Category Archives: News About Our Clients

Sequenced changeover of all process control parameters yields successful implementation of system upgrade with minimal downtime

Lisle, Illinois – Synergy Systems, Inc., a consulting engineering firm and Recognized System Integrator for Rockwell Automation, today announced the completion of a successful upgrade on the main blast furnace and stove control system at a major Midwest steel producer. Unique to this 18-month project was the absence of production downtime experienced by the client, during the transition from legacy control system elements to a Rockwell Automation ControlLogix and Wonderware-based HMI platform. Synergy Systems termed its protocol on this project the System Transition Execution Plan (STEP). During the implementation of STEP, the client experienced no interruption in overall blast furnace or stove control system operations, as it transitioned from an older DCS (distributed control system) to the new system, which was entirely designed and installed by Synergy Systems engineers, working onsite at the steel mill with client personnel.

At the heart of the concept, according to Synergy Systems VP Marc L. Hunter, “We developed our strategy around a core principle that targeted zero downtime during the changeover. Essentially, we created a building block operation, in which each control input/output on the old system was upgraded with parallel monitoring of performance values and system readouts. Only when each new component was functioning properly and the signals were inline with the existing monitored values did we execute the changeover of the control strategies, which was then integrated loop-by-loop into the new process LAN.” Utilizing this strategy, Synergy Systems enabled the client to maintain full production at the mill, throughout the entire project. Client engineering confirmed their complete satisfaction with the performance on this major project.

The STEP upgrades included all the following procedures: replacement of legacy PLC hardware with AB ControlLogix, replacement of DCS/PLC interface, movement of I/O from DCS to ControlLogix, deployment of Wonderware HMI, movement of control from DCS to ControlLogix, Wonderware historian integration and finally Level 2 interface via Wonderware HMI. Essentially, the control scheme for each system element was installed in parallel to the legacy control, then connected to the new ControlLogix processor and monitored on a channel of the client’s overall process control LAN for comparison to the older output.

Using this STEP approach, minimal process impact occurred and there was a significant savings realized for the client, both in operational expense and total project cost. As Hunter explains, “This project, because it happened in steps, so to speak, could be costed as a maintenance, not a capital, expense. The major capital expenditure diminished, owing to our strategy of loop-by-loop cutover and a gradual evolution of the graphical user interface, plus a progressive integration with the plant historian software. Collateral benefits to the client included a gradual weaning away from the legacy system, which allowed our team to thoroughly familiarize our client’s operational and maintenance personnel with the new hardware and software, as the changeover progressed.”

The determination to upgrade this system had resulted from numerous factors, according to the client. The I/O had become obsolete and the legacy system was UNIX-based, so many of the client’s current engineering staff onsite were not familiar with it. However, because a need existed to retain overall control strategies and functional client knowledge of system operations, Synergy Systems devised this STEP protocol to make the transition more gradual and self-teaching.

According to the client’s plant production & technologies manager on the project, “The blast furnace and stove control systems needed to be upgraded from a legacy DCS (Distributed Control System) to a Rockwell Automation PLC (Programmable Logic Controller) platform, with Schneider Electric Software Wonderware human machine interface and historian, along with statistical reporting mechanisms. Synergy Systems was challenged with cost-effective project deliverables requiring a proven transition plan, zero production outages, minimal risk implementation with no impact to production or product quality, improved technology with future expansion capabilities, improved process controls, enhanced operator interface, significant improvements to system reliability and stringent budgetary guidelines. This project required verification and movement of nearly 2000 I/O points, installation of new workstations, network communication upgrades, development of over 60 HMI screens with built-in diagnostics and alarms, extensive PLC programming, system functional documentation development and drawing approval, historian upgrades and onsite training. Finally, total project implementation and completion were required within a two-year period.”

He continued, “Synergy delivered beyond our expectations on every challenge presented. The innovative approach, level of engineering delivered and tools selected ensured a successful transition without impact to our production or product quality. Synergy’s professional manner plus their willingness to listen and offer solutions always made it easy for our Operations and Automation team personnel to work with them. The upgraded control systems have been in operation for nearly a year now, with high levels of reliability and efficient operations realized. Synergy proved to be an extremely cost-effective yet resourceful company, with a focus on the future of our mill control requirements. Our plant now has the technology to further enhance the automation strategies and drive flexibility and productivity that were not available with the legacy automation platform.”

For more information on this application, please contact:

Synergy Systems, Inc.
1982 Ohio Street
Lisle, IL 60532 USA
Phone: 630.724.1960
www.synsysinc.com
info@synsysinc.com
Attention:
Marc L. Hunter, VP
hunter@synsysinc.com

Product demonstrations and technical presentations from principals impress large crowd

On May 14, 2015, Exact Metrology held an open house at its Brookfield, Wisconsin facility and the event was attended by over 125 local area companies, comprising quality assessment, design engineering and management personnel from many of the leading manufacturers in the region. Hosted by company co-president Dean Solberg, the day included ongoing product demonstrations of the various metrology equipment brands offered for sale, lease and rental by Exact, as well as the testing procedures provided as a service by this unique metrology supplier.

Services on display at the Brookfield open house included 3D scanning, reverse engineering, quality inspection, instant scan-to-CAD comparison and a full suite of PolyWorks software solutions. Equipment shown at the event included Aicon 3D systems, Breuckmann 3D scanners, Leica Geosystems, Romer and Hexagon brands of scanning devices and related hardware, all of which were available for hands-on use by event attendees.

A new product of great interest to attendees was the Breuckmann steroScan, a flexible scanning system for precise 3D digitization and metrology. Applications for this product include quality inspection, reverse engineering, rapid prototyping, deformation analysis and digital documentation. Because of the adjustable focal length of the scanner, products from small components up to large sections of automotive and aircraft parts can be scanned with high resolution and accuracy. Breuckmann is a company of Aicon 3D Systems.

During the event, technical presentations were made by Aicon, PolyWorks by InnovMetric and Exact personnel on the newest advancements in 3D scanning technologies. The presentations were given to a “full house” of interested attendees.

As Dean Solberg commented, “We seek to find the right combination of equipment and services to suit the applications and challenges presented by our customers. In some cases, it’s a matter of matching the right standard equipment to the job, while at other times we bring custom solutions and services to our customers, whether they buy, lease, rent or simply use our services to achieve the desired results on projects.” Solberg credited his staff of metrology engineers, technicians and customer service personnel for their hard work, dedication and adaptability in seeking their correct solution to all customer challenges.

Exact Metrology is an ISO 9001:2008 Certified Company.

For more information on this new system, please contact:

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

—

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.

High precision 3D mapping supports installation of a new beam transport line for scientific research

Fermi National Accelerator Laboratory (Fermilab), America’s premier high-energy particle accelerator laboratory, in Batavia, Illinois, collaborates with scientists from around the world to perform pioneering research, operate world-leading particle accelerators, plus experiment and develop technologies for science supporting U.S. industry.

In 2014, Fermilab contracted Exact Metrology to work on a project known by its location as “Main Injector Ring Section MI-10.” Horst Friedsam, Head of the Alignment & Metrology Department at Fermilab, led the week-long project with Exact Metrology, which involved 3D mapping of existing equipment in order to yield data to support the placement and installation of an additional beam transport line.

Exact Metrology performed the scanning in section 10 of the Main Injector Accelerator, which is situated in a tunnel about 10 m below ground with a circumference of approximately two miles. The Main Injector accelerates a proton particle beam, arriving from the 8 GeV (Giga-electron-Volts) Booster, to 120 GeV and subsequently blasts it into a stationary target to generate the world’s highest intensity neutrino beams.

Recently, Fermilab has been working on a new Deep Underground Neutrino Project (DUNE) to provide a neutrino beam to the Homestake Mine in South Dakota. This project features access to research facilities 2 miles below ground, which is ideal for neutrino experiments requiring shielding from cosmic ray events. In order to deliver a neutrino beam to the DUNE, a new beam transport line that fits within the existing beam line infrastructure was required. As a result, data scanning, full CAD modeling and photo overlays of a large section of the currently installed Main Injector equipment was needed. The collected data were crucial for the design of new beam elements and visualizing interferences with existing components.

3D Map will help Fermilab install a new beam transport line

The Alignment & Metrology Department maintained a high precision control network throughout the laboratory complex. For the scanning process, a Leica ScanStation P20 ultra-high speed 3D Scanner was used in conjunction with special laser scanner targets, modified to fit within the existing control network points. Exact Metrology’s Leica ScanStation P20 was chosen for its combination of high accuracy and low scan noise, plus its industry-leading environmental specifications for industrial as-built documentation. The software chosen to aid the process was Leica Cyclone, producing TruView—a web-enabled panoramic point viewer allowing the user to view, pan, zoom, measure and mark up point cloud data over the web. Additionally, RSL300 laser scanner target markers from Berntsen International Inc. were mounted concentric to 1.5” radius steel half spheres interfacing with Exact Metrology’s laser tracker nests. The coordinates of the control network, determined at the millimeter level, were provided to Exact Metrology to globally register all scans relative to Fermilab’s system. Thus, the end product provides information for all scanned objects in the common coordinate system used for the entire Fermilab site.

Fermilab has a long-existing relationship with Exact Metrology, having purchased and rented equipment from their instrument pool plus contracted for metrology services as on-site work, such as this scan.

Exact Metrology is an ISO 9001:2008 Certified Company.

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.

For more information on this new system, please contact:

EXACT METROLOGY, INC.
11575 Goldcoast Drive
Cincinnati, Ohio 45249
Phone: 513-831-6620
Toll Free: 866-722-2600
www.exactmetrology.com
stevey@exactmetrology.com
Steve Young, President

Or

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

Or

FERMI NATIONAL ACCELERATOR LABORATORY (FERMILAB)
1117 N Washington Ave
Batavia, IL 60510
Phone: 630-840-2787
Horst Friedsam
—

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.

Advanced motors, drives and rapid feedback controls make substantial improvements in machine performance at Grand Rapids supplier to poly foam insulation and padding industries

As Rick Hungerford, president and CEO of Edge-Sweets (ESCO) points out, think of the mattress that remembers, the steering wheel that saves lives or the bandage pad with built-in antibiotic.  All these products start from blocks of cast polyurethane foam in various densities, then get cut, profiled or shaped by special machinery.  ESCO is a leading manufacturer of such machinery, supplying the furniture, mattress, automotive, packaging, pipe insulation, healthcare and other industries with automated CNC profilers and horizontal cutting machines.  Production speeds up to 840 inches per minute (21.33 meters per minute) are achieved on flexible and rebonded polyurethane, latex and viscoelastic materials, when used as either stand-alone cutting machinery or in tandem with automated materials handling and packaging lines.   The ESCO end user base reaches into many industries in the global market.

On two recent developments in the company’s machinery line, an engineering evaluation of competing motor, drive and controls lines was conducted, under the direction of Hungerford, who notes, “On our PMIII-1530, a horizontal profile saw with a 1.5 meter x 3 meter block cutting capability, we worked with one of our most trusted local suppliers of automation components, Wes Morgan from Electro-Matic Products, who introduced us to the Siemens motion controller, servomotor, gearmotor and drive package. We were seeking a controls platform that would have global support and standards compliance, as more of our machines are utilized for production outside the U.S. today than at any time in the past.” Hungerford further noted that, while the axes of motion are relatively limited on his company’s machine lines, the high-tension maintained and the need for precise positioning of the cutting wire on this machine made it necessary to have the most accurate and durable motor and drive combinations available onboard.

Rick Hungerford Jr., president and CEO of ESCO (left), inspects the drives cabinet with Wes Morgan of Electro-Matic, the local Grand Rapids supplier of the Siemens product line.

Incorporating the Simotion motion controller, Sinamics low-voltage drives and Simotics S-1FK7 servomotors from Siemens gave ESCO not only the performance levels desired, but also the global application engineering, technical support and parts inventory benefits of this international supplier. “Our machines are in use around the world,” states Hungerford, “and we needed great confidence in our control package supplier’s ability to support the machines and our sales team with parts and service, everywhere in the marketplace. In Siemens, we found such a partner. Plus, their local representative here in Grand Rapids, Electro-Matic, had established a solid relationship with our company and my team.”

Functionally, according to Hungerford, the Siemens package allowed a single, common DC bus without stand-alone drives plus the system provided by Siemens is scalable to allow the cutting machine being interfaced with additional mechanisms and loading/unloading devices as part of an overall automated production line for customers. The PMIII-1530 is operated by a single PC plus a remote operator pendant that allows free movement with full operation control of the machine during setup.

In selecting and programming the proper components for the ESCO machine, Siemens and Electro-Matic Products provided an optimized solution using the Sizer and Simotion Scout software provided by the component manufacturer. Once all the parts are in-house, construction of this machine is typically achieved in approximately 30 days, according to Hungerford, as ESCO does the bulk of the framework and final assembly onsite at the Grand Rapids factory.

The Foamular® industrial pipe insulation produced on the PMIII-1530 is used in the oil and gas industry.

The operation of the machine (as shown in the photos) begins with the CAM programming software written by the ESCO engineering team, plus additional data programs made available through ASTM for pipe and tube configuration. Hungerford mused, “It’s sorta like Etch-A-Sketch, but hardly a toy. Our engineers can take the canned programs and quickly make the necessary adjustments to the cutting paths to suit the machine cutting capabilities and the workpieces our customers are producing.” The software program is vital in accomplishing both an effective cutting as well as optimum utilization of the raw materials, through the nesting of the parts in the master workpiece block, done by the computational algorithms in the program.

The workpiece is then loaded onto the vacuum table, the cutting head is positioned and the process begins. The material used by the ESCO customer, in this case, is Owens Corning Foamular^®, a rigid polystyrene prepared in a tongue-and-groove configuration for industrial pipe insulation as the end product.

In operation, the motors, drives and feedback devices work in tandem to ensure a quick, smooth and efficient cutting of the material into the desired shapes.

The customer using the upgraded controls model of this ESCO machine is currently reporting a reduction in its cutting cycle times from 3½ hours to 20 minutes, according to Hungerford.

Commenting further about the drive performance, Wes Morgan of Electro-Matic noted that the Sinamics drive platform offered three distinct benefits. “The product line is consistent across a wide range of motor capacities, which is a real advantage for ESCO. Also, the regenerative feedback feature creates substantial energy savings for the end users, plus the Sinamics drives have a smaller footprint, owing to the dual motor modules and common DC bus system and this results in a more compact control cabinet.” He also noted the Simotion motion controller allows ESCO a single platform to perform simple axis to very complex integrated motion controls with a standard product, resulting in greater efficiencies in the design, programming and installation time for this builder and its customers.

—

On the second machine where ESCO implemented a controls upgrade, the HTX high-tension slitter/stacker incorporates a Simatic PLC, Sinamics variable frequency drives, Simotics servomotors, motor starters and contactors from Siemens. This machine, instead of a cutting wire, utilizes a tangential razor-like blade in a slit-and-retract motion, with the blade articulating on each pass through the material workpiece and then being automatically coated with silicone in the blade housing to maintain cut integrity.

The unit shown in the photographs here is the HTX 51-88 (indicating a 51” high x 88” wide x 132” long cutting zone), making ¼” thick cuts in a poly foam block. The machine is further capable of 1/8” cuts in production, as Hungerford noted. “This machine operates in tandem with other machinery we build, so the conveyor feed mechanism positions the workpiece for the cutting at the first station, then indexes it through the HTX to the next stations, where additional cuts and profilings are performed.

ESCO also produces vertical cutting machines, convoluters, roll splitters, contour cutting machines, metering and dispensing solutions for lab and production use, plus the company supplies fully integrated systems for polyurethane processing, including robots, curing ovens and mold designs to its worldwide customer base.

For more information on this story, please contact:

EDGE-SWEETS COMPANY
ESCO GROUP INC.
2887 Three Mile Road NW
Grand Rapids, MI 49534
Phone: 616-453-5458
Web: www.edge-sweets.com
Email: info@edge-sweets.com
Attention: Rick Hungerford, Jr., President & CEO

or

SIEMENS INDUSTRY, INC.
DIGITAL FACTORY
GENERAL MOTION CONTROL
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/lv-drives
Email: SiemensMTBUMarCom.industry@siemens.com
Attention: John Meyer, Manager, Marketing Communications

Watch videos of these machines in operation! https://youtu.be/4lpQ22d7niM

Fond du Lac, Wisconsin tooling supplier and metal stamper uses press and diework relationship with Heim to further develop its business, enter new markets and prosper

Deep draw gear cover entirely produced by Ultratech, ready to assemble at Amarillo Gear

Covers for Corvette brake assemblies made by Brembo

Ultratech Tool & Design Inc. (Fond du Lac, Wisconsin) began as a tool shop in 1990 (happy 25^th anniversary!), serving the small engine manufacturing sector, Over the course of the past seven to ten years, the company has been supplying stampings from its 32-ton to 600-ton presses, with products ranging from simple washers to complex automotive and aerospace components.  As President Bill Melang notes, “We took the tooling expertise we had from the start and built the business around it.  This approach gave us the ability to see our customers’ challenges from the inside and help them find better solutions for their own production.” Major manufacturers in industries such as automotive, consumer goods, electrical products and aerospace populate the ranks of Ultratech’s North American customer base.

GM Sierra dust shields

All jobs begin here with the tool design.  Ultratech uses Solidworks and Logopress software to produce its designs, then interacts with its customers in that fluid exchange of ideas, engineering suggestions and production fine tuning that creates the finished product.  That product is made entirely in-house at Ultratech on the latest CNC machines and CMM test equipment.   Melang comments, “We try our best to stay ahead of the competition with our machine tools and design protocols, using the best technology available in the market.”  Sensor selection on the dies, for example, is performed in the shop’s sensor lab, where simulation of the die-in-press scenario translates to a tool that is less likely to crash, plus Ultratech produces dies with complex in-die tapping and nut/stud insertion capabilities, as well as lamination dies.

Welding operations

Out on the production floor, another key reason for the shop’s success stands at the center of the operation.  Back in 2002, according to Melang, the company formed a working relationship with The Heim Group (Chicago, Illinois), buying their first Heim press.  Today, there is an 80-ton Heim OBS with 5000 lb. feed line, plus a 500-ton Heim Maxi-Stamper with 10,000 lb. feed and a 600-ton Heim Maxi-Stamper with 20,000 lb. feed.  Complementing this equipment is a full resistance welding, heat treating and assembly cell operation.   Ultratech also supplies its customers a range of finishing and part coating options to facilitate ready-to-assemble requirements.

PEM riveting operations

Describing the partnership his company enjoys with Heim, Bill Melang observes, “Back in 2002, we bought our first Heim press.  It was an older machine and Heim helped us with a rebuild.  Since that time, we’ve developed a value-adding relationship with Heim, as they’ve provided us considerable assistance with press utilization and maintenance advice, while I think we’ve also been helpful to them with die design ideas.”

Heim President Katie Heim further comments, “Our relationship with Ultratech has benefited both our companies, over the years.  As our industry knows, the die dictates the press and we’ve worked closely with Bill and his team, as this particular customer’s knowledge of die design and performance characteristics in the press has created a real synergy with our engineers, who bring decades of press design and die handling mechanics to the task.  The fact that Ultratech also has some of the nicest people in the industry, starting with Bill, is the icing on the cake, so to speak,” Katie remarks.

Galvanized stakes for hold downs on a satellite receiver

This American-made press builder, Katie notes, is quite often asked for a turnkey system of press, die and coil handling equipment, including complex die and part handling mechanisms, in a single package.  She observes, “The knowledge we’ve shared with and acquired from Ultratech has made us both stronger players in the market today.”   She added that the decline in the workforce numbers and equipment manufacturers based in America has created the need for companies such as Heim to be more pro-active in the turnkey area, as customers today seek this assistance on a much more frequent basis than previously occurred.

Heim 80-ton stamping press at Ultratech

Katie Heim is third generation owner of the business, which has built presses in Chicago for nearly 70 years and today boasts over 55,000 machines in the global stamping market.

Heim produces presses to 1000 tons and also supplies coil handling, part transfer mechanisms and complete die systems in turnkey packages for customers worldwide.

Ultratech is an ISO 9001:2008 certified supplier and is currently advancing to the TS automotive specification that will enhance the company’s involvement as a supplier to that industry.   The shop employs 25 people, including the next generation, as Bill Melang’s son is in the business and has recently completed a plant expansion of 30,000 square feet.

Lastly, Bill Melang mentioned the assistance he’s received from Jack Best and Tony Mase at Heim.  “There isn’t a single question we’ve thrown their way that went unanswered.  They do what they say they’ll do and that gives us great confidence in their abilities to handle our very fast-paced variety of needs for presses and support engineering.”

For more information on this story, please contact:

Bill Melang, President
ULTRATECH TOOL & DESIGN INC.
1210 Scott Street
Fond du Lac, WI 54936-0548
Phone: 920-922-0257
www.ultratechtooldesign.com
bmelang@ultratechtooldesign.com

OR

Katie Heim, President
THE HEIM GROUP
6360 W. 73^rd St.
Chicago, IL 60638
Phone: 08-496-7400
www.theheimgroup.com
katie@theheimgroup.com