Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Servo-electric pump drive optimizes hydraulic presses — from a technical and energy efficiency perspective
The servo-electric pump control for presses, developed by Lasco Umformtechnik GmbH in Coburg, uses far less energy than conventional valve control systems, often well into the double-digit range, according to this press builder.
A hydraulic pump directly coupled with a servomotor is an energy-efficient solution that delivers a highly dynamic performance with double-digit energy savings typical. The press manufacturer Lasco uses this servo-electric pump drive for solid and sheet metal forming presses. “This drive system provides us many performance advantages,” says Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik GmbH.
Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik:
“The innovative servo technology that we have developed for hydraulic presses was previously not available on the market.”
“Our new servo technology provides substantial energy savings for companies operating our presses,” says Harald Barnickel, Head of the Electrical Engineering Department at Lasco Umformtechnik GmbH, a machine tool builder in Coburg, Germany, in describing the significant advantages of this innovative forming press technology. This well-known manufacturer of systems for solid forming and sheet metal forming produces screw presses, forging hammers, forging and cross wedge rolls, and even complete plants that are used by the building materials industry to produce sand-lime products. When Lasco was first founded in 1863, the main focus was on the iron foundry. However, just a few years later, it began producing water turbines, followed by forging machines in 1880. Since then, the company has concentrated on producing machines for forming technology, and has been active worldwide for many years. “As a solution provider, we develop customized systems for optimized workpiece transport within the press as well as for feeding and removing workpieces,” Barnickel reports. The company has a strong focus on continuous improvement in its processes and technology. And the servo technology mentioned above is exactly this kind of technological milestone, as demonstrated through Lasco’s implementation in a recently delivered deep drawing press with a press force of 800 tons for up to 40 strokes per minute.
A fast controller at the core
At the core of this type of solution is a Simotics 1PH8 servomotor from Siemens, which directly drives the hydraulic pump. This drive is controlled by the Sinamics S120 drive platform. A Simotion D445 motion control system handles the complete path, velocity and position control of the axes —
the Simotion controller and Sinamics drive are both from the same manufacturer. With a response time of 250 µs, up to 256 axes can be rapidly synchronized and precise axis motion and curve profiles are executed. “The initial applications have demonstrated that this type of servo technology provides outstanding results,” says Barnickel. This applies to the closed-loop control performance as well as to its energy efficiency and the application as a whole.
The challenge on the deep drawing press was to control the press force and press speed, based on a motion profile that could be set individually. The hydraulic force and thus the press force can be adjusted at the servomotor by means of the torque. The plunger speed is controlled by the motor speed and thus by the volumetric flow rate of the pump. For the project described, axial reciprocating pumps with a fixed displacement per revolution were used.
Scalability of the pump systems is a significant advantage
Four such pump systems connected simultaneously for a maximum pressure of 250 bar supply the pressure line for the press stroke of the plunger; three additional pump systems are responsible for the return stroke of the press plunger. “The possibility of scaling, in other words adapting this kind of standard servo solution to the actual requirements, is another advantage of this new technology that certainly cannot be underestimated,” notes Barnickel.
The hydraulic oil tank of the deep drawing press holds about 2377 gallons (9,000 liters). Because of the high flow rate of 16,000 l/min, filling valves are used for the fast downward motion of the plunger. The servo pumps provide the required flow rate for the actual pressing operation, with a speed of up to 100 mm/s. In the past, high-precision control valves with zero overlap were necessary to obtain the precise traversing profiles. Today, this function is handled by the motion control system, in conjunction with the servo pumps. Thanks to this new technology, the valve systems in the press can be reduced by up to 40 percent. The remaining valve technology is mainly needed to comply with machine safety specifications.
Energy milestone
As a result of the new technology, expensive, traditional valve systems were eliminated, and energy efficiency has been significantly improved. Electrical expert Barnickel knows this only too well. “In the past, the large cooling systems for the hydraulic oil had to be installed before the first test run at Lasco. But now, with servo technology, significantly smaller units can be used, and they are not required until the press is actually operational at the customer’s facility.” One reason for this is that the oil is no longer forced through the narrow gaps at the control edges of the control valves, which means that these types of technology-related losses no longer occur in the first place. The press manufacturer is seeing efficiency improvements well into the double-digit range depending on the application, significantly reducing users’ electricity costs, compared to older machines.
When comparing the new technology with very basic hydraulic presses using conventional technology, the amount of energy saved is certainly less than with presses equipped with complex control systems. The energy-saving effect is especially apparent during the drawing operation, during which the drawing pressure is provided by a pump equipped with a servomotor, with the motor of the die cushion pump thereby operating as a generator.
Another advantage of the electrical system used here is that energy can actually be recovered when the hydraulic fluid decompresses. This happens when the system is decompressed after the pressing operation and the main cylinder pressure must be reduced from 250 bar down to approximately 10 bar before the filling valve to the tank can be released. This operation takes approximately 100 ms. In the case of a compressibility of the hydraulic oil used of approximately 2.5 percent by volume, with a cylinder volume of approximately 800 liters of oil, the “spring energy” in the oil flows through the axial reciprocating pump and drives the servomotor. This effect is amplified when the press mechanical system is relieved. In this so-called generator or regenerative operation, the corresponding electrical energy is fed into the DC link of the S120 drive during each cycle. “However, in addition to the energy recovered, the other advantage is that there are no additional power losses in the form of heat, as would be the case with conventional concepts,” Barnickel explains.
Straightforward optimization — and everything immediately documented
Although the Siemens Simotion controller has been specifically optimized to address motion control applications, Simotion can also control the complete system. However, Lasco’s philosophy is to separate the various press tasks, and it therefore uses a separate PLC for the system control. As a fail-safe control, this also addresses the safety technology requirements. Simotion can be programmed in various ways, for instance, with high-level-language, graphic programming, or Motion Control Chart (MCC) as well as a classic logic control. The trace function with eight-channel plotter supports commissioning engineers and ensures detailed documentation of the press operation. Control parameters are saved in the drive, which guarantees seamless documentation of the drive system.
The drive unit for the pump control consists of Simotics servomotors, Sinamics S120 drives and Simotion D445 motion control devices from Siemens.
Safety technology simply integrated
In addition, the fail-safe Simatic S7-319 F 3PN/DP PLC from Siemens, used here as the press system control, allows all safety technology to be implemented without any major additional expense. The fail-safe signals are read via distributed Simatic ET200S I/O stations from the same manufacturer and transferred to the control via Profisafe. This represents a simple yet complete solution for Lasco press engineer Harald Barnickel, who notes, “As a consequence, we obtain a clear machine structure.”
For instance, there are generally two monitored valves, which monitor the reduced traversing speed of the plunger, when setting up. The new solution is far more precise, where the fail-safe S120 drive also monitors the reduced speed (Safely Limited Speed: SLS) as well as a safe stop (Safe Stop 1: SS1).
Simple parameterization through a seamless, integrated system
The press experts at Lasco also view the integrated, seamless nature of the Siemens systems as an additional benefit. For example, the drive automatically identifies the servomotor and reads its parameters. Another interesting feature of this servo solution is that the 1PH8 motors are available either as synchronous or asynchronous motors. The application itself, or more specifically, the dynamic performance required, is the decisive element in selecting the appropriate motor type, according to Barnickel.
Both versions have the same mechanical mounting dimensions, the same wiring and the same encoder connection. Here, too, this state-of-the-art technology has some significant advantages. For instance, instead of a typical 17-core cable, a single cable with RJ45 connector is sufficient.
And finally, this new drive concept for hydraulic presses, based on a servo-electric pump control, results in a significant overall improvement: “In addition to the energy savings, its extremely precise controllability is far superior to that of a classic valve control,” says Harald Barnickel. As he further noted, any defined motion profiles can be precisely implemented using this concept.
The motion control system has also proven itself to be extremely valuable in certain steps of the pressing process. For instance, if the plunger moves to upper dead center, then the closed-loop position control in Simotion ensures that any leakages are compensated. “A far higher precision is achieved when using servo technology than when using pure valve technology,” Barnickel summarizes.
Servo technology ensures dynamic performance of the press
The development of new servo technology for large hydraulic presses, based on the Simotion motion control system from Siemens, has already awakened significant interest among customers of Lasco Umformtechnik GmbH. However, it is not only when building new machines that this dynamic company of 400 employees benefits from lower costs and improved quality; the drive concept described is also suitable for modernization and retrofit projects.
With the standard concept, comprising the Simotics 1PH8 servomotor, the Sinamics S120 drive platform and the motion control unit, Lasco Umformtechnik GmbH has clearly demonstrated that, when hydraulic presses are equipped with servo-electric pump drives instead of pure valve technology, the dynamic performance, precision and especially energy consumption on the press are improved. This results in tangible press improvements that are decisive in the marketplace. For Barnickel, it’s clear: “Anyone who addresses the challenges of press technology with E-motion (energy in motion) is creating innovation.”
For more information on this story, please contact:
Siemens Industry, Inc.
Drive Technologies — Motion Control Business
5300 Triangle Parkway, Suite 100
Norcross, GA 30092
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/motioncontrol
Email: SiemensMTBUMarCom.industry@siemens.com
Attention: John Meyer, Manager, Marketing Communications
A name you may not yet know, but NOARK Electric provides reliable products and efficient solutions to intelligent power and energy systems worldwide. This global supplier of electrical components and intelligent control systems recently presented an assortment of UL 489 Listed circuit breakers, relays and contactors at the AHR Expo in Dallas. This show represented the company’s first trade show in the North American market. According to Tony Diaz, North American Product Marketing Manager, the company secured solid leads from numerous distributors, rep agencies, OEMs and panel builders of electrical systems.
The NOARK value proposition centers on products that improve the profitability and maintain the highest levels of performance for customer end products, through the combination of local support with local inventory, exceptional value and superior product quality, backed by the industry’s first 5-YEAR WARRANTY.
Among the many offerings now available in the North American market are the following NOARK products:
ALL ABOVE NOARK PRODUCTS ARE UL489 LISTED.
Key personnel for Noark in North America include Paul Xu, VP of Strategy & Marketing, Ken Hilborn, Sales & Marketing Director, Tony Diaz, Product Marketing Manager and Kirk Wilson, West Region Manager.
NOARK Electric, Inc., the North American headquarters of the company, was previously located in Rockford, IL and, due to its rapid growth and inventory commitments, has recently moved to a larger facility in Oak Creek, WI, just south of Milwaukee.
The company is currently in the process of establishing a representative and distribution network to serve its primary markets, which include the building trades and electric panel board builders in various industries.
A global supplier, NOARK currently operates four R&D centers, three distribution centers, 15 office locations and employs over 1000 associates. Sales for the company exceed $2 billion worldwide.
For more information, please contact:
NOARK Electric, Inc.
9817 South 13th Street
Oak Creek, WI 53154
Phone: 414-304-8189
Website: www.noark-electric.com
Email: tony.diaz@noark-electric.com
Attention: Tony Diaz
Highlights include two-sided machining and servo drive technology
Recently, Northern Italian machine tool manufacturer Biglia introduced its multi-functional turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC. The mechanical concept, together with the scalable control, provides users with the most diverse standard turning and milling operations. The result is increased flexibility and higher speeds for end users. That quality machine tools are built in Northern Italy is nothing new. And this fact is confirmed again by the “Quattro” series from the machine tool manufacturer Biglia. These machines are multifunctional turning centers that are valued throughout Europe for their high reliability and performance power. The machines are available in different versions from 11 to 15 CNC axes. They are also intended for different turning diameters (45, 52, 65, 71 and 80 mm).
Biglia has equipped its turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC control. The individual machines have 11 to 15 NC axes.
The two opposing spindles form a special feature of the “Quattro” series. This allows the workpiece to be machined from two sides, which reduces the machining time. The second spindle can also be moved linearly in two directions (lengthwise and crosswise). This provides some leeway in the case of additional milling operations, but it can also be used for automatic workpiece unloading. Two turrets, mounted on the y-axis, ensure proper positioning of the necessary tools.
The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.
This innovative machining technology allows the creation of not only rotary but also prismatic workpieces – including polygons. Dealing with everything in one setup not only reduces cycle times, it also enhances accuracy. The machines are developed on the basis of a modular concept that ensures flexible application options – from the universal CNC lathe, to complete machining of complex workpieces with powered tools (c- and y-axis).
Getting it right, from the start
By offering the Siemens Sinumerik 840D sl CNC control, Biglia now wants to expand its previous options and its own market by combining its technologies with that of the Siemens control. “In this project, which is of personal significance to all of us who worked on it and of strategic significance for Biglia, we wanted to do everything perfect right from the start and to get the most out of it,” says Giovanni Delmondo, Business Development Manager for machine tools with Siemens Italy. The result is an all-round successful machine series with a highly modern control that already includes the innovative system expansions of recent months – including increased energy efficiency options offered by the control and drive systems from Siemens.
To illustrate this, Giovanni Delmondo points out that “the fans on the spindles are shut down automatically when they are not required, or certain services such as hydraulics, lubricant supply, or compressed air are deactivated during machine standstill times. This is handled via special screen forms on the control and is extremely simple, using the Run MyScreens function.”
Also notable is the standard energy efficiency solution from Siemens in the Sinamics S120 drives onboard this machine series. This includes automatic power factor correction or regenerative feedback of the energy generated in braking operations, a substantial factor in energy savings.
Performance and scalability
The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.
The centerpiece of the automation concept of these Biglia turning centers is the Sinumerik 840D sl control. This is a universal and flexible CNC system, implemented in the Sinamics S120 design (see Fig. 3). It is suitable for up to 31 NC axes. Whether you are turning, drilling, milling, grinding, laser-machining, nibbling or punching, the Sinumerik 840D sl is suitable for use in the most diverse machining technologies. The CNC control also has PLC (programmable logic controller) functionalities, so that a special PLC can be eliminated, if applicable.
This high-end control from Siemens is ideally suited to medium and complex tasks and production and can be adapted to the task, thanks to scalable hardware. The CNC is also characterized by openness, so the operator interface and also the software present few limits to specific job adaptability. This applies all the way to supplementing the NC core of the control; however, a special license is required for this adaptation.
On the Biglia turning centers, the control was equipped with the Sinumerik Operate user interface, making operation simple and intuitive. Three different methods of parts programming are possible: Classic ISO code programming, programming with the help of the integrated ProgramGuide with graphical support of the selected cycles, and the new two-channel ShopTurn with graphical 3D simulation. The user is led step-by-step through the cycles, whether for simple metal removal, drilling, thread cutting, pocket milling, groove milling or engraving. Complex programming cycles for complex contours are also possible. The “ProgramSync” function for automatic synchronization of the machining programs via two channels ensures a significant increase in machine productivity. The control is equipped with a 15″ monitor and integral keyboard.
Siemens CNC in metalcutting applications.
The Quattro series from Biglia also uses the highly effective personnel and machine protection system provided by the Sinumerik control concept with the Sinumerik Safety Integrated package.
Biglia is also breaking new ground with servo drives. Thus, the new servo motor generation 1PH8 from Siemens is used for the main spindle motors in this series. The linear axes are further equipped with the new 1FK 7 G2 series of permanent-magnet synchronous motors. These motor types from Siemens enable onsite replacement of the encoders without having to dismantle the complete motor. This combination of machine and CNC control in the Quattro turning centers from Biglia provides users with greater flexibility.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensSiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
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Heimatec is a world leader in the development and manufacturing of live tools, angle heads and multi-spindle drill heads. With U.S. head quarters located in the Chicagoland area and company head quarters and manufacturing in Renchen Germany, we are dedicated to supplying our customers the most innovative tooling technology possible.
Check out the new look at www.heimatecinc.com!
For more info on Heimatec:
Preben Hansen, President
HEIMATEC INC.
16 E. Piper Lane Suite 129
Prospect Heights, IL 60070
Phone: 847-749-0633
Fax: 847-749-2445
Email: info@heimatecinc.com
Website: www.heimatecinc.com
Connect with Heimatec Inc: 
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Heimatec is an international tooling manufacturer, based in Renchen, Germany. Its experienced staff is dedicated to providing customers the most innovative tooling technology possible. In 2010, the company opened Heimatec Inc. in Prospect Heights, IL, near Chicago, to serve its growing North American customer base with sales and service, plus an extensive inventory of products. Heimatec serves the auto, aero, medical, off-highway, rail, energy, woodworking, composites and other industries, as well as an ever-increasing number of machine tool OEM’s worldwide.
Continue readingSaws built for low vibration work best
by Willy Goellner, CEO, Advanced Machine & Engineering, Rockford, IL
Carbide saws equipped with carbide or coated cermet-tipped blades are designed to cut extremely hard materials. How effective the blade is depends in large part on how the saw is built.
Fig. 2 Close loop force distribution on pivot saw
The relatively brittle carbide or cermet tips require very rigid and backlash free machines, operating with low vibration to avoid cracking of the cutting tips and ensure an equal chip load on each tooth of the saw blade. This is especially important with the spindle drive. The spindle drive gears must have low backlash and must be supported by preloaded, heavy-duty bearings to minimize vibration. The same is true with the blade feed mechanism and the head slide or pivot mechanism.
Generally, there are two types of saws, differentiating in the way the blade is fed into the work piece: slide-type or pivot-type saws. The more common saws are slide-type machines, where the head slide could be arranged in a vertical, horizontal or angular position. The preloaded slide could glide on box ways or preloaded linear ways. Experts still argue whether box ways using low friction lining and hydraulically preloaded way clamps have a better dampening effect than linear ways with hardened balls, rollers and blocks.
Pivot-type saws are simpler, have fewer components and, if properly designed with oversized taper roller bearings, can be made very rigid by preloading the pivot bearings to the limits. Built for extreme stiffness, a pivot mechanism for the spindle gear box would be nested in a rigid base close to the floor, fed by a heavy duty ball screw attached to an upper sub-assembly, such as the fixture frame, and having the spindle located between the pivot point and the feed mechanism. Due to the feed force and the center of gravity of the head, the ball screw is always under tension, which eliminates the need for a preloaded ball screw and provides a very positive feed for interrupted cutting, enhanced longevity and efficiency.
This arrangement provides a closed loop force distribution since closed frames are stiffer than open profiles. It also subsequently reduces the remaining deflection of the feed mechanism due to the ratio of ball screw and spindle in relation to the pivot point and contains the cutting forces within the machine structure.
Fig. 1 Open loop force distribution on horizontal slide saw
Compared to a standard slide machine (Fig. 1), a pivot machine would be stiffer and less expensive. Pivot saws are built to saw material up to 24” (600 mm) stock size and have proven themselves in various standard and special saw systems.
Circular carbide tipped blades are limited to a maximum of 80 inch blade diameter and can therefore only cut up to about 30 inch diameter material. However, the cutting volume per minute is much higher with circular carbide saws, compared to carbide tipped band saws. In this range up to 30 inch material, carbide saws using circular blades really shine.
For more information, visit www.ame.com or contact:
Tim Waterman
ADVANCED MACHINE & ENGINEERING CO.
2500 Latham St.
Rockford, IL 61103
Phone: 815-316-5277
Fax: 815-962-6483
E-mail: info@ame.com
Connect with AME online: 
Cost-efficiency and flexibility in one complete panel
Siemens Industry, Inc. introduced today its new Sinamics DC Master (DCM) Base Drive as a result of increasing demand for base drive panels using the Sinamics DC Master converter.
This pre-wired solution is offered complete and fully tested with all necessary components mounted onto a back panel. Sinamics DC Master Base Drives are an extremely flexible and cost-effective solution for new installations and retrofits where space is limited. They are ideal for end-users and third-parties such as system integrators and Siemens solution partners.
Sinamics DC Master Base Drives offer more power per panel in the same footprint as compared to the previous two generations of base drives. These base drives are rated from 15A–850A continuous current.
Standard features of the new SINAMICS DCM Base Drive include — input fuses, output DC fuses (regen only), control transformer, AC line contactors, PROFIBUS, BOP20, UL508A Certification and 65KA SCCR rating. They are ready-to-order with deliveries available after February 2012.
For more information about the Sinamics DC Master Base Drive, visit our web page www.usa.siemens.com/motioncontrol.
Please forward all inquiries to:
Siemens Industry, Inc.
Motion Control Business
390 Kent Avenue
Elk Grove Village, IL 60007
Attn: Marketing Communications
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.
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The ideal and efficient solution for closed-loop temperature control
The improved TCP3000 temperature controller from Siemens is a scalable, pre-engineered solution to make plastics extruder machines more simple and economic
ATLANTA — Siemens Industry, Inc. unveiled today its improved TCP3000 temperature controller for plastics machines making extruders more simple and economic.
This pre-configured solution allows OEMs to save time and expense when equipping their machines; provides users with the highest degree of flexibility, scalability and performance; and offers simple and clear operator screens for temperature zone monitoring and control.
The TCP3000 can be operated using the new Simatic Multi-Panels including the 10-inch MP 277 and the 12-, 15- or 19-inch MP 377. It is supported by standard Simatic PLC software from Siemens, which requires no special high-level programming expertise.
Machine operators, technicians and maintenance engineers have a wide range of screens
at their disposal for easy and convenient operation and service. These include:
For more information about our solutions for extrusion, visit our website: www.usa.siemens.com/plastics.
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.
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No. 987 is an 850ºF electric cabinet oven from Grieve, currently used for baking various paint samples at the customer’s facility. Workspace dimensions of this oven measure 20” W x 20” D x 20” H. 10 KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 600 CFM, 1/2-HP recirculating blower provides horizontal airflow to the workload.
This Grieve cabinet oven features 4” insulated walls, aluminized steel exterior, Type 304, 2B stainless steel interior, a silhouette plate with removable cover inside the door opening and an oven hearth driven by a ¼-HP motor through a gear reducer with a torque limiting device variable from 1 to 27 RPM. This 19” diameter oven hearth is constructed from Type 304 stainless steel with 1” studs on 1” centers to support the paint coupons in process.
All safety equipment required for handling flammable solvents are onboard No. 987, including explosion-venting door hardware.
Controls onboard No. 987 include a digital indicating, time proportioning temperature controller and excess temperature controller with separate heating element control contactors. An auto door switch stops hearth movement when the oven door is opened.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese
VR Series “cut and stack” accumulator utilizes leading-edge motion control products to efficiently transfer film blanks from point of cutting to positioning in counted stack
Drilling Technical Services Inc. (DTS) in Milford, Ohio is machine builder specializing in the mid-width and narrow web press market. Its sister company, Pre-Owned Press & Parts Solutions, offers full reconfiguration engineering and remanufacturing services, plus full installation and commissioning on pre-owned presses
As a machine builder specializing in the design, engineering and system integration of narrow and mid-web label solutions as well as flexible packaging and folding carton machinery, Drilling Technical Services (DTS) of Milford, Ohio sees this global industry from many perspectives. Much of the machinery and equipment solutions devised by DTS end up on the production lines of major label and filmic product producers worldwide. Recently, company owner Joe Drilling and his team had one of those “light bulb moments” where a specific market need could be addressed by a better solution.
It involved the delicate world of thin film substrate processing and the need for a high-speed cut-and-stack solution.
The VR Series “cut and stack” accumulator stacker machines for thin film in-mold label (IML) substrate processing features Siemens HMI, drives and servomotor technology to handle the delicate thin film substrates processed, with precision, accuracy, high speed and with fast changeover for the machine user
As Joe Drilling explains, “The primary challenge was to create a solution that took into consideration the unique environmental and material factors of each customer. The materials our machines process are normally very thin film products that accumulate static quite easily. Due to their structural instability, it always requires special transport
techniques to convey these products from the point of cutting to the point of positioning in a counted stack.” Superior blank control throughout the process, converting blank shapes in multiple streams and integrating the equipment into continuous print cut processes or offline converting systems further complicated the challenges.
DTS team handles the design, engineering, build and line integration of the company’s various machine types for customers in the label, film, packaging and printing industries
Further, the DTS team saw the industry trends toward smaller footprint equipment, greater energy savings, quick changeover and portability. Collectively, these factors presented a daunting set of circumstances to Drilling and his design staff.
DTS realized the control scheme on the machine would be vital, so they turned to their longtime partner Siemens for assistance. Through the integration of high-precision Sinamics drives and Simotion motion control, coupled with the complementary suite of Simotics servomotors and Simatic HMI touchscreen product, the VR Series of in-mold label (IML) accumulator stacker machines began to take shape.
Unique blank shapes are accumulated in 1, 2 or 3 streams on a small footprint machine requiring only 3’ x 4’ of floor space, capable of handling web widths from 13”-26”. The VR Series machines from DTS provide end users with simple matrix separation, while diverting scrap at the process start-up or as a component in the overall quality inspection system. The machines can create serialized groups through a “bottom up” stack format with total static control, so they can be utilized in a normal press room environment. 
Noting the high-precision servo technology and motion control accuracy of the Siemens equipment onboard the VR Series, Drilling observed, “The axes communication and control are also extremely compact and this facilitated our designing a very portable machine with quick changeover capability, something our customers consistently demand.”
DTS further relies on the Siemens international sales and technical support teams, as this builder’s equipment is found in labeling, printing and converting plants worldwide. Drilling notes his company has received a high level of consistent service, application engineering assistance and support from the Siemens personnel and affiliated contractors.
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Joe Drilling has a pride in his company that’s classic American entrepreneur. After years at a leading label machine builder, he founded DTS as a virtual engineering company specializing in the mechanical, electrical and process engineering of mid-width and narrow web printing, drying, converting, RFID and digital print equipment. DTS has a particular emphasis on web transportation, die-cutting and laminating solutions. As the installed base grew and in response to current market conditions, Drilling founded a second company in Milford, Pre-Owned Press & Parts Solution LLC (POPPS), specializing in the evaluation, reconfiguration, remanufacturing, sale, commissioning and servicing of pre-owned presses.
Another vital component of the business models at both DTS and POPPS is the engineering of energy recovery systems for containment of utility costs, an ongoing challenge in the printing and labeling industries. The two companies primarily serve the needs of the flexible packaging, folding carton, tag and label, health and beauty, wine and beer, plus other label market segments.
For more information on this story, please contact:
DRILLING TECHNICAL SERVICES INC.
6062 Kells Lane
Milford, OH 45150
Phone: 513-831-2952
Fax: 513-831-4825
Web: www.drillingtechservices.com
Email: jdrilling@drillingtechservices.com
Attention: Joe Drilling, President
or
SIEMENS INDUSTRY, INC.
Drive Technologies — Motion Control
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/motioncontrol
Email: SiemensMTBUMarCom.industry@siemens.com
Attention: John Meyer, Manager, Marketing Communications
No. 889 is a 350ºF, gas-heated walk-in oven from Grieve, currently used for curing carbon/epoxy components hung on monorail tracks at the customer’s facility. Workspace dimensions of this oven measure 36” W x 282” D x 48” H. 350,000 BTU/HR are installed in a modulating natural gas burner to heat the oven chamber, while a 10,000 CFM, 7-1/2 HP recirculating blower provides combination airflow to the workload.
This Grieve oven has 4” insulated walls, top-mounted heating chamber, aluminized steel interior and exterior, plus five (5) monorail tracks mounted at the top of the oven’s workspace.
All safety equipment required by IRI, FM and NFPA Standard 86 for gas-heated equipment are included on this walk-in oven, including a 325 CFM, 1/3-HP powered forced exhauster.
Controls on No. 889 include a digital programming temperature controller and 6-point strip chart recorder with 1-point air temperature, 2-point vacuum and 3-point load temperature recording capability.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, Illinois 60073-2835
USA
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese