Protection of a handling machine in cheese manufacturing

To protect a handling machine against moisture, a C2000 Safety Light Grid with an IP67enclosure rating has been installed.

At a French Camembert factory, employees often work near hazardous areas such as stack collectors. Since hands and fingers are most susceptible to injury, a reliable safety solution that doesn’t interfere with the production process is required. At an ambient temperature of 77° F, the safety system has an atmospheric humidity of up to 85 percent. The machine must be washed off once or twice a day using alkaline or acidic cleaning agents. Cold water (41 to 50° F) at a pressure of 40 psi is also used for rinsing and cleaning.

The compact design and PMMA acrylic tube housing of the SICK C2000 Safety Light Grid is ideal for use in this harsh environment. The protective housing was designed without trap points for dirt or contamination. A pressure equalization membrane integrated into one of the end caps prevents the penetration of moisture and ensures condensation does not form on the window. The cable entry is provided using proven PG cable glands.

The resistance of the materials used for the IP 67 housing series and the cable was positively assessed in material compatibility tests performed by Ecolab (Henkel) for the cleaning products P 3 (P3-topax 56, P3-topax 66, P3-topax 91, P3-topactive 200, P3-topactive DES). The low pressure foam method (COP cleaning and disinfection) for the food processing industry is recommended.

The C2000 Safety Light Grid is an electro-sensitive protective equipment of Type 2 in accordance with IEC 61496. The parallel light beams generate a flat protective field in front of the dangerous area. Any Unauthorized or inadvertent movement within the running machine by an employee results in the interruption of one or more light beams. The evaluation electronics for the C2000 detect this situation within a few milliseconds and immediately generate a shutdown signal for the stack collector.

Using the C2000 Safety Light Grid in an IP 67 housing ensures reliable protection despite harsh ambient conditions. The machine protection meets not only the requirements in relation to hygiene, resistance to cleaning, availability, and safety, but also the requirements in relation to ergonomics and productivity, as the stack collector is always accessible when shutdown.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
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Edge detection/guidance from the packaging material

Edge Detection and positioning in web guide applications

Flow pack machines and wrapping machines use packaging material on film rolls. The film has to be guided in the correct position into the packaging machine. When the film is too far to the left or right the packaging is of bad quality and the packaging design could be destroyed which leads to wasted products.

The AT20 Line Array Sensors  form SICK are the only line array sensors available that have diffuse mode, making them ideal for harsh environments where dirt and dust can interfere with retro-reflective sensors. These sensors are designed for edge detection/positioning in web guide applications.

Benefit
Reduces downtime. The array sensor offered in diffuse mode, making it ideal for environments where dirt and dust can interfere with other types of solutions that require a reflector.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
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CHEP Increases The Availability For Pallet Transport With The Reflex Array Sensor

Damaged pallets have to be detected before they are sent back out into the world again. A reflex array sensor reliably detects all kinds of pallets and reduces the investment of sensors in comparison to a small light grid.

Things are extremely busy at CHEP´s Belgian site in Bornem, with dozens of trucks arriving and leaving every hour, bringing in stacks of blue pallets and picking them up again. Pallets which are sorted, inspected and repaired on site, so that they can be sent back out into the world again. But the quality of all these pallets isn´t the same. How do you detect damaged pallets?

100 mm. Such a light array can detect a pallet perfectly, even if (for example) one block of the pallet is missing. Due to the continuous automatic adjustment of the switching threshold the sensor still works perfectly after 4 months operations in that harsh, dusty environment. Fast and easy in commissioning The two reflex array sensors were installed very easy. Only one sensor, only one power supply connection and only one reflector. The red light array – thanks to the PinPoint LED – is visible very well on the reflector. Furthermore the alignment of the reflex array sensor is supported by an optical alignment. Extension of reliability with the active contamination compensation The reliability of an optical detecting system is reduced due to dust depending on the operating time. The continuous adjustment of the switching threshold keeps a constant distance between the signal and the threshold over a certain time period. This new active contamination compensation increases the availability of the reflex array sensor significantly. That means the cleaning intervals for the optical surfaces will be extended and finally the effort will be reduced.

This is an application story from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
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Position control of solar fields in harsh environments

Solar fields are automatically adapted to the sun’s position in a large solar park by means of SICK encoders. Inductive proximity sensors from SICK also prevent the moving mechanism from overrunning in the end positions.

The EAR Group is a significant provider of ready-to-use photovoltaic systems in Italy. One of the plants that the company built on 30,000 m² in Cerbera, Italy, consists of 93 solar fields, with 33 solar panels each. Inverters convert the direct current generated on-site into alternating current. The overall performance of the plant is 700 kWp. The fields were designed so that they automatically follow the sun. This results in substantially greater energy efficiency than with rigid fields. The movement is controlled by so-called trackers, in each of which two precision drives work: one aligns the solar field to the vertical position of the sun, and the other adapts the field according to the horizontal movement of the sun. Monitoring these two movements requires a solution that works reliably even under harsh environmental conditions. In addition, the trackers should be able to align the solar fields so that they can receive the maximum sunlight in both summer and winter.

Application Solution
The EAR Group found the ideal solution for the detection of the angular change of the solar fields in the DFS60 incremental encoders with through hollow shaft. The sensor has a very high resolution, enabling precise adjustment of the solar fields. The very compact, integration-friendly design and the robustness in outdoor applications were also convincing. Features such as the metal code disk, the double shaft bearing, the housing’s high enclosure rating, and the water-resistant cable outlet make the sensor a solution that guarantees maximum availability in any weather and at temperatures between −20°C and +100°C.

Benefit
More efficiency by adapting the solar fields

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
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The Benefits of Electric Actuators for Mobile Off-Highway Applications

Trend Toward Electric Actuators

Off-highway vehicle manufacturers are taking a long, hard look at the way they use motion control systems in off-highway vehicles. Once dominated by pneumatic and hydraulic systems, equipment is increasingly equipped with electric actuators.

Electric actuators are smaller, lighter and cleaner than hydraulic systems–all attributes that brighten a company’s bottom line. In fact, electric actuators:

  • Eliminate the need for hydraulic pumps and hoses
  • Eliminate the cost and bulk associated with hydraulic systems
  • Eliminate environmentally hazardous oil and leakage
  • Eliminate high energy consumption of hydraulic systems

Rugged and reliable, our electro-mechanical actuators withstand harsh environments. They operate in extremes of heat and cold, dust, dirt and much and continue to run flawlessly and function efficiently. Typical applications include:

  • Constructions/Road Maintenance
  • Farm/Forestry
  • Turf/Lawn & Garden
  • Railways
  • Recreational

Tri-Phase Automation is a Thomson distributor in Wisconsin
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Eden E is perfect for the food industry

Eden E a non-contact safety sensor for harsh environments

In the past the production was interrupted at least once a week due to the failure of mechanical switches. The production interruptions have been responsible for significant loss in revenue over the past years.

ABB/Jokab’s Eden E has replaced mechanical switches on filling machines from ELOPAK in order to increase reliability and ensure a high level of safety. Depending on the type of filling machine up to 27 Eden E sensors are used. Each machine is also equipped with two Vital safety modules to achieve safety category 4 for the monitoring of hatches.

Eden E is a special version of Eden being designed for harsh environments. Tests show that Eden E can be used in temperatures from -70°C to 100°C. . A major advantage obtained by using Eden E, compared to a mechanical switch, is that physical keys are not required. This means that future alignment problems due to mechanical deterioration of the assembly do not cause mechanical failure and hence safety problems.

This application success story is from ABB Jokab
Tri-Phase Automation is an ABB Jokab distributor in Wisconsin.
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Exlar’s FT Series Actuator for Coal Diverter Gate

Exlar’s FT Series Actuator Performs in Class II Hazardous Location Environment

Application:
Coal Diverter Gate /Damper Control

Drawing of Exlar’s FT60 actuator installed on the
coal diverter gate.

The Challenge
The customer was using an Andco hydraulic actuator to control their coal diverter gate. Due to the actuator’s age, the customer was experiencing difficulties sourcing replacement parts for the unit. The Andco actuator also utilized old technology that the customer wanted to update through the purchase of a new actuator solution. This application required an actuator with a long stroke length that could control the motion of their large coal diverter gate. This application also required a solution that was rated for Class II hazardous locations because of the presence of coal dust in the facility.

Application Solution
The customer had previous experience with Exlar on a turbine application and felt comfortable with the Exlar product. They worked with the local Exlar representative and decided to purchase two FT60 actuators. The actuators provided the necessary stroke length for this challenging application; one actuator with a 12 inch stroke and the other with a 24 inch stroke. Operating in a Class II environment was required for this actuator solution and Exlar’s FT60 combined with a Explosion Proof motor and a Grove gear reducer satisfied this requirement. The customer also required a special trunnion mount and motor support bracket for their application which Exlar willingly designed. This non-standard trunnion mount and custom motor support was easily incorporated on to the FT60 actuator because of Exlar’s immense experience designing and manufacturing custom made actuator solutions for their customers.

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

Electromechanical systems meeting military standards

Challenge
The Aerospace & Defense industry has been a key market for Wittenstein as it continues to develop solutions which meet the needs of the most demanding environments. The radar tracking turret requires precision, repeatability and reliability.

Application Solution
Wittenstein’s TPM rotary servo actuator has technical specifications that fit the application requirements. As a special solution, Wittenstein offers the TPM gear motor solution that meets the applicable military standards. The TPM rotary servo actuator is a complete electromechanical solution, containing gearbox and motor in one integrated package. Certain benefits of the TPM can also be seen in the alpha TP mechanical servo gearbox. And if required Wittenstein can provide the electronics as part of the package to make your actuator as smart as it needs to be, offering redundancy in the safety systems.

Benefits
Offering a reliable electromechanical solution which can withstand extreme weather conditions and requires low maintenance, Wittenstein has created a solution for the military and other high-demanding markets.

This is a Wittenstein application solution.
Tri-Phase Automation is a Wittenstein distributor in Wisconsin.
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Sixnet’s™ Industrial Ethernet Switches

Networking Equipment donated to Aid Chilean Miner Rescue Efforts

Challenge
With Chilean miners trapped, rescuers needed to send down the ‘Phoenix’ rescue pod networked with a camera for video transmission in order to inspect the rock structure of the tunnel walls. The rescue pod was expected to endure very rugged conditions including extreme heat and a very wet environment. These conditions usually make transmitting the video images back to the rescuers a major problem.

Application Solution
Known for its compact size and rugged reliability in extreme conditions, Red Lion/Sixnet’s SLX-5ES-2ST industrial Ethernet switches were used in test runs of the Phoenix to remotely video the tunnel walls and the movements of the capsule. While in the tunnel, the industrial-grade switches endured 95 degree Fahrenheit temperatures and wet conditions to transmit the video images to a nearby control room.

Benefit
The SLX-5ES-2ST is a compact, 5-port industrial Ethernet switch that weighs only six ounces and offers connectivity for both fiber and copper cabling. Red Lion/Sixnet’s connectivity products are used in a variety of industries including power & utilities, oil & gas, military, maritime, transportation, video & security and others.

This is an application from Redlion/Sixnet

Tri-Phase Automation is a distributor of Redlion/Sixnet in Wisconsin.  For more information, contact Tri-Phase Automation Sales or Get A Quote

Eliminate Additional Costs with AquaTrue Planetary Gearheads

Revolutionary, corrosion-resistant and watertight gearheads for demanding applications

Challenge
Thomson/Micron’s  AquaTRUE gearhead combines the high performance and torque capacity of Micron’s True Planetary gearheads with features specifically designed to meet the strict requirements of applications such as food and beverage handling, packaging and dispensing. The AquaTRUE’s IP66/IP67 and IP69K protection is able to handle caustic cleaning chemicals as well as high pressure washdown. Until now, manufacturers have been unable to use gearheads in many applications involving harsh environments because there was not a product available that met those needs.

Application Solution
The gearhead’s 304 stainless steel housing eliminates the concern for rust or any type of corrosion. The AquaTRUE has a laser etched permanent product label and a smooth, round external housing that is designed without any external seams or corners for bacteria to collect. This makes the AquaTRUE very easy to clean and a perfect fit in any washdown environment.

Benefits
The AquaTRUE is engineered to be placed anywhere in the application’s design, regardless of environmental factors. This eliminates the cost of additional components such as enclosures, shielding or mechanical transmissions.

Tri-Phase Automation is a Thomson distributor in Wisconsin
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