Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Saves time, money and engineering through series of online selections; makes spec writing much easier
Hennig, Inc., Machesney Park, Ill., announces the immediate availability of its new online configurator for equipment builders, consulting/specifying engineers, architectural spec writers, contractors and others involved in the delivery of power generation systems. Through the use of the Hennig configurator’s computer software, integrated and fully interactive at the company website, spec writers can immediately begin the process of designing the ideal enclosure and fuel tank configurations from the Hennig offerings. Every parameter for all popular power gen unit brands have been incorporated into this unique online service by Hennig, a major supplier of enclosures and fuel tanks to the industry.
All performance and dimensional requirements are menu-selected, along with all electric, HVAC, exhaust system, roof, door and materials of construction on the enclosure. Likewise, for the sub-base diesel fuel tank, all size and accessory specs are selectable on a downloadable .xls menu for easy completion. Upon completion of the selections, a .doc is generated for the enclosure spec and another for the fuel tank.
The created specification can then be electronically submitted to Hennig for a fast and accurate quotation of price and delivery.
“Through this system, the Hennig enclosure and fuel tank are precisely matched to the generator and the particular conditions of the installation. No settling for less and no need to make a standard product ‘fit’ the requirement. It really is a useful time and money saving tool,” says Robin Moore, the Hennig vice-president for engineering and operations.
Hennig manufactures all enclosures and fuel tanks in its Rockford, Illinois facility, located approximately 90 miles northwest of Chicago. Here, experienced power gen engineers work in concert with the company’s vertically integrated metalworking, fabricating, finishing and test departments to ensure the highest quality and reliable construction of the enclosures and fuel tanks to suit the specification mandated by customers. Hennig then ships the finished units to the construction site, power gen subcontractor or other location with full guarantees of satisfaction, backed by the company’s service and after-sale assistance team.
Typical Hennig genset enclosure and fuel tank
Hennig currently builds enclosures and fuel tanks to be compatible with CAT, Cummins, Detroit Diesel (MTU Onsite Energy), Kohler and all other leading brands of power generators. The company also works with the power gen distributors, plus design/engineering firms, consulting engineering firms and all levels of the building contractor community. Spec writers at all these types of companies can utilize the new Hennig configurator to save time, money and engineering effort in the construction of gensets.
To learn more about Hennig Enclosure Systems, visit www.hennigenclosuresystems.com or contact:
Tim Waterman
Hennig Inc.
9900 N. Alpine Rd.
Machesney Park, IL 61115
(815) 316-5277
info@hennig.ame.com
www.hennigworldwide.com
Connect with Hennig online: 
—
Hennig, Inc., at www.hennigworldwide.com, has been designing and producing custom machine protection and chip/coolant management products for state-of-the-art machine tools for over 50 years. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Hennig has manufacturing facilities in the U.S., Germany, Czech Republic, France, Brazil, India, Japan, China and South Korea. Its North American repair centers are located in Machesney Park, Ill.; Chandler, Okla.; Livonia, Mich.; Blue Ash, Ohio; Mexico City, Mexico; and Saltillo, Mexico.
Continue reading
Seeing is believing at IMTS
Sinumerik MDynamics Milling Roadshow is coming to IMTS 2010.
If your company is looking for the way to more efficiently cut parts for aerospace, automotive or medical, one thing is certain — the demand for five-axis CNC machining has risen dramatically. And now there’s MDynamics: using one solid CAD/CAM/CNC process chain will get you to market faster than your five-axis competitors who will be lagging under a less integrated approach.
What is Sinumerik MDynamics?
“For users, it is extremely important to get from the blueprint to the finished part quickly, precisely and cost-effectively,” says John Meyer, marketing communications manager, Siemens Industry, Inc. “Sinumerik MDynamics combines our milling expertise together with our powerful Sinumerik CNC hardware platform, intelligent CNC functions, and our unique CAD/CAM/CNC process chain to form integrated technology packages for three- and five-axis milling.”
Seeing is believing.
According to Robert Scholz, international business development manager, Siemens Industry, Inc., Motion Control Business, “Together with leading machine tool OEMs, Siemens will demonstrate how users can benefit from accurate, high-speed machining and perfect workpiece surfaces. Every roadshow event will demonstrate part programming and simulation with NX CAM, followed by five-axis part manufacturing using MDynamics functions and Sinumerik CNC. With real applications for the automotive, aerospace and medical industry, we will prove to our customers that we are the perfect fit for every industry.”
From A-Z and everything in between, Siemens has you covered.
By providing a uniform and integrated system that ranges from programming directly at the CNC for simple parts, to a CAD/CAM system for complex workpieces, Siemens has the right solution for all CNC machining needs. With NX CAM, Siemens provides manufacturing engineers with an open and flexible 3D system that applies not only to the development of part models and drawings, but also to full NC programming and machining simulation. NX enables 3D and 2D construction in a full-, partial- and non-paramaterized form. The fully-integrated NX CAD/CAM system supports a complete part model to CNC program process and even offers 3D quality inspection programming in the same system. NX CAM provides optimized output for Siemens-controlled machines with additional programming commands and automated post-processor functions. During planning and into production, special focus is placed on the process related to the workpiece.
This process chain includes:
Product and process development using advanced CAD/CAM software
Part program generation for the most advanced machine tools
Optimized part program and post-processor output for maximum machining performance
Integrated and offline simulation for checking and optimization of manufacturing process on the PC
Optimized and highly-efficient manufacturing on the machine
See what Sinumerik MDynamics can do for your business!
Attend the Siemens Sinumerik MDynamics Milling Roadshow.
Roadshow schedule
20-minute demonstrations every day
during IMTS, September 13–18, 2010
12:30 p.m. — Milling for Medical
DMG/ Mori Seiki, booth S-8900
1:30 p.m. — Milling for Automotive
Grob Systems, booth S-9066
2:30 p.m. — Milling for Aerospace
MAG, booth S-8519
www.usa.siemens.com/cncroadshow
Continue reading
No. 898 is an electrically-heated 650°F(~343.3°C) universal oven from Grieve, currently used for heat depyrogenation. 12 KW are installed in Incoloy sheathed tubular heating elements. Workspace dimensions are 36” wide x 36” deep x 36” high. The unit has 6” insulated walls and a type 304, 2B finish stainless steel interior and an aluminized steel exterior.
A 600 CFM, 1/2-HP recirculating blower provides universal airflow to the oven. The oven is also equipped with positive latching door hardware, a solenoid operated door lock and an integral leg stand. Safety equipment is included for handling flammable solvents and the floor of the oven contains an explosion venting panel.
Controls onboard No. 898 include a digital indicating temperature controller, motor control push buttons and an on-off heat switch.
For more information, please contact: THE GRIEVE CORPORATION, 500 HartRoad, 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.
Continue reading
60” x 120” workpiece capacity complements state-of-the-industry laser and machine control technology
Han-Kwang USA announces immediate availability of its new Series PL, specifically Model PL 3015, a long bed, 2D flying optic laser system capable of handling 60” wide x 120” long workpieces. With a long bed gantry arrangement, less motion is required on the machine, providing greater working stability and reduced maintenance requirements.
Model PL 3015 features rapid single axis speed of 4724 ipm, simultaneous X-Y axis speed of 7900 ipm and maximum cutting speed of 1181 ipm, all with positioning accuracies better than +/- 0.004” per 118” of travel and repeatability to 0.001”. A dual shuttle pallet system is onboard to maintain optimum productivity in processing.
This Han-Kwang laser system features a powerful Panasonic CO2 laser resonator in 2, 2.5, 4 and 6 KW versions, as well as the builder’s patented beam radius control, which optimizes the beam 
diameter for various material substrates and thickness variations, resulting in improved part quality. Additionally, the constant beam delivery system on the Han-Kwang laser provides better consistency in the beam quality at the focal point. These features and benefits to the user are delivered in the S5 high-speed cutting head found on the machine. The advanced Han-Kwang sensing board and head design improve cutting speed for all sheet metals, according to the manufacturer.
A plasma monitoring unit constantly tracks cut errors to further reduce out-of-tolerance conditions in the cutting cycle, while a built-in lens crack sensor monitors the state of lens contamination, with instant alerts through the onboard Siemens CNC to provide operators and maintenance personnel useful and immediate alarm notifications.
All machine mechanical movements and laser cutting operations are controlled by the powerful Siemens SINUMERIK 840D CNC. With its open architecture, 10GM hard drive and plain language commands, the CNC enables faster start-up and reduced time to first part for the programmers and operators alike. Further, a remote service support feature allows online communication to the CNC manufacturer for troubleshooting assistance. 
An optional rotary axis is available for tube cutting up to 12” OD with this Han-Kwang laser system. Fully automated materials handling systems, pallet towers and other equipment for production improvement are also offered by the company.
For more information, the name of a local Han-Kwang dealer or to arrange a demonstration, please contact:
HAN-KWANG USA INC. 1120 Garfield Street Lombard, IL 60148 Phone: 630-916-0200 Fax: 630-916-0300 Web: www.hankwangus.com Email: salesusa@hankwang.co.kr Attention: Robert Won or Erik Kim
Siemens CNC controls all machine movements, allows remote service support
Editor note: Robert Won, director for North American operations, is available for interviews to discuss the company, its laser technology and other aspects of the industry. Han-Kwang is Korea’s largest laser builder and the company has embarked on an aggressive marketing effort in North America.
Agency contact: Tim Daro Bernard & Company tdaro@bernardandcompany.com 847-934-4500
Continue reading
The weather mostly cooperated and over 250 people came out for the festivities.
Leading manufacturer of high-precision gears feeds, educates and entertains over 250 employees, suppliers and others
Roscoe, IL-Forest City Gear supplies some of the world’s leading companies with high-precision gear work. These include such diverse yet demanding customers as aircraft, military ordnance, every car in the starting field at the Indy 500, the winning boat in the America’s Cup and, perhaps their crowning achievement (pun intended), the Mars Rover. Already onboard Spirit and Opportunity, Forest City Gear products will deploy the solar panels and drive the wheels on the next generation of the Rover project, scheduled for lift-off in late 2011.
Meanwhile, back on planet Earth, the company celebrated its 55th year in business with a good old-fashioned corn boil on the company premises, July 24, 2010. Owners Fred and Wendy Young, along with their family, welcomed all the employees, their families, many suppliers, customers and friends of the company from the local Roscoe, IL community, to dine, socialize and stay out of the rain with them. Fred also gave tours of the facility, explaining to even the youngest visitors how a gear is made, measured and applied in the “real world” of mechanical motion, in all the industries served by this longtime market leader.
Highlight of the event were the karaoke performances by many of the employees, including the owners, who took all in attendance back to the halcyon hippie days of the 60’s with their heartfelt rendition of “I Got You, Babe” by Sonny & Cher. While the likelihood of the Young’s leaving the gear business for the glitz and glamour of the entertainment world is minute, every second of their performance brought rousing cheers from the enthralled mass, under the big top tent erected in the company’s parking lot.
There was face painting and a bouncy house for the kids, though Fred was looking at the latter with a mischievous grin, all afternoon!
In the end, despite a bit of rain, a good time was had by all, as they say. The hosts had allocated 4.5 ears of corn for all in attendance and many folks ate their quota and then some, while many were seen exiting the event with ears aplenty in hand, courtesy of Wendy!
Besides, where else on a rainy Saturday could one get a detailed explanation of the AGMA gear rating system?
See photos attached for more of the fun. For the real risk-takers, click here to see the Young’s singing for their supper!
For more information on the event or the company, please contact:
FOREST CITY GEAR CO., INC. 11715 Main Street Roscoe, IL 61073-0080 Phone: 815-623-2168 Fax: 815-623-6620 Web: www.forestcitygear.com Email: sales@forestcitygear.com Attention: Fred Young or Wendy Young
PR agency contact for Forest City Gear: Tim Daro Bernard & Company 847-934-4500
Continue reading
No. 796 is an electrically-heated 500°F(~260°C) Class 100 cleanroom cabinet oven from Grieve, currently used for drying water from stainless steel and Teflon filter assemblies. 10 KW are installed in Incoloy sheathed tubular heating elements. Workspace dimensions are 24” wide x 36” deep x 27” high.
The unit has 4” insulated walls and a Type 304, 2B finish stainless steel interior with continuously welded seams. The exterior is finished in white epoxy paint and has a #4 brushed finish stainless steel door cover and control panel face.
A 600 CFM, 3/4-HP recirculating blower provides horizontal airflow to the oven and a 24” x 24” x 6” thick stainless steel high temperature HEPA recirculating filter helps to purify the air to the Class 100 standard. The oven is also equipped with a 12” x 12” x 6” thick HEPA fresh air filter with 2” prefilter. Safety equipment is included for handling flammable solvents, including explosion venting door hardware.
Controls onboard this Grieve cleanroom oven include a digital programming temperature controller and SCR power controller.
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.
Continue reading
60” x 120” workpiece capacity complements state-of-the-industry laser and machine control technology
Han-Kwang USA announces immediate availability of its new Series PS, specifically Model PS 3015, a short gantry, 2D flying optic laser system capable of handling 60” wide x 120” long workpieces. With the short gantry arrangement, operator vision is enhanced on the machine, plus the more compact design facilitates a high degree of regulation in the cutting process.
Model PS 3015 features rapid single axis speed of 4724 ipm, simultaneous X-Y axis speed of 7900 ipm, driven by twin servos on the gantry and maximum cutting speed of 1181 ipm, all with positioning accuracies better than +/- 0.004” per 118” of travel and repeatability to 0.001”. A dual shuttle pallet system is onboard to maintain optimum productivity in processing.
This Han-Kwang laser system features a powerful Panasonic CO2 laser resonator in 2.5, 4 and 6 KW versions, as well as the builder’s patented beam radius control, which optimizes the beam diameter for various material substrates and thickness variations, 
resulting in improved part quality. Additionally, the constant beam delivery system on the Han-Kwang laser provides better consistency in the beam quality at the focal point. These features and benefits to the user are delivered in the S5 high-speed cutting head found on the machine. The advanced Han-Kwang sensing board and head design improve cutting speed for all sheet metals, according to the manufacturer.
A plasma monitoring unit constantly tracks cut errors to further reduce out-of-tolerance conditions in the cutting cycle, while a built-in lens crack sensor monitors the state of lens contamination, with instant alerts through the onboard Siemens CNC to provide operators and maintenance personnel useful and immediate alarm notifications.
All machine mechanical movements and laser cutting operations are controlled by the powerful Siemens SINUMERIK 840D CNC. With its open architecture, 10GB hard drive and plain language commands, the CNC enables faster start-up and reduced time to first part for the programmers and operators alike. Further, a remote service support feature allows online communication to the CNC manufacturer for troubleshooting assistance.
An optional rotary axis is available for tube cutting up to 12” OD with this Han-Kwang laser system. Fully automated materials handling systems, pallet towers and other equipment for production improvement are also offered by the company.
For more information, the name of a local Han-Kwang dealer or to arrange a demonstration, please contact:
HAN-KWANG USA INC. 1120 Garfield Street Lombard, IL 60148 Phone: 630-916-0200 Fax: 630-916-0300 Web: www.hankwangus.com Email: salesusa@hankwang.co.kr Attention: Robert Won or Erik Kim
Editor note: Robert Won, director for North American operations, is available for interviews to discuss the company, its laser technology and other aspects of the industry. Han-Kwang is Korea’s largest laser builder and the company has embarked on an aggressive marketing effort in North America.
Continue reading
A practical alternative to mechanical braking and non-regen drives systems in the converting, packaging, wireforming and printing industries
by William Gilbert, Industry Business Development Manager, Converting and Cranes, Motion Control Solutions
During the operation of any converting machine, whether for film, foil, wire, paper or board, plus most large printing presses, rolls of materials are handled by unwinds, often still driven by pneumatically operated braking systems. The traditional tension control system for an unwind stand is a simple mechanical brake. In principal, the unwind brake mechanically operates much like the braking system on your car, with a disk, caliper and pads, but is controlled by a tension sensor linked to a setpoint controller. As the roll unwinds, the tension is maintained by the brake for smooth passage of the material through the dies or rollers, resulting in better package alignment, less wrinkling, better print registration, even more consistent wire dimensioning and other production positives. These mechanical brake unwinds are effective in controlling the tension, but have inherent problems of heat and power loss, plus mechanical wear and constant maintenance needs, substantially impacting machine uptime.
The typical mechanical brake is pneumatically controlled and may utilize several sets of friction pads to control the web tension as the roll dimension decreases. Plus, a reasonable pressure range in many applications might be from 15-90psi or a 6:1 drop, a range significantly less than the core to full roll ratio for most jobs, an obvious inefficiency in operation.
To affect good tension control on the brake, these friction pad sets need to be manually changed in an out of the brake assembly, depending on the desired operating tension and the roll diameter changes involved. Often, the adjustments are several per roll during this manual changeover. Because the mechanical brake creates the unwind tension through friction, it generates substantial heat and often requires a separately powered fan for cooling to operate effectively. This friction also means the pads are subject to rapid wear, requiring frequent and time-consuming changes or maintenance checks.
For almost a decade now, this old technology has been gradually replaced, though usually in the lower power ranges, by newer precision technology, involving AC motors, drives and electronic loadcells. On converting lines today, a further leap forward is being made with the onset of 
active front end technology.
With such technology, the operating principle is as follows.
Since the unwind application is regenerative (regen) in nature, a driven unwind needs to return the energy that the mechanical the brake produced as heat back to the AC line. In the past, regen DC drives have been successfully applied as driven unwinds, but DC drive systems are no longer common and even during their prime were very costly. Early in the AC drive technology for these applications, the drives did not have the capability to regenerate the power back to the AC line and, when applied as unwind brakes, required regen resistors to dissipate the tension energy. This was wasteful and costly.
Today’s AC drive systems now have the technology to regenerate the energy back to the AC line just as the DC drive did, but with added benefits to the user and machine designer alike. Sending the tension energy back to the line means power that once was wasted can now be retained, instead of the system producing heat and worn parts. When the drive is equipped with active front end technology, it will return the previously wasted energy with near unity power factors, something not possible for any DC drive system.
Even an open loop AC drive motor combination offers a tension control range far beyond the limits of a pneumatic braking system. Synchronous AC motors can offer precision open loop torque control without a tension sensor, thereby saving further cost and inventory. Today’s highly accurate tension control systems can be designed with high resolution (sin/cos) feedback encoders on both the unwind motor and dancer position feedback. Additionally, in more advanced active front end designs, the regen capability of the drive can actually assist in the increase of stopping times and tension control regulation, owing to the four quadrant control, i.e., the motor can sink or supply current to the motor in both directions.
AC regen drive systems can also offer today’s machine designer software configurations with a wider range of control flexibility. They can be configured to operate in the most basic mode with no motor encoder or with tension feedback to system configurations, utilizing either dancer position sensors or loadcells. Alternatively, they can function as a programmable logic controller (PLC), controlling the machine functions on the unwind, while also connecting directly to a human-machine interface (HMI) panel. In most converting, packaging and printing applications, the dancer position sensor can be used to calculate the starting diameter of a roll, eliminating additional diameter sensors and the possibility of operator error in the roll diameter input. Further enhancements for unwind spindle motion such as jog for threading have also emerged for operator convenience through active front end technology.
Beyond the obvious cost savings of pad replacements on mechanical braking systems, AC motors are virtually maintenance free by comparison to DC motors, as AC motors have no brushes, do not require controller contactors to reverse direction of motor rotation or have commutators. Fewer moving parts invariably means less motor maintenance, for additional cost and time savings.
In the most advanced systems, common DC bus regulation, energy-monitoring devices for near unity power and, through the use of mechatronic services often provided by the manufacturers, “turn off” parameters in vector drives are possible. Mechatronic services can also be utilized for the proper tuning of these drives onsite or during machine build. For designers, such services further assist in the proper sizing of motors, based on the mechanical and electrical forces generated by machine operation or computerized simulation of it.
This combination of improved operation, reduced maintenance, motor power savings and conservation of nearly all energy within the system make AC regen drives with active front end technology a decided advantage for machine designers and end users of converting, packaging, printing, wireforming and other roll-fed machinery, where driven unwinds can be implemented.
For more information on regenerative drive motors and systems, please contact:
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.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communications
Editor Note: Siemens will make the author as well as various other product and market specialists available to you for interviews on the many aspects of regenerative drive motors detailed in this article, as they apply to the particular nature of your audience. Please contact the agency to arrange. Thanks!
PR agency contact: Tim Daro Bernard & Company 847-934-4500 tdaro@bernardandcompany.com
Continue reading
Permanent magnet synchronous torque motors offer significant advantages on high energy consuming and high dynamic applications
by Harald Poesch, Product Marketing Manager, Servomotors
Today’s machine designer must evaluate more factors than ever in approaching a new project. Likewise, the integrator and retrofit engineer has expanded options, not only as a result of new technologies, but also because of critical areas of focus such as reduced 
energy consumption, faster assembly time, vendor reduction and smaller footprint achievement.
In the realm of motion control, one type of motor with a relatively short history has made significant advancements that necessitate a new look at its potential in many application areas. These applications range from machine tool rotary tables to various packaging, printing, converting, extruding, papermaking, plastic film and materials handling machinery, anywhere direction must be reversed with a very high degree of accuracy, no backlash (hysteresis) and the maintaining of motion control, contrasting the necessary decoupling of a conventional motor and gearbox.
Enter the often-overlooked permanent magnet, synchronous torque motor.
Torque motors are direct drives built for rotary axes where high torque and high precision are required at relatively low speeds. With significantly lower installation time, maintenance requirements, component part count and space allowance, these motor types are frequently viable alternatives to geared motors.
Two popular varieties of torque motors exist today. They are the complete torque motor, requiring only direct flange-mounting to the machine and connection of the rotor to the machine shaft, and the built-in torque motor, where the stator and rotor are supplied as individual components that are directly integrated into the machine mechanics.
Complete torque motors are often found on extruder main drives, feed heads on injection molding machines, roller drives on papermaking machines, wire drawing devices, textile machine web stretching and winders/cross cutters on packaging equipment.
Built-in torque motors are typically used on machine tool rotary tables, swivel axes, dynamic tool turrets and turning spindles, as well as printing press cylinders, chill rolls in cast film and foil stretching machines, indexing tables in metalforming presses and all other types of 
high-dynamic, high-precision path and speed control applications.
Both types of torque motors feature a hollow shaft, which allows media or mechanical components to be guided through the rotor cavity.
Torque motors are multiple pair pole synchronous motors, similar in operation to rotary synchronous servo motors. The rotor is equipped with permanent magnets, while the stator contains the motor windings. The high number of pole pairs leads to a design generating high maximum torque at low speeds. In the past, since eddy current losses increase with the number of pole pairs and the running speed of the motor, torque motors were considered applicable only at relatively low speeds. New water-cooled designs have countered this principle, allowing a high power density. Today’s torque motors can accommodate speeds of 1000 rpm or higher.
As a result of these higher pole pair designs and because many mechanical power transmission components that generate backlash, heat, friction and noise are eliminated, torque motors offer these benefits to designers:
While higher in cost than geared motors, it is currently estimated that torque motors offer the designer a payback of three to four years in energy savings alone, which does not include the immediate increased performance and upfront cost savings, both in installation and maintenance. Obvious vendor reduction and inventory advantages are also realized through the use of these motors.
On a typical multi-layer blown film line, for example, the use of torque motors can reduce the footprint of the extrusion section by half and the consumed production space decreases accordingly, leading to an increase in production rates per square foot. 
Torque motors were also long thought to be susceptible to chemical and other ambient atmospheric contamination, but new designs have been adapted to withstand corrosive atmospheres such as a paper mill dry hood and, being water-cooled, are performing satisfactorily in many harsh environments without heat damage. Enclosures are available up to an IP54 rating with overload capability up to 2.5 times the rated torque.
Torque motors reduce mechanical efficiency losses to an absolute minimum because they eliminate mechanical transmission in the drive train. Compared to geared motor solutions, the efficiency gain is typically in the range of 10 percent, while the gain is closer to 70 percent when hydraulic motors are replaced in applications such as injection molding machines. Further, due to the direct and constant control of the load shaft on torque motors, with no backlash or decoupling occurring, a significantly higher precision in motion is achieved, which is not possible in a geared or belt-driven solution.
For example, in the production of stretched film, the application of torque motors on chill rolls, pull rolls, stretch rolls and winders has resulted in a dramatic improvement in production quality. The more accurate speed control of the direct driven rolls results in faster start-ups during the changeover from one film product to another, because the likelihood of cracks in the web is minimized. In addition, the higher control accuracy enables the production of a thinner film that is 10 times more consistent in its thickness. Likewise, the stiff drive train configuration achieved with torque motors allows faster ramping up and down in cyclic applications, leading to shorter cycles and increased product output in the same time period. In many applications with very short cyclic times, such as indexing tables or injection molding machines, the changeover from conventional drives to direct driven solutions has resulted in production increases of 25-30 percent typically. These results indicate that a lower component count now means a lower product lifecycle cost, as well as reduced potential failure rates in the field.
Other features on today’s torque motors that make them more appealing for the machine designer include:
The emerging science of mechatronics is also critical for direct drives such as torque and linear motors in the integration process because the electronic machine control protocols are so crucial in monitoring and executing the electromechanical motions. A keen knowledge of three 
disciplines (mechanical, electrical and electronic engineering) is fundamental in determining the proper unit to suit the load. Mechatronics addresses such topics for the machine builder as proper encoder location, reaction vs. dynamic force calculations and how best to integrate a high dynamic direct drive mechanically into the machine.
Additionally, through various advanced computerized simulation techniques, mechatronic performance can be validated and troubleshooting on the design can be accomplished before the first machine is ever built. Even in the field, before and after a retrofit or rebuild, the mechatronic services currently available can be used for product application determination, full performance analysis and controls compatibility. While the performance of a new motor or drive might be deemed satisfactory by mechatronic analysis, other mechanical, electrical or electronic components might be found lacking. It is precisely this comprehensive, integrated approach that is fast earning mechatronics its place in the overall scheme of machine development and utilization.
In conclusion, with today’s emphasis on cost containment, energy efficiency and higher productivity on every type of machine design, it is imperative that all viable options be explored. In designing the drive train on many machines, the advantages of torque motors described in this paper will have a positive impact on the overall project results. Torque motors can offer great flexibility in design, retrofit and rebuild applications, plus they have expanded capabilities that lobby for their implementation on more types of machines.
For further information on torque motors, please contact:
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
Gear manufacturer supplying various defense sector customers completed registration process on March 31, 2010
Roscoe, IL-Forest City Gear supplies some of the world’s leading companies with high-precision gear work. These include products for various defense sector contractors, which would be subject to the strict guidelines of the International Traffic in Arms Regulations (ITAR). This standard is designed to “establish and maintain a procedure for identifying and complying with export authorization requirements for the sale and shipment of defense articles, the performance of defense services and the transfer of technical data” by the companies involved, pursuant to the Arms Export Control Act. Applicable products include those on the United States Munitions List (USML).
Specifically, ITAR requires that Forest City Gear maintain a strict record of all manufacturing procedures and defense articles produced, as well as visitor records and the tracking of all potentially sensitive documents such as engineering data and shipping logs. Under the guidelines, only U.S. citizens may visit the facility, where no cameras or laptops are permitted and only citizens may work for the company, during the design, engineering, manufacture, production and handling of products and all relevant data related to defense projects. Exchange of data, especially via the Internet, is highly restricted, plus no non-citizen may access data in any way, without authorization from the State Department or a specially issued exemption. A non-citizen may also visit the plant, but only with a previously completed letter of authorization, stating they understand and comply with all relevant ITAR standards. And any non-citizen must be accompanied by a company official at all times.
The registration process was completed on March 31, 2010, after over a year’s effort to comply with all applicable standards, procedures and paperwork.
Overseeing the registration process and executing all documents for Forest City Gear was the company’s CEO, Fred Young. Quality Manager Joe Luy will oversee the internal process and procedure.
Forest City Gear supplies gears and gearwork for all types of military ordnance, as well as numerous military aircraft, vehicles, instrumentation and other defense devices. The company has also supplied gears on Jeep’s for decades, long before they became consumer items.
The company recently celebrated its 55th anniversary. Forest City Gear was founded in 1955 by Fred Young’s parents, Stetler and Evelyn Young, in Rockford, Illinois, near the company’s current facility in Roscoe.
ITAR is managed by the Department of Homeland Security, the Directorate of Defense Trade Controls and other government agencies, at this time. Only vendors listed on the Approved ITAR Vendor List are sent quote requests on ITAR-restricted materials and products.
For more information on the company, please contact: FOREST CITY GEAR CO., INC. 11715 Main Street Roscoe, IL 61073-0080 Phone: 815-623-2168 Fax: 815-623-6620 Web: www.forestcitygear.com Email: sales@forestcitygear.com Attention: Fred Young or Joe Luy
PR agency contact for Forest City Gear: Tim Daro Bernard & Company 847-934-4500 tdaro@bernardandcompany.com
Continue reading