Monitoring a Foil Winder with Pepperl+Fuchs Rotary Encoder

The company ATH Automatisierung und Anlagentechnik Hameln GmbH develops, among other products, control technology for winding machines used in the most varied sectors of the foil, paper and fleece industry.

In a foil winder large reels of foil are wound up or down. During the winding of the foil mechanical movements must be tuned via the control technology of the drive motors. To capture the positions of existing linear and rotary axes, absolute encoders are used permitting the precise indexing of positions. This precision is necessary for the high demands on the winding quality, especially with thin foils (6 µm) and high speeds (1000 m/min) in order to be able to carry out the winding process and the coil reel change.

For the control of the drive motors, the Pepperl Fuchs singleturn and multiturn absolute encoders PVS58N-011AGR0BN-0013 and PVM58N-011AGR0BN-1213 are used. The rotary encoder technology replaces mechanical movement capturing devices which are expensive to install. The failure liability is reduced. The reduction of the failure frequency provides a cost saving during plant operation since expensive outages can be avoided.

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

MAAC machinery saves 50% of support cost using eWON remote access

Remote access enables MAAC machinery to connect to their machine just as if they were beside them and to have access to PLC’s, Drives and HMI devices and any other device connected to the machine subnet including an IP camera.


  • Save maintenance trip
  • Deliver a cutting-edge service
  • Improve flexibility
  • Quick and efficient troubleshooting

Re-posted from eWon’s success story June 4, 2017
Read the Success story MAAC machinery saves 50% of support

Tri-Phase Automation is a distributor of eWon in Wisconsin.
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So many labels, so little time. Just use Checker

An application success story from Cognex

OTE Group produce special hydrating, cleaning and lubricating fluids for the lens care market. As well as their own three product lines they deliver more than 100 private labels to customers with their own brands. Delivering the finished products all over the world, they need to be sure that all bottles reach their destinations in perfect condition and in good time.

When faced with the challenge of boosting their quality the company decided to use the Cognex Checker® vision sensor to ensure that the production code is present and also to check if the label is on the bottle. Using Checker ensures that quality control is improved meaning better traceability and faster more reliable production. OTE Group maintain high quality standards conforming to ISO standards for filling and manufacturing and so they cannot afford to take chances.

Checker has given OTE peace of mind with a 100% reliable inspection of each bottle – both their codes and labels. Before this they relied on random sampling but this is not enough to satisfy the strict requirements of their customers from the medical and pharmaceutical industry.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Vision Sensor Helps Automate High-Speed Loading of Transparent Cartons

An application success story from Cognex

Vision Sensor Helps Automate High-Speed Loading of Transparent Cartons

The Challenge
A beverage manufacturer uses transparent cartons to package its bottled drinks so that their distinctive branded labels are visible to consumers. The need to orient the bottles so that the right part of the label is visible makes automated packaging a challenge.

Application Solutions
Recently, this producer became the first to successfully automate high-speed carton loading with the use of a bucket auto load cartoner, using Cognex Checker® vision sensors. A leading producer of cartoner machines evaluated several sensors from leading companies but each seemed to have problems with one or more label types. “For example, one sensor worked with the red labels but not with the black or blue labels.” “Another sensor worked with the red and blue labels but not the black. Then we tried the Cognex Checker 3G1 and found that it was able to read all of the different labels without difficulty.”

The machine meets the beverage manufacturer’s requirement of 450 bottles per minute and has been tested to 600 bottles per minute. In both cases the Cognex Checker 3G1 vision sensors have been able to align every single bottle except for those with misformed sleeves.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Track and trace of pharmaceutical folding boxes with Cognex vision systems: certain to be original

Cognex taking a role in the fight against counterfeit pharmaceutical packages

An application success story from Cognex

According to the EU Commission, the rate of counterfeit drugs has risen by around 400 per cent since 2005. The Customs departments of European countries seize up to 2.4 million counterfeit pharmaceutical packages each year. According to World Health Organization (WHO) estimates, it is assumed that around 10 per cent of all medicines worldwide are counterfeits.

The DataMan 200, developed specifically for the efficient reading of even the most complex Data Matrix and linear barcodes, verifies that the label is applied in the first step. As the world’s first scanner with autofocus, its liquid lens ensures fast and highly accurate focus settings without any mechanical parts. To ensure optimal lighting conditions, it has integrated illumination with laser alignment.

“A significant contribution to the success,” according to Krempien Petersen CEO Stefan Klöpping, “has been because of internationally standardized and proven components, such as the DataMan 200 and the In-Sight 5613 vision system from Cognex. Only 40 pieces out of 250,000 during the two-shift operation are scrapped each day, a successful number for any operation.”

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Sweet Temptation: Chocolate Bar and Pieces Boxing Machine

Candy sorting
Fig. 1: Chocolate storage container as a preliminary stage for boxing

A solution story from Pepperl+Fuchs

LEKO-Verpackungstechnik GmbH in Murnau designs and builds special machinery for confectionery technology. These special machines are designed for the isolation, packaging and boxing of small chocolate bars and pieces. The task of this system is to combine individual chocolate pieces into layers and then insert them into various vending boxes. During implementation two chocolate varieties (Napolitanis and alcohol-filled chocolates) and several vending box formats must be taken into account.


candy bar packaging
Fig. 2: Conveyor belt with chocolate detection

Via five sorting pots the chocolates are moved into the correct position and deposited in the correct orientation onto a collection conveyor. The jamming control of the sorting pots is controlled by reflective light barriers. The 180° rotation and the counting are triggered via light sensors with background light elimination and a fixed sensor distance. The reference position of the servo-motor axes is determined via inductive proximity switches.

The detection of packaged chocolates on the white conveyor belt is carried out by the reflection light sensor with background elimination ML4.1-8-H-20-RT. Due to its low black/white difference, the sensor reliably detects every passing item in spite of highly reflective aluminum packaging at a very small distance from the white conveyor belts. The fixed sensor distance prevents a maladjustment during ongoing production.

Fig. 3: Chocolate detection in the box infeed

For the detection of products in the collector rail of the sorting pots, the stacking height of the lining placement unit and the jamming control of the vending boxes, the reflective light barrier with pole filter ML7-55/59/103 is used. The advantages of this light barrier for the client lie in its compact design and small visible beam spot. The distance between the reflective light barrier and the reflector can be kept extremely low.

Fig. 4: Detection of motor rotations
Fig. 4: Detection of motor rotations

The reference position of the servo axes is captured by the proximity switches.

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

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.


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.

Level measurement in buffer tanks in bottling systems and machines

sick-buffering-tanks-filling-systemsAn application solution from SICK

The level measurement in buffer tanks is a key application in bottling machines. The correct level must be measured in order to ensure the liquid supply to the bottling systems. The SICK LFP Inox level sensor reliably distinguishes between liquid media and foaming. Using FDA-compliant materials, the LFP Inox is suitable for applications with stringent hygiene requirements.

Tri-Phase Automation is a Distributor of SICK sensors in Wisconsin.

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Thermoforming Equipment with Electric Linear Actuator

A Packaging Solution from Exlar.

Powerful Roller Screw Actuators Replace Hydraulics.

Commodore Technology


The customer’s thermoforming equipment was using two opposing vertical hydraulic cylinders that came together to compress polystyrene sheets into foam trays at a high rate of speed. These trays are commonly found in grocery stores mainly in the meat department for meat and fish, fast food containers, restaurant take out containers, etc.

The customer wanted a “green” solution that eliminated the undesirable traits of hydraulics – such as mess from hydraulic fluid leaks, constant maintenance, etc. They were also seeking a higher production rate and improved product consistency.

The Exlar proposal consisted of an Exlar®FT35-0410 with high capacity screw, 2:1 parallel mount, oil ports with site gauge and a Schneider servo motor / drive.

The Exlar actuation solution nearly doubled the production rate from 20 cpm to 37 cpm.  It also provides significantly better consistency of the finished product

Tri-Phase Automation is a distributor of Exlar in Wisconsin.
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