Eliminate Bottlenecks in Canning Plants with VFD

Article Posted by Parker’s Electromechanical Team on 15th July, 2020 on the Parker Motion & Control Technology Blog

How do you eliminate a bottleneck in a food and beverage canning plant?  Apply good engineering design and use a variable frequency drive solution. Beverage bottling or canning has always been a complex process, requiring strict control over a number of operating parameters. Accuracy of line speed, liquid flow rate, and pressure, temperature, and timing is crucial to maximizing output and reducing or eliminating the rejected products.

Jam ups result in lost production

Parker was contracted by a beverage packaging facility with a problem. The plant was losing production due to jam-ups and inconsistent temperature control of a can warmer line, resulting in a rejected product. Not only was the rejected product wasted, but it then had to be destroyed and disposed of at considerable expense. Factoring in lost production time, a jam could cost up to $6000 per incident.

Faced with a 9 month waiting period for major capital approval to replace the line, the maintenance department was instead tasked with upgrading the existing control system. The existing system was over 20 years old and used a fixed speed “across the line” starters for pump control.

The customer was open to replacing these with variable frequency drives (VFDs) for their better controllability and accompanying energy savings, but physical mounting space would not permit the estimated 80″ wide cabinet required for eight conventional drives and the peripheral devices that each separate drive required. Typically each drive requires additional components like line fuses, circuit breaker or disconnect, and an input line reactor. With a limited budget, material and installation costs had to be kept to a minimum.

Engineered benefits of a VFD solution

Parker proposed a variable speed drive system solution to take control of 8 axes of motion on the canning line. It came with a number of benefits:

• The compact AC890 series, by virtue of its “bookshelf” design, required much less mounting space than conventional drives.
• The common bus design eliminated the need for eight individual line reactors and circuit breakers, requiring only one for the common supply that would feed the lineup of DC input drive modules.
• The common bus architecture delivered energy efficiency. When in operation, if one or more of the eight motors are subject to an overhauling load, the resulting regenerated energy will be shared across the DC bus with other drives in the system.
• Space savings were realized by the fact that the AC890 has abundant I/O and processor capability onboard, eliminating the need for additional PLC equipment. The drive itself would take on the analog and high-speed counter functions.

To communicate with the outside world, one of a number of available protocols can be selected and installed in the AC890 drive in the form of an option card. In this case, an Ethernet/IP communication card provided compatibility with the existing network. The complete system was comfortably fit on a 36″ x 60″ panel, which was installed in an existing stainless steel enclosure, eliminating the expense of a new one.

Efficient cooling

To efficiently cool the drives, an air-to-liquid heat exchanger was used. Makeup water from the can warming loop was used to supply the heat exchanger, using far less energy than an air conditioner, and have the side benefit of pre-heating the makeup water. This results in less energy used to heat the cans, by capturing waste heat from drives. In addition, advanced features in the AC890 allow the hot water pumps and conveyors to be coordinated for better can temperature control. Line jam-ups, caused by cans getting excessively hot and deforming, were eliminated once the more efficient and better-coordinated control system was installed.

Production problem eliminated

In summary, this system retrofit was successful in eliminating a serious production problem that led to the rejected products, and in doing so, also yields significant energy savings. Due to the compact size and common bus architecture of the AC890, an economical installation was achieved, using no additional plant floor space, and easily tying into the existing communications network. 

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For further information on Parker products contact Micromech on 01376 333333 or Email sales@micromech.co.uk

Disclaimer
Licensing for these images came with permission from the Parker Hannifin Media Manager collection.
Article reposted with Parker Hannifin’s permission.

Success Story from Kollmorgen – Food Processor Meets Hygienic Requirements with Innovative Motor Design

Patented Kollmorgen Motors Prevent Ingress in Washdown Environments

Challenge

In the food processing industry, washdown procedures are one of the principal causes of motor failure. Even though they are needed to maintain strict hygienic requirements, the harsh environment and constant use mean that the motors must be frequently cleaned and maintained to stay at peak working condition. This poses a challenge for even the most experienced machine designers.

For a Dutch company that specializes in creating cutting, placing and packaging machines, making easy-to-clean machines that withstand rigorous washdowns is a way of life. However, for one of its recent projects—its largest ever with 118 motors and 190 drives—the company needed to create two fully customized production lines for a Canadian food processor while meeting strict hygienic requirements. With four tracks per machine line that cuts, bakes, chills and packs the food uniformly in weight and appearance, it took well over a year from design to delivery of the processing machines.

Compounding the challenge was the additional restrictive requirements from the food processor: no hollow pipes used for the connections, no sweating of material and using C-frame construction. However, the builder’s standard machines used stainless-steel motors that were only rated to IP67 and had a shaft that stuck through the machine cabinet, allowing water ingress into the machine and motor. This simply would not work for the food processing environment. Luckily, the machine builder was able to find a partner that could supply the right motors it needed to get the job done.

Solution

To address the hygienic issues and requirements, the partner chose Kollmorgen’s AKMH servo motors for the machine design. With the ability to be cleaned in under 3 minutes and no need for a protective cover, Kollmorgen’s AKMH motors are designed for the food and beverage industry.

During operations, a motor’s internal operating temperature can exceed 100°C, which causes the internal pressure to rise and push gasses out past the seals. But following operation, temperatures return to ambient, sometimes as low as 0°C with internal pressure in the motor dropping by 5.5 psi. This change in pressure can pull in water and corrosive chemicals past the seals, which can quickly destroy precision motor bearings in the motor.

Kollmorgen created a unique patented design that prevents the ingress of water and chemicals during and after operation. The motor’s vented design uses a breather port installed directly on the motor that allows for continuous pressure equalization. The port has a gore membrane that allows air to pass through but prevents ingress of contaminants. It’s a simple design that allows for easier cleaning during washdowns but one that also protects the bearings in the motor during operation.

The motor is constructed from 316L stainless steel. The motor is completely polished with a 32 μm finish with no physical seams to prevent food or pathogens from entering the motor. Even the nameplate is laser engraved to minimize seams in the housing, which can withstand up to 100 bars of pressure.

Getting Started

For the machine builder, the success of the project was contingent on creating one of the most hygienic production lines for its largest project ever. Thanks to the patented design and advanced construction of Kollmorgen’s motors, the machine builder delivered a fully modular production line that met the food processor’s strict requirements.

The design process was also simplified because of the ease of integration with the motor and drive pairing selected. Kollmorgen motors are uniquely designed to work within the voltage, current and induction ratings of any third-party drives. This ease of integration helps to maximize the performance of your motion system and minimize motor failure risks, which can lead to increased maintenance costs and lost production time.

Kollmorgen can help you realize any motion requirement. Whether you’re looking to upgrade an existing machine or build something from scratch, Kollmorgen has the motors, drives, cables and controls to create the most ambitious designs. And we possess a wide range of expertise across the food and beverage industry, from creating highly sealed motors impervious to washdowns to motors that provide exact cutting and packaging motions hundreds of times a minute.

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As a Gold Partner, Micromech are able to supply and provide expertise on Kollmorgen products. Contact our sales team on 01376 333333 or sales@micromech.co.uk for price and delivery or technical assistance. 

Disclaimer
The use of this news article and images came with permission from Kollmorgen.

Equip Your Linear Motion Stage for Challenging Environments

When your motion system needs to position a load along a single axis with micron precision, a linear motion positioning stage is hard to beat. Chances are, however, your linear stage’s intended operating environment could present conditions that may compromise its performance. And, if your stage will be used in a cleanroom or hygienic environment, you must be certain that it will meet the stringent cleanliness standards.

For example, Akribis’ versatile Dual Guide Linear Motion Stage (DGL) Series is well-suited for industrial applications such as pick and place, inspection, dispensing, inspection equipment or any other material handling or general industrial application where accuracy is critical, including printing, laser marking, machining and spot welding. Many of these applications can be tough on motion systems. That’s why it’s important to protect your linear stage from dust, dirt and other particles that can otherwise affect its accuracy or cause damage. Here’s how you can get the most reliability and performance from your linear stage:

• Bellows. These textile-based covers can help protect the stage’s internal components from contamination via any large or small debris to ensure the stage maintains its sub-micron performance.
  
• Cleanroom covers. Akribis offers both standard and conventional covers in clear anodized or black anodized aluminum to prevent particles generated through normal carriage motion from dispersing into the hygienic environment. In addition, our cleanroom covers offer tight tolerances to prevent harmful particles or debris in harsh environments from entering the stage.

Our DGL Series is especially versatile for cleanrooms. For example, not only can customers equip standard DGL Series stages with cleanroom covers, they can also build an X-Y stack with multiple stroke actions for cleanroom applications requiring multi-axis positioning. As with all cleanroom or harsh environment applications, make sure that your unit meets industry standards pertaining to particles, cleanliness, lubricants and vacuum operation.

If a standard linear stage and protection options don’t quite fit your needs, Akribis’ technical staff is available to work with your team. From prototyping to production, we can help you build the right linear positioning stage for your application at an attractive price.

Ensure Optimal, Reliable Performance

When implementing a linear motor positioning stage in challenging environments, machine designers must give extra attention to potential situations that can compromise the stage’s accuracy or prohibit its use. In addition to the DGL Series, Akribis Systems offers a wide range of linear motor stages plus bellows and cover options to ensure your stage performs optimally in dirty environments and without generating contaminants in cleanrooms. Be sure to contact our experienced sales engineers who can help you begin your selection.

For more details on the Akribis range or for technical help call 01376 333333 email sales@micromech.co.uk

Disclaimer
The use of these images came with permission from Akribis Systems.

The Big Debate – Stepper vs Servo

What is the best motor technology to use in a motion control application? There are numerous technologies to create motion, from hydraulic to pneumatic or electromechanical. In the world of precision motion control, many machine designers face a choice between step motor or servo motor technologies to solve their performance requirements. Both stepper motors and servo motors have a place in the motion control world but understanding when to use each has created a big debate.

Let’s check in on the ongoing debate of stepper vs servo…

Engineer A: “I like using stepper motors. They are simple to use, easy to set up and are reliable. I don’t need a lot of fancy control schemes to get my system from point A to point B.”

Engineer B: “I prefer a servo motor. The ability to cover a wide speed and torque range suits my multi-axis machine design perfectly.”

The engineers in this debate come from two different industries and have vastly different mechanical systems. Engineer A likes the simplicity of the stepper motor – from its set up and operation to how easy it is to get up and running. Based on the comment about point-to-point positioning, Engineer A has likely chosen the best solution for their particular machine. Stepper motors are a solid choice for simple point to point applications where load disturbances are minimal. Engineer B prefers the broad capabilities of servo motors, which makes sense in applications that require precise control and have multiple axes of coordinated motion. The high bandwidth and precision control of closed loop servo motors makes tight coordinated motion possible for multi-axis machinery.

Engineer B: “I had a bad experience with stepper motors when we attempted to use them on an axis with varying load disturbances.”

Engineer A: “I tried using a servo, but when it reached position it moved back and forth slightly as it came to a stop, which caused issues in the product finish.”

When Engineer B used a stepper motor on an axis that had some unpredictable load disturbances, some of these variations caused the motor to lose count, which eventually caused position errors. While this issue can be corrected by adding feedback to the stepper motor, it highlights one application where the open loop stepper may not be the best choice. In Engineer A’s case, an improperly tuned servo motor may “hunt” for position. Move and settle times can vary from application to application depending on motor sizing, inertia mismatch, and servo loop tuning. In the case of a simple point to point move with minimal load disturbances, a stepper motor is likely a better choice to stop at the designated point and hold position without hunting.

For Engineer A, the simple point to point positioning was best served using a stepper motor, while for Engineer B, the multi-axis coordination was better accommodated with servo motors. This “debate” explores only a few attributes that can influence the choice of servo vs stepper. To help determine which motor technology best fits each situation, Kollmorgen reviews numerous application attributes in the white paper “Stepper Motor vs Servo Motor – Which Should it Be?”

This blog was a collaborative effort among a team of motion and automation experts at Kollmorgen, including engineers, customer service and design experts. 

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As a Gold Partner, Micromech are able to supply and provide expertise on Kollmorgen products. Contact our sales team on 01376 333333 or sales@micromech.co.uk for price and delivery or technical assistance. 

Disclaimer
The use of this news article and images came with permission from Kollmorgen.