MillerCoors Minimizes Downtime Losses With Thermal Edge Enclosure Air Conditioners

MillerCoors  operates multiple breweries located throughout the United States and produces such popular brands as Coors, Miller, as well as a wide variety of specialty and craft beers.

The company relies upon Programmable Logic Controllers (PLCs) housed in electronic enclosures to control their automated brewing and packaging operations. These critical devices can cost over $100,000.  They raise internal cabinet temperatures to 131° Fahrenheit and would quickly overheat without proper cooling.

The solution:

Thermal Edge Enclosure Air Conditioners
Thermal Edge Enclosure Air Conditioners

MillerCoors needed enclosure air conditioners capable of communicating with their PLCs that could report problems before high internal temperatures impacted component longevity and potential productivity.

The solution includes Thermal Edge air conditioners equipped with an EtherNet/IP port and communication software.

Read the full success story

Tri-Phase Automation is a distributor of Thermal Edge in Wisconsin and Northern IL.


Red Lion Wind Energy

An application brief from Red Lion

A leading Power Company with 10,000 employees and annual revenues $15 billion that supplies over 40,000 megawatts of energy to millions of users across the USA and Canada.

Project Scope
With over 7,500 megawatts of renewable energy being generated from 9,000 wind turbines located at 75 sites across North America, the Power Company needed a more optimal networking communication solution to improve wind farm operations and avoid costly downtime. Its current SCADA system was utilizing a serial multi-drop string network that not only had data limitations, but was also experiencing reliability issues during temperature fluctuations.

The Power Company’s mission was to update its wind farm communication system, which included fiber optics, serial servers and Ethernet switch. After evaluating a number of different options, Red Lions’ Sixnet SLX series of industrial Ethernet switch was selected for its rugged reliability.  The project was completed in two phases with new hardware being installed followed by the transition for old equipment to the new communication system.  Deployed at the cored of the wind turbine-to -SCADA communication system, the Red Lion’s Sixnet Ethernet switches manage and process control signaling, condition-based monitoring and data collections. The industrial switches also allow IP-enable devices to be used throughout the turbine with fiber optic network providing noise suppression.

Located in environments subject to extreme temperatures, humidity, vibration, dust and electromagnetic interference from rotating generators and radio transmitters, wind turbines require industrial-grade equipment. Sixnet switches – tested to comply with the most demanding industrial standards – provide the rugged reliability and high performance vital to meeting wind farm conditions. Designed for fault tolerance, the switches use dual-independent power supplies and are fully compatible with fiber optic ring network topologies. Built-in redundancy ensures wind farm data automatically gets rerouted should equipment fail.  In fact, switch performance under electrical transient fault conditions makes it one of the most reliable elements in the wind turbines. Compatible with both multimode and single-mode fiber, the switches offer plug-and play simplicity when interfacing between the ring network and a SCADA system. The use of ring technology also enables turbine maintenance to be performed without communication loss. Additionally, new turbines can be seamlessly networked without downtime. This scalability coupled with ease of use enables the Power Company to benefit from real-time deterministic performance and around-the-clock security without downtime. This scalability coupled with ease of use enables the Power Company to benefit from real-time deterministic performance and around-the-clock security.

Tri-Phase Automation is a distributor of Red Lion products in Wisconsin.

Safe Gluing and Opening

With the UGB ultrasonic sensor for splice monitoring

A solution from Pepperl+Fuchs

Fig. 1: UGB transmitter above the packaging paper
Fig. 1: UGB transmitter above the packaging paper

Vacuum packages are frequently used to store coffee. To increase the customers’ benefit, the outer package of vacuum-packed coffee has a tear strip. The tear strip is glued onto the back of the printed paper by the coffee producer. This process must be monitored to ensure that all papers have a tear strip.

Depending on the coffee type, the color, thickness and texture of the packaging paper types may vary. The tear strip may be of different colors as well. Until now, sensors that were used to monitor splices had to be adjusted extensively after each paper change. In addition, the reliability of the monitoring process was unsatisfactory.

Fig. 2: UGB transmitter below the packaging paper
Fig. 2: UGB transmitter below the packaging paper

The Solution
The UGB ultrasonic splice detection sensor from Pepperl Fuchs is the solution! This ultrasonic sensor ignores the paper color and texture. With the electrical TEACH-IN input, it is easy to adjust to new paper types and, monitoring 100 packages per minute, the sensor enables very short processing times. Here, the packaging paper passes over a 30 mm hole in the sheet metal. The ultrasonic transmitter sends its signals to the ultrasonic receiver through the hole and accurately detects the paper.

he UGB ultrasonic sensor features high reliability, few adjustments during paper changes and low processing times. The MH-UDB1 assembly aid eliminates installation errors and ensures safe splice monitoring.

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin.

RFID Monitors Hose Connections

A solution from Pepperl+Fuchs

RFID readers and tags monitor hose connections
RFID readers and tags monitor hose connections

In chemical, pharmaceutical, and aseptic process equipment, process components and liquids must be transported from their storage tanks to a process reactor. It is of vital importance that these components are not spilled and that the wrong liquids are never introduced into the reactor, as this could result in costly process interruptions that must be prevented.

Small RFID read heads are mounted near the metal hose couplings. Reliable operation under harsh environmental conditions is assured.

Customer advantage
Process security and prevention of downtime by eliminating the introduction of the wrong process components and liquids.

What has been done
Chemical plants typically utilize continuous process methods. Process interruptions and errors frequently result in significant yield losses and associated costs. In order to protect such processes with nearly 100% reliability, and to exclude any human and external machine introduced errors, the hose couplings are equipped with RFID technology. A hose connection with an incorrect process medium for the current process can be securely identified. The transport valves for this invalid connection will not open and the error will be clearly displayed, allowing an immediate response by the operators. Important for these kinds of applications are reliable RFID hardware components and RFID tags that can be flush mounted inside a protective metal collar. In food and beverage applications, hose and pipes are regularly flushed using sanitary cleaning solutions. In this case, it is also important to securely separate the cleaning agents from the food.

Monitoring hose connections with RFID guarantees the introduction of the right material at the right time and assures that the correct measuring equipment is used for the process.

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin.  For more information Contact Tri-Phase Automation.

Vision Sensors for Post Print Processing

pf-post-print-sensorA solution from Pepperl+Fuchs

Vision sensor are used for sheet verification in all common collating, folding, and binding machines. The vision sensor ensures safe sheet verification in high-speed applications by image comparison and 1-D and 2-D code reading.

  • Comparing of sheet sequences and reliable detection of misfed sheets
  • Automatic Teach-In of reference sheets reduces operator workload and downtime
  • Safe detection even on reflective surfaces
  • Innovative image processing technology ensures reading of very large barcodes

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin. For more information Contact Tri-Phase Automation

Industrial RFID F61 Reading Head for a Track Switch Reading Point in Conveyor Systems

Decentralized control of intelligent container with integrated RFID transponder

A solution from Pepperl+Fuchs

Modular track switch detects the topology via a connection to the IDENTControl interface
Modular track switch detects the topology via a connection to the IDENTControl interface

In conveyor and production systems, work steps and conveyor routes are often centrally controlled. The F61 RFID reading head from Pepperl+Fuchs forms the basis for the track switch reading point that helps you optimize your processes. Logistics processes, like congested conveyor belt sections, can continue without disruptions.

The F61 reading head even allows the decentralized control of intelligent containers with integrated, writeable RFID transponders directly at the scene. The transponders in the containers integrate all the required information, which is present throughout the entire conveyor process.

The “Internet of things” principle should be transferred to warehouse, conveyor, and production systems. All goods are accompanied by a transponder that carries information on the origin, quality assurance, and other processes and transport destinations. Write operations can be used to update this data at any time. A decision is made to select the next process step and the best conveyor route. A large antenna fitted to the track switches and work stations makes the transponder position noncritical. As a result, time-critical adjustments in combination with a central database are rendered superfluous, and data communication to the higher level is reduced. Due to the modular structure of the conveyor modules and automatic topology detection, the conveyor route operates almost fully automatically and transports goods to their destination.

Featuring an extremely slim design, the F61 reading head is ideal for integrating in machines or installing in locations with limited space.

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin.

Inclination Sensors for Position Detection of the Arm System on Aerial Work Platforms

A solutions from Pepperl+Fuchs

inclination SensorsInclination sensors are in use on the WT1000 aerial work platform manufactured by Palfinger Platforms GmbH. The WT1000 is the tallest all-terrain aerial work platform in the world, and has been specifically developed for installing and servicing wind turbines. The platform has an extreme working height of over100 m and can reach heights that conventional aerial work platforms cannot.

The exact position of the work platform arm system must be monitored continuously to guarantee the stability of the aerial work platform, the safety of personnel, and to prevent damage to the wind turbine.  Palfinger relies on the reliable F99 series inclination sensors from Pepperl+Fuchs.  The inclination sensors detect the exact position of the arm system on the aerial work platform.

Inclination sensors ensure accurate position detection of the arm system on aerial work platforms
Inclination sensors ensure accurate position detection of the arm system on aerial work platforms

Palfinger Platforms defined two angular measurement ranges between 0° and 360° for detecting the position of the arm system on their aerial work platforms. The F99 inclination sensors were then adapted by Pepperl+Fuchs according to these specific requirements. To reduce the effect of vibrations on the sensor element, the angle measurement was equipped with a special filter.

Tri-Phase Automation is a distributor of Pepperl+Fuchs products in Wisconsin.  Contact Tri-Phase Automation

Disinfecting process purifies raw sewage

A solution from Pepperl+Fuchs

pf-disinfection-process-of-raw-sewageIn disinfecting waste water there is the need to accurately batch in chemicals and biological products to purify the raw sewage so that it can safely be released into the environment. Robust continuous level transmitters and point level sensors are required throughout the waste water treatment facility to accomplish this. Methane, acetone, chlorine, and ethanol are used. These gases create hazardous areas where intrinsic safety, purge, or explosion proof solutions will be used.

Large parts of the earth are covered with water, but supplying the world’s population with clean drinking water (potable water) is one of the greatest challenges. Pepperl+Fuchs has a comprehensive line of level sensors products for continuous level measurement and detection instruments for waste water treatment facilities. We can solve your particular measurement tasks in a variety of media and application areas in the waste water treatment facility.

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin. Contact Tri-Phase Sales or Get a Quote

Automatic Identification of Mounting Devices on Hydraulic Excavators

An application solution from Pepperl Fuchs

pf-auto-identification-of-mounting-device-on-excavatorsThe Challenge:
A system that can be used for fast changes of all hydraulic mounting devices on a hydraulic excavator from the cab.

Liebherr presented the latest development phase of the LIKUFIX system with a new TOOL MANAGEMENT system at Bauma 2007. With the inductive RFID system Pepperl Fuchs IDENT-I System P, the mounting tool is automatically detected by LIKUFIX during the change process. All necessary parameters are set on the excavator by the control system. The IPH-18GM-V1 read/write head is mounted in the excavator’s quick change system. Each mounting tool also contains a fully potted IPC03-16GK data carrier. Relevant information such as oil quantity, pressure, and type, or operating hours of mounting tools is recorded in this RFID chip and transferred inductively. The information is communicated through the IC-KP1-B16-LBH-SUBD control interface via a CAN-Bus interface from the IPH-18GM-V1 write/ read head directly to the excavator control unit.This TOOL MANAGEMENT system makes excavators even more economical and prevents incorrect operations by the excavator driver.  The result is lower operating and maintenance costs with greater productivity.

Advantages of the Pepperl Fuchs RFID System:

  • Sturdy design with fully potted electronics in the IPH-18GM-V1 write/read head
  • High temperature resistance
  • Serial communication allows for mounting between write/read head and IC-KP1-B16-LBH-SUBD control interface independent of length
  • Direct communication with excavator control via CAN-Bus interface
  • Rugged IPC03-16GK passive data carriers with protection type IP68/ IP69KStandardized economical data carriers

Tri-Phase Automation is a distributor of Pepperl Fuchs in Wisconsin.
Contact Tri-Phase Sales or Get a Quote

Direct Drive Technology Improves Flexo Printing Quality and Throughput

A printing solution from Kollmorgen

kollmorgen-improving-flexoFlexographic printing technology has become increasingly popular because it more easily maintains printing quality and reduces startup time and waste.

But flexo printing quality depends on maintaining extremely accurate synchronization of the anilox roller and plate cylinder used in each print deck module. Traditionally, this has been accomplished either by gearing the anilox roller and plate cylinder together and driving both with a single AC induction motor or by using separate servomotors to drive each axis through gearboxes. As press speed and printing quality requirements have increased, the inevitable inaccuracies in the gearing system have become a limiting factor on press print quality and speed.  Recent advancements make it possible to synchronize the anilox roller and plate cylinder to a much higher level of precision without mechanical transmissions by using closed loop control technology and driving both directly with independent, Direct Drive rotary (DDr). Eliminating the mechanical transmission enables the servo loop gain to be increased, thereby increasing the bandwidth of the servo loop. Speed control and phasing between the anilox and plate cylinder can be closely controlled in the absence of gear backlash, thus providing for higher speeds and inaccuracies for improved print quality. Throughput is also increased because the higher control loop gain enables faster machine operation. This article will examine the trend towards DDr systems in flexo presses and consider alternative implementation methods. Read the full Kollmorgen whitepaper: Direct Drive Technology Improves Flexo Printing Quality and Throughput


Tri-Phase Automation is a distributor of Kollmorgen in Wisconsin.
Contact Tri-Phase Sales or Get a Quote