Bottle Filling Line Rejection System

This application rejects bottles or cans from a filling line.

The level of liquid in the bottle determines if it is accepted or rejected. This is sensed as the bottle passes through an inspection process upstream from the actuator station. If it fails this test a signal is given to the SMAC controller to perform a cycle. There is a delay between the bottle being sensed and the signal being given, which is controlled by a PLC on the line.

There are two routines programmed into the unit. The first (program “A”) is a two-stage move consisting of a slow move out to an interrupt position, followed by a fast out and retract move. The second (program “B”) is a simple out and retract, for high speed applications. There are three “A” profiles set in the controller and one “B” profile, along with an edit routine for each. The three different “A” profiles are selected using input channels, the program has to be stopped and MS240 typed to run profile “B.” There are a number of registers used to store the three positions (start, interrupt, final) and two accelerations (initial, final). Editing is done through an OMRON PLC using the RS232. All setup is by touch screen via RS232 to the controller. The operator sets the profile needed. The LAL90-50 actuator and LAC1 controller sit inside a stainless steel box. This is necessary as the unit will be in an environment that will be washed down regularly. The rod exits the box through a 10mm wiper seal. The cable from the actuator will have the 25-pin D-type connector replaced by a 15-pin connector and will plug directly into the controller.

The SMAC system improves upon the previous method because: – The previous system was pneumatic, and if the cylinder did not reject any bottles for several hours and then had to reject one, static friction in the seals would cause the first cycle to be slow and ejector could be hit by the next bottle in the line. – The profile can be changed for different bottle shapes. Slow approach then high speed means bottles do not fall over, an important factor for high-cost liquid bottling. This could not be done with the previous system. – Out and back movements in 50ms means the actuator is suitable for lines up to 1,200 bottles per minute, good for filling glass bottles. (Cans run about 2,200 per minute and are usually split into two inspection lines of 1,100 per minute each.)

This application success story is from SMAC.
Tri-Phase Automation is a SMAC distributor in Wisconsin.
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SoftPLC Produces a BioMass of Power

SoftPLC handles biomass electric power plant

In Northern California, SoftPLC controllers, Tealware I/O and Web Studio are used by Blue Lake Power in their biomass electric power plant. The plant was originally a coal-fired plant that has been converted to burn woody waste. It uses wood chips as its mains fuel source for a conventional boiler which powers a steam-turbine generator.

Four SoftPLC’s are used for material handling, for both the input fuel and the ash by-product conveyors, and for all of the process control. Hardbook CPU’s with remote Tealware I/O connected via Ethernet are used for all the systems. Web Studio is used for the plant SCADA system which includes a redundant server, several desktop client stations and two large LCD displays in the control room. Web Studio is also used as the HMI running on portable tablet PC’s by the maintenance crew.

The Blue Lake plant adds over 93,000 MWh of renewable power to California’s grid and provides significant economic and environmental benefits for the city of Blue Lake and the state of California. The plant’s fuel procurement plan improves forest health, reduces hazardous fuels, and provides stability to the woods industry and local communities.

This application success story is from SoftPLC
Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Automated Tube Handling System Ensures Accurate Analysis of Human Fluids

Galil’s motion technology maneuvers the robotic arms of NGNY’s automated sorter and decapper of clinical lab vials containing human fluids for analysis

Challenge
When clinical lab scientists research and analyze human fluids to develop new drugs, find cures, prescribe treatment or solve crimes, they require samples not compromised by contamination, infection or misidentification. To prevent this from occurring during the sample preparation phase, NGNY Devices SL of Barcelona, Spain, developed their STDK500 Automatic Sorter Decapper system. It automates the pre- and post-process of handling, sorting and decapping the vials or tubes of samples, which are organized in trays used with the analysis equipment. The STDK500 consists of a robotic arm for inputting the tubes and another for outputting them, plus a conveyor and decapping module.

Application Solution
Galil DMC-2183 8-axis motion controller handles the precise motion of the robots, with axes 1– 4 assigned to the input robot and axes 5–8 assigned to the output robot. Directly attached to the controller are two Galil AMP-20440 4-axis 200 W servo drive boards which minimize space, cost and wiring. Each robot moves independently on its own Cartesian axis X-Y-Z and T, with rotation of the tube gripper on the Z- axis. Galil’s DMC-2143 4-axis controller with a single AMP-20440 board maneuvers the decapping module.

Benefit
Joan Viladomat, design engineer at NGNY Devices SL, said “This has been our first design using Galil controllers, and we found that they have an easy and intuitive programming method, which makes them very suitable for our applications.”

This is an application from GalilTri-Phase Automation is a distributor of Galil in Wisconsin.  For more information, contact Tri-Phase Automation Sales or Get A Quote

Galil Motion Controllers Used in Treatment of Cancer

FSI Treats Prostate Cancer with Ultrasound and Galil Helps Them Do It

Challenge
A new investigational device developed by Focus Surgery, Inc. uses high-intensity focused ultrasound to destroy cancer in the prostate gland. During treatment, a Galil motion controller moves an ultrasonic transducer with pinpoint accuracy so that the prostate tissue selected for destruction by the doctor is actually destroyed. If clinical trials are successful, the new device could replace radiation, hormone therapy and surgery in the treatment of prostate cancer.

Application Solution
This new groundbreaking device is called the Sonablate® 500. A Galil DMC-1822 two-axis PCI motion controller directs the transducer in the probe precisely, allowing the transducer to focus to a point the size of a grain of rice. The probe sweeps the transducer back and forth to accomplish the image-guided therapy. The PC gives high-level position commands and Galil makes sure the motors get there precisely.

This is an application from GalilTri-Phase Automation is a distributor of Galil in Wisconsin.  For more information, contact Tri-Phase Automation Sales or Get A Quote

Galil and TomoTherapy Target Cancerous Tumors with Precision

Galil places Hi·Art® treatment system within 1 mm accuracy

Challenge
Focused radiation is an effective means for treating cancerous tumors, particularly when there is a clear-cut shot at the target. Getting a clear-cut shot is no simple task. To address this challenge for clinicians, TomoTherapy Incorporated of Madison, WI, developed its Hi·Art® treatment system, a radiation therapy device that effectively utilizes 3D CT imaging to ensure accurate treatments for patients on a daily basis.

Application Solution
Essentially, the patient lays on a table or couch that slides into the rotating gantry for continuous 360° delivery of helical IMRT that uses tens of thousands of narrow beamlets, all targeting the tumor and individually-optimized to contribute to the total tumor dose. Handling the x-y-z motion of the couch is Galil Motion Control’s integrated DMC-2153 5-axis controller.

Benefit
The x-y-z motion controllers place the table to within /- 1 mm accuracy, and TomoTherapy is moving toward sub-millimeter accuracy in future models.

This is an application of GalilTri-Phase Automation is a distributor of Galil in Wisconsin.  For more information, contact Tri-Phase Automation Sales or Get A Quote

TechniScan Medical Systems uses Galil

TechniScan Facilitates Precise and Painless Breast Exams using Galil Controllers

Challenge
Early detection and treatment is one way to try to beat breast cancer, which is why over 50 million women get screened for the disease each year. While necessary and often effective, mammography screenings can be traumatic and then there’s the chance of getting a false result. To improve this process, TechniScan Medical Systems developed their painless, non-invasive UltraSound CT (USCT™) imaging system. It augments mammography exams by providing more accurate, detailed information about the physical structures and bulk tissue properties within the breast.

Application Solution
During the exam, opposing transmitting and receiving transducer arrays rotate around the breast in 2-degree increments, producing ultrasonic sound transmission data for the breast at each rotational position, and with approximately 1mm resolution. All the precise movement and I/O required is handled by Galil’s DMC- 2143 4-axis Ethernet controller, SDM- 20620 stepper module, and DB-28040 I/O daughter board TechniScan’s Systems. TechniScan’s Systems Engineer, Martin Kammeyer liked being able to communicate commands and status from the host processor to the Galil controller via the Ethernet interface. Additionally, because the DMC-2143 controller performs all the functions related to I/O and motion control, the host processor is isolated from such details as bit manipulation, event timing and error detection.

Benefit
Since the stepper drives and I/O are integrated right on to the controller, it significantly shortened the development time and reduced the complexity of the design.

This is an application story from GalilTri-Phase Automation is a distributor of Galil in Wisconsin.  For more information, contact Tri-Phase Automation Sales or Get A Quote

Bottling, Filling and Conveying – Kollmorgen’s Motion Solutions for Food & Beverage Manufacturers

Here are bottling, filling and conveying solutions from Kollmorgen.

Get a Quote from Tri-Phase Automation, a high tech automation distributor in Wisconsin.

Bottling Filling and Conveyingsmac-liquid-dosing

Whatever you’re producing – juices, milk, beer, wine, soda or maybe an entirely new beverage category – the packaging can be as important as the product. Your packaging processes can make the difference in terms of controlling volume, eliminating waste, maximizing throughput and ensuring quality. Even more, better packaging can strengthen your brand reputation, improve your competitive position on the shelf and increase consumer satisfaction – driving higher sales and profitability.

Uncork Innovation and Performance.

To compete effectively today, beverage manufacturers are looking to wow customers with new products in innovative containers. At the same time, they’re looking to maximize profitability by increasing bottling line uptime and throughput. They can’t afford sluggish performance or wasted product during changeovers – let alone the “Monday Morning Shock” of a machine that won’t run after an extensive cleaning performed over the weekend. Kollmorgen removes the barriers to full performance and true innovation.

Mechanical Systems Are Stuck in the Past. Look to the Future.

With servo control of each axis, your machine can deliver far greater uptime and throughput, along with the configuration flexibility to enable innovative package designs, fine-tuned portion control, pushbutton changeovers and more. There’s no backlash and slop from transmission components, and no limitation on your ability to program motion optimally for each independent process – from beverage preparation to filling, capping, cleaning and labeling.

Clean It Faster. Make It Last Longer.

Kollmorgen’s food grade, washdown-ready motors and gearheads make it easy to clean the machine and keep it productive over an extended lifetime with minimal maintenance. With a smooth cylindrical design and sealing systems that allow us to double the industry’s standard warranty period, our stainless steel servo motors and AquaTRUE™ planetary gearheads last longer and reduce your cleaning time by as much as 85 percent.