Nominal cycle | Average current | Confirms continuous demand. |
| Recovery event | Peak current + voltage dip | Protects restart margin. |
| Warm cabinet | Thermal output stability | Catches late-stage power derating. |
Recovery headroom check
const headroomPct = ((psuMaxCurrent - recoveryPeakCurrent) / psuMaxCurrent) * 100;
console.log(`Recovery headroom ${headroomPct.toFixed(1)}%`);Continue Reading
Need Help with Your Motion Control Project?
Talk to our engineering team about sizing, integration, or technical requirements. Or subscribe for future articles.