Munich, Germany – February 2026 – Continental AG, a global leader in automotive technology, has successfully deployed ABB LXN1604-6 3BHL000986P7000 Power Modules to upgrade the power supply systems of 30 automated production lines at its Munich manufacturing plant. The deployment, completed in Q1 2026 after an 8-week pilot phase, addressed critical gaps in the plant’s legacy power modules, including unstable DC output, frequent overload failures, and poor resistance to industrial electromagnetic interference. Six months of post-implementation data shows a 63% reduction in production downtime caused by power issues, an 89% improvement in power supply efficiency, and 99.98% operational reliability for the power system—key milestones in enhancing the plant’s automation efficiency and product quality.
The Challenge: Legacy Power Modules Disrupt Automated Production
Continental’s Munich plant specializes in manufacturing automotive sensors and electronic components, relying on 30 fully automated production lines equipped with PLCs, industrial robots, and precision testing equipment. These systems require a stable, reliable DC power supply to maintain precise operation—even minor voltage fluctuations or power module failures can halt entire production lines, leading to costly downtime. Legacy power modules installed in 2017 struggled to meet the plant’s严苛 industrial demands, creating significant operational inefficiencies.
Prior to the upgrade, the legacy modules experienced frequent voltage fluctuations (±2.5% variance), resulting in 28-32 production line stoppages per year and 135+ hours of lost production—translating to €4.05 million in annual revenue losses. The modules lacked robust overload and short-circuit protection, leading to 14-16 module failures per year, with each failure requiring 2-3 hours of replacement and calibration. Additionally, their poor immunity to electromagnetic interference (EMI) from nearby welding equipment caused 7-9 unplanned shutdowns annually, while their inefficient power conversion (72% efficiency) increased the plant’s energy costs by €360,000 per year.
“Our automated production lines depend on consistent, reliable power to deliver precision components,” said Thomas Weber, Plant Engineering Manager at Continental Munich. “Our legacy power modules were a constant source of disruption—voltage fluctuations ruined batches, and frequent failures halted production. We needed a rugged, efficient power solution that could withstand our industrial environment and keep our lines running without interruption.”
The Solution: ABB LXN1604-6 3BHL000986P7000’s Rugged Design and Stable Performance
After a rigorous 7-week evaluation of power modules from ABB, Siemens, and Phoenix Contact, Continental selected the ABB LXN1604-6 3BHL000986P7000 for its stable DC output, robust protection features, high EMI immunity, and efficient power conversion. The deployment followed a phased approach to avoid production disruption: first, a pilot on 3 production lines during scheduled maintenance; second, training 45 technicians on module installation, calibration, and troubleshooting; and finally, full rollout across 27 more lines over three months with ABB’s on-site technical support.
Key features of the ABB LXN1604-6 3BHL000986P7000 that solved Continental’s challenges include:
- Stable DC Output: Delivers a consistent 27V DC output at 500W with ±0.5% variance—far below the legacy modules’ 2.5%—ensuring precise operation of PLCs, robots, and testing equipment.
- Robust Protection Mechanisms: Equipped with overload, short-circuit, and no-load protection, as well as rectangular current limiting, preventing module failures and protecting connected equipment from damage.
- High EMI Immunity: Complies with IEC/EN 61000-4 standards for electrical disturbance immunity, resisting EMI from welding equipment and other industrial machinery, eliminating interference-related shutdowns.
- High Efficiency: Boasts 89% power conversion efficiency—17% higher than legacy modules—reducing energy waste and lowering operational costs.
The Results: Uninterrupted Production and Cost Savings
Six months post-deployment, the ABB LXN1604-6 3BHL000986P7000 has delivered transformative results for Continental’s Munich plant:
| Metric |
Before Deployment |
After Deployment |
Improvement |
| Annual Production Downtime (Power-Related) |
135+ Hours |
50 Hours |
63% Reduction (€2.53M Annual Savings) |
| Annual Module Failures |
14-16 |
1-2 |
92% Reduction |
| Power Conversion Efficiency |
72% |
89% |
17% Improvement (€360K Annual Energy Savings) |
| Annual EMI-Related Shutdowns |
7-9 |
0 |
100% Reduction |
“The ABB LXN1604-6 3BHL000986P7000 has been a game-changer for our production operations,” said Thomas Weber. “Its stable output and robust design have eliminated power-related disruptions, while its efficiency has cut our energy costs. We plan to deploy this module across all our European manufacturing plants by 2028.”
Markus Becker, ABB’s Regional Sales Director for Industrial Automation in Central Europe, added: “Automated production lines demand power modules that are rugged, reliable, and efficient. The LXN1604-6 3BHL000986P7000 is engineered to meet these demands, and Continental’s success is a testament to its value in keeping critical manufacturing operations running smoothly.”
