Advanced Automation: Pre-Engineered to Custom-Built Systems

/

Empire offers two distinct approaches to achieve the best finishing solution for each robotic application.  The first approach is a pre-engineered blasting system. These systems have two types of design layouts starting with two forms of pedestal-mounted robot machines and an inverted robot machine. Most applications fit these machines with the ability to process parts up to 2ft dia. x 2ft high. In each solution the robot is manipulating the blast nozzle.  Each design includes a dc motor-driven 7th axis that can be upgraded to a servo-driven axis which provides the operator with infinite flexibly and more precision.

A main advantage of the pre-engineered system is that engineering costs are removed since it is predesigned.  At the same time, a number of standard options are available that will cost less than custom-designed systems. Lastly, a pre-engineered system can be produced much faster that a custom-built solution.

RBT 36 close interior

Pre-engineered System

A custom-built system is used generally if a part is too large for a pre-engineered solution or if it is more desirable to manipulate the part instead of the nozzle.  The customer may have a specific material handling need that is out of the range of the pre-engineered system capabilities.

ROBOT PACKAGE ROOM INTERNAL

  Custom Design

To determine which approach is the best solution, Empire analyzes customer-supplied drawings and part dimensions, integration and support needs. The plant layout is reviewed and becomes part of the design criteria to ensure proper installation and efficient production.  Empire arranges a meeting with the customer if necessary then provides a proposal.

Once the equipment is produced, a factory acceptance test is conducted at Empire’s facility. The customer visits Empire to test the equipment and receive operational and maintenance training.  Once the test is complete and the equipment is approved, Empire’s service technicians can be provided to supervise the installation and startup as well as provide on-site training.

Modified Cabinets for Process Parts

/

For some applications, a part’s finishing specifications may be beyond the capabilities of a standard blasting cabinet. Empire is able to take the standard product line and modify the cabinets and technology to fit the application requirements. As an example, a customer may have a part that weighs 2,000lbs.; however the standard Pro Finish cabinet can only handle a 1,000lb capacity. Through Empire’s modified program, the upgraded design could include a raising the gloves and window in the cabinet to accommodate the customer’s largest part an in/out turntable or modified DC drive for part handling.

Modified Cabinet

 Typically the process would begin with an RFP through an authorized Empire distributor. The proposal information is filled out by the customer and aided by the distributor to get an understanding of how they want to process the part and cabinet features such as a turntable, outside platform etc. We develop a quotation that would fit a certain range of adjustments to standard equipment. During quoting proposal drawings are sometimes developed for customer clarification.

This proposal is sent to the customer for review and feedback.  We will put together an approval drawing after the order is accepted. The process usually goes smoothly since I believe we are modifying the top cabinets in the industry and most companies are familiar them.

During the proposal stage we may get a sample part to review and possibly process. Processing would be performed by Empire’s Product Support Team in our demonstration lab. After the proposal stage is complete and an order is received an approval drawing is generated with all of the important details of the system shown.

After the approval drawing is finalized the order is released to Production and Fabrication.  From there the modified cabinet goes to paint then on to final assembly. After assembly is complete we perform pneumatic and electrical tests to ensure the system is working properly.

Final inspection is performed by:

  • Assembly department
  • Technical  service department
  • Designer of the project
  • Product manager of the Modified Cabinets division

With stringent inspection and quality checks the cabinet is ready for shipping and installation.

Modified Cabinet 2

At this point the customer may come to Empire’s facility to inspect the system, or for a “runoff” to test the system. If the test is satisfactory, the cabinet is cleaned and prepared for shipment. The distributor then helps to setup the system upon arrival at the customer’s facility. Regional managers may also attend the setup and help with training if necessary.

A modified cabinet project will generally take approximately 8 to12 weeks from inquiry to installation.

Eliminate The Guesswork Out Of Cleaning And Peening

/

Welcome to the most sophisticated and comprehensive test facility for airblast peening and cleaning applications. Welcome to the Demo Center at Empire in Langhorne, PA (USA).

Whether you are an existing user of cleaning or peening equipment, or a novice to the process, the Empire Demo Center has tremendous potential with tips to increase your productivity and add to the profitability of your operation.

As an advanced manufacturing plant, you have other critical parts of your production process that demand your attention. Most often, this results in an unintentional neglect of processes such as blast cleaning and shot peening. Interestingly, this neglect could lead to higher operating costs and equipment wear than normal. Let’s take the instance when your customer has introduced a new product and would like to partner with you and develop the cleaning or shot peening specifications and procedure for this new component. Empire is here to help with its demo center in both instances. Here’s how:

  • Review your existing application and equipment use with Empire by testing your production parts in one of over ten machine types on Demo Center.
  • Demo results could prove that maybe you have been using higher blast pressure than required, perhaps a different media type or size could provide you better results. Both changes will reduce your operating costs.
  • The Demo Center has equipment with varying and increasing degrees of automation. If your new production needs demand a slightly higher degree of automation, the Demo Center provides you the choice of equipment to test the same.
  • Shot peening is a process that’s either misunderstood or completely new to a lot of end users. Visit the Demo Center. Our experts in this process will carry out peening tests on your part samples, to varying levels of impact energy (shot peening intensity), that you will be able to conduct fatigue tests on at your plant. Along the way, we will also help you develop your peening parameters and even help you conform to an established specification.

Empire Demo Lab

The Empire Demo Center has the entire range of airblast equipment available for tests, starting from the simplest manual handblast cabinet to sophisticated robotic cells for single part flow. All this equipment is available for your testing, most times without any charge.

We look forward to seeing you in our Demo Center and help you increase the profitability of your cleaning and peening operation!

Ingersoll Rand Releases New Extended Life Rotary Compressor Lubricant

/

Ingersoll Rand, a global leader in air compressors, professional tools and lifting equipment, has launched an extended life rotary compressor lubricant, Ultra EL. This advanced synthetic rotary lubricant performs up to 16,000 hours — twice as long as other synthetic rotary lubricants — to increase uptime and reduce life-cycle costs.

Ingersoll Rand Ultra EL is a high-performance lubricant blend that provides advanced cooling technologies that allow air compressors to run cooler and more efficiently — even in high ambient temperature environments. Ultra EL also reduces wear and increases component longevity, increasing overall compressor performance.

Ultra EL is best suited for high-demand, multi-shift applications. When used in demanding environments, Ultra EL helps cut change-out frequency in half which maximizes uptime and lowers the facility's maintenance needs, disposal costs and environmental impact. Ultra EL also prevents critical compressor components from varnishing which further increases the longevity of the compressed air system. In addition to saving time and money, Ultra EL has a higher flash point (522° F) than most synthetic lubricants.

“Ultra EL lubricant is compatible with Ingersoll Rand Ultra Coolant and can be used in most brands of rotary screw compressors,” said Ryan Cook, aftermarket leader – North America, Ingersoll Rand. “This makes it easy and cost-effective for compressor owners to upgrade their lubricant and improve the performance of their existing air systems.”

Ultra EL is available in four standard sizes, including 1 liter, 5 liter, 15 liter and 208 liter drums, to meet various application needs. To learn more about the Ultra EL extended life rotary compressor lubricant from Ingersoll Rand, visit ingersollrandproducts.com/UltraEL.

http://processandpower.squarespace.com/blog/2013/12/10/ingersoll-rand-launches-new-more-efficient-centac-c800-centr.html?SSScrollPosition=103

Plant Engineering Readers Vote Ingersoll Rand R-Series Compressor 2012 Product of the Year

/

Ingersoll Rand, a world leader in creating and sustaining safe, comfortable and efficient environments, is the winner of the prestigious 2012 Plant Engineering Product of the Year Award. The Ingersoll Rand R-Series Contact-Cooled Rotary Screw Air Compressor claimed the grand award by receiving the most overall votes from Plant Engineering readers. The Ingersoll Rand Heat of Compression (HOC) dryer also earned a gold award in the compressed air category.

“This year’s finalists stretch across all areas where a plant manager’s influence is felt and his knowledge is required,” said Bob Vavra, editor of Plant Engineering. “From motors and drives to maintenance and lighting, the things a plant manager must specify and purchase perform very different functions. They all have one common element: they must help him or her do the job better, smarter, safely and more efficiently. That has been the hallmark of the Plant Engineering Product of the Year program for the past 25 years.”

The Product of the Year award winners are determined by popular vote. Plant Engineering subscribers cast votes for 116 finalists from October to December 2012.

“Many industry leaders rely on Plant Engineering as a trustworthy third-party resource for product information, best practices and industry news. It is an honor to accept the Product of the Year Award from their loyal readers — many of whom are our customers,” said Tracy Guilford, marketing communications manager at Ingersoll Rand. “We’re pleased to know Ingersoll Rand products are helping them increase energy savings, productivity and sustainability.”

R-Series Air Compressors Increase Operating Efficiency

Ingersoll Rand continuously innovates to manufacture efficient, reliable compressed air solutions. The Ingersoll Rand R-Series Compressor features an integrated Total Air System (TAS) that combines the dryer and filtration systems into a single package. This eliminates air leaks in the piping between units and results in better flow efficiency. The R-Series product line includes a variable-speed drive (VSD) option to increase the efficiency of variable-demand applications. The VSD compressor is equipped with a hybrid permanent magnet motor — the highest-efficiency motor available from Ingersoll Rand — to increase energy savings.

The compressor features V-Shield™ technology, which ensures that the compressor’s piping system is composed of stainless steel pipes, metal-flex hoses and elastomeric face seals to prevent leaks. It is manufactured with a sequential cooling system for added operating efficiency. Independently mounted coolers reduce thermal stress, decrease discharge temperatures and lower the energy required to remove condensation in downstream air treatment. As a result, the compressor produces drier air more cost effectively.

 

The TAS, VSD and V-Shield technologies are coupled with a Web-enabled Xe-Series controller. The Xe-Series control system allows plant managers to remotely access vital compressor data via the Internet on any PC, tablet or Web-enabled smartphone. Plant managers can also program the Xe-Series controller to send automatic email notifications if trips or warnings occur to ensure quicker response times.

HOC Dryers Produce Clean, Dry Air More Cost Effectively

The gold award-winning Ingersoll Rand HOC dryer provides a greener approach to compressed air treatment. The HOC dryers recycle the heat naturally generated during the compression process to produce clean, dry air at a fraction of the cost of traditional desiccant dryers. This high-tech, low-energy solution is more cost effective to operate than desiccant dryers without compromising productivity and efficiency.

Ingersoll Rand received engraved Product of the Year awards at a dinner banquet held at the Hotel Sofitel Chicago Water Tower in Chicago on March 18. To learn more about the Ingersoll Rand R-Series air compressors and HOC dryers, visit ingersollrandproducts.com.

Ingersoll Rand Introduces New Energy-Saving Dryers for Small Compressed Air Systems

/

Ingersoll Rand, a world leader in creating and sustaining safe, comfortable and efficient environments, is introducing a new line of energy-saving, refrigerated compressed air dryers. The Ingersoll Rand D-EC Energy-Saving Refrigerated Compressed Air Dryers are available in eight models, ranging in capacities from 10 to 125 standard cubic feet per minute (SCFM). The D-EC dryers are ideal for small commercial compressed air users such as machine shops, automotive repair and refinishing businesses and light manufacturing applications.

The D-EC cycling dryers incorporate a thermal mass that stores cold energy, providing enhanced operating efficiency over competitive non-cycling products in this range. The thermal mass cools the air flowing through the dryer, allowing the refrigeration system to turn off during periods of low demand without degrading air quality.
The new D-EC dryers offer many features that are not typically available on small capacity models. The patented, multi-layer heat exchanger combines the chiller, evaporator and pre-cooler/reheater to optimize the efficiency of the dryer and compressed air system. In addition, the precooler/reheater exchanger warms the air exiting the dryer, thereby eliminating the potential for ambient moisture to condense on the outer surface of the downstream piping.
 
A timer-based solenoid drain is installed on the D-EC dryers to automatically empty moisture from the dryer at regular intervals. Air temperatures affect the amount of moisture in a compressed air system; users can adjust the timer to empty more frequently during the summer when there is more humidity in the air.

The D-EC dryer is configured to minimize pressure drop, which maximizes the efficiency of the entire compressed air system. The dryer includes a digital controller that automatically adjusts the airflow and temperature to keep the system within the parameters defined by the plant manager. This ensures worry-free operation and extends the dryer’s usable product life.

“Most facilities have varying degrees of compressed air use where first shift, for example, may have higher demand than second and third shifts,” explained Christopher Ursillo, marketing manager – air treatment, Ingersoll Rand. “Non-cycling dryers run at full power continuously,
while Ingersoll Rand D-EC cycling dryers automatically adjust to the current compressed air volume. This enables operators to minimize energy consumption and operating costs.”
The energy-efficient D-EC dryer uses a minimal amount of refrigerant to cool the compressed air. This maximizes its environmental stability and helps facilities adhere to sustainable manufacturing practices. The compact design also minimizes the dryer’s footprint and installation and shipping costs.
For more information about the new D-EC Energy-Saving Refrigerated Compressed Air Dryers, visit ingersollrandproducts.com/air.

Ingersoll Rand Launches New, More Efficient Centac® C800 Centrifugal Compressor

/

Ingersoll Rand, a global leader in air compressors, tools, fluid management and material handling equipment, is launching the new Centac C800 centrifugal air compressor at the 42nd Turbomachinery Symposia, in Houston, October 1-3. The C800 is built on the latest generation, integrated and simplified centrifugal compressor platform, and is an extension of the Centac C1000 product line. Certified as ISO 8573-1Class 0, the C800 provides 100 percent clean, oil-free air, and is designed to minimize downtime and lower total cost of ownership.

The single largest contributor to life-cycle cost is loss of production. The Centac C800 is designed with features to maximize asset availability including tapered polygon attachments to create a precision fit and evenly distribute torque and a simplified oil piping system with an integrated oil filter to keep the system running at ideal conditions. The compressor’s integrated AGMA rated gears, flex pad hydrodynamic bearings and components work to reduce vibration and error-proof alignment, minimizing downtime and lowering operational costs.

The optimized components and systems in the Centac C800 reduce energy use by up to 6 percent at full load. The backward-leaning impellers are designed with leading edge software and computational fluid dynamics that maximize peak efficiency and provide greater turndown. Furthermore, inlet guide vanes (IGVs) are standard on the new C800 delivering up to 10 percent additional energy savings at partial load.

Maintenance is easier on the C800 air compressor with a one-piece removable inducer, in-place roddable coolers, bull gear inspection ports, and open cooler casing which offer increased access to critical components. The fully configured compressor package also affords efficient installation — no special foundation or grouting required. The single inlet and outlet connections for cooling water also reduce installation time and cost. These features were specifically designed to optimize and enable system efficiency and reliability.

The Web-enabled Xe-Series controller enhances productivity and enables plant and operations managers to remotely access and adjust the system from virtually anywhere. It presents real-time monitoring and trending of critical components, making it easy to predict maintenance needs and correct operating parameters from Web-enabled smartphones, tablets and personal computers.

“Lost production caused by unscheduled downtime is the largest contributor to a compressor’s life-cycle cost,” said George Mankos, global category leader, centrifugal technology, Ingersoll Rand. “Ingersoll Rand manufactured the C800 with fewer parts, integrated components — and easily accessible critical components — to increase the compressor’s reliability and efficiency.”

Ingersoll Rand Expands Contact-Cooled Rotary Screw Air Compressor Platform

/
37-45 kW R-Series air compressor offers new option for industrial customers 
 
DAVIDSON, N.C. — February 6, 2013 — Ingersoll Rand, a world leader in creating and sustaining safe, comfortable and efficient environments, recently released the latest model in the contact-cooled Rotary Screw Air Compressor line — the R-Series 37-45 kW  (50-60 hp).
 
“The R-Series product line offers reliable, productive and efficient air compressors in the ranges our customers need,” said Scott Hardeman, marketing manager – Customer Center and Association of Ingersoll Rand Distributors (AIRD) channels, Ingersoll Rand. “We also offer add-on features so each customer can customize the product for their unique application requirements.”
 
The 37-45 kW compressor is equipped with the same V-Shield™ technology as the larger 55-160 kW units. The V-Shield ensures that the compressor’s piping system is composed of stainless steel pipes, metal-flex hoses and elastomeric face seals to prevent leaks. The piping system is also configured to minimize the adverse affects of vibration, including loosening of connections, unwanted flexing in joints, air leaks and extreme noises.  
 
Along with the V-Shield technology, the 37-45 kW compressor comes in fixed-speed or Nirvana Variable-Speed Drive (VSD) options. Fixed-speed units are best suited for constant-demand systems; VSD units increase the efficiency of variable-demand applications. The VSD compressor is also equipped with a Hybrid Permanent Magnet motor — the highest-efficiency motor available from Ingersoll Rand — to increase energy savings.
 
The R-Series compressor is manufactured with a sequential cooling system for added operating efficiency. Independently mounted coolers reduce thermal stress, decrease discharge temperatures and lower the energy required to remove condensation in downstream air treatment. As a result, the compressor produces dryer air more cost effectively.
 
Coupled with the sequential cooling system, the compressor’s Progressive Adaptive Control (PAC) continuously monitors filtration and temperatures. This control technology defines operating parameters and eliminates moisture build-up that can damage internal components of the compressor and result in unexpected downtime. 
 
 
 
The integrated Total Air System (TAS) previously introduced on the 55-75kW Ingersoll Rand R-Series compressors is available on the 37-45 kW units. The TAS combines the dryer and filtration systems into a single package which eliminates air leaks in the piping between units and results in better flow efficiency.
 
The R-Series compressor relies on the Xe-Series controller to continuously monitor vital system data and automatically adjusts to stay within key operating parameters, preventing damage and unexpected downtime. The Xe-Series controller has real-time electronic maintenance indicators and changes the fan speed according to ambient temperature to reduce noise and optimize energy use. The web-enabled control system allows plant managers to remotely access vital compressor data via the internet by a computer or  mobile device with standard web browsers for quicker response times.
 
For more information about the R-Series Contact-Cooled Rotary Screw Air Compressor, visit ingersollrandproducts.com/air.

Hood Packaging Earns Hefty Energy Efficiency Rebate

/

Pictured in the photo from left to right is: Tandee White, customer service manager with Entergy, Ronnie Owens, Kaleb Pack, Riley Baker, Jacob West, Shane Culverhouse, Benji Brown, Chris Robertson, Curt SociaMonticello, Ark.– Entergy Arkansas presented Hood Packaging with a rebate check in the amount of $98,422 for energy efficiency improvements implemented at the plant last year.

Entergy Arkansas offers 16 programs through which residential and business customers can receive incentives and rebates for implementing energy efficiency improvements in their facilities.

Early last year representatives from Hood Packaging met with CLEAResult, a contractor that implements some of the programs for Entergy Arkansas, to discuss ways to save on their electric bill. The rebate was a result of compressed air project.  The compressed air project saved energy by eliminating old machines that were operating inefficiently.  

Curt Socia, Hood Packaging Monticello Maintenance Superintendent, thanked Entergy for making the program available and easy to implement. He said “We are very pleased with the results and particularly happy with the can-do attitudes of everyone at CLEAResult and Process & Power for engineering and installation of the air compressor system.  They helped immensely in making the project goals achievable as well as improving our plant in a cost-effective manner.   Our plant and the community is better off as a result of the efforts.” They hope to implement other energy-saving initiatives in the future.

“If you have even had a thought about making improvements to your home or business that would save energy, I encouraged you to call us,” said Tandee White, customer service manager for Entergy Arkansas. “We have programs that fit almost every need – residential, commercial, industrial, city, school, etc. Our partners for these programs help make it easy to manage and calculate your savings. The key is to call before you make the change. In some cases, to award rebates, they need to collect data before improvements are made.” For more information on energy efficiency programs through Entergy Arkansas, go to www.entergyarkansas.com and click on Entergy Solutions or call 1-877-212-2420.

Entergy Arkansas, which celebrates its 100th birthday this year, provides electricity to approximately 700,000 customers in 63 counties. Entergy Arkansas is a subsidiary of Entergy Corporation, an integrated energy company engaged primarily in electric power production and retail distribution operations. Entergy Corporation’s utilities own and operate power plants with approximately 30,000 megawatts of electric generating capacity, including more than 10,000 megawatts of nuclear power, making it one of the nation’s leading nuclear generators. The Entergy utilities deliver electricity to 2.8 million utility customers in Arkansas, Louisiana, Mississippi and Texas. Entergy Corporation has annual revenues of more than $11 billion and approximately 15,000 employees.

EntergyArkansas.com
Tandee White
(870) 367-6184 ext 1
(870) 623-9949
twhite2@entergy.com

Grundfos GO

/

The Grundfos GO is a groundbreaking new app that provides intuitive wireless pump control and full access to Grundfos online tools. The GO is a combination of a mobile interface and a free app available in the App Store and Google Play. To manage pumps by remote control, installers must simply install the app and connect the Grundfos mobile interface to an iPhone, iPad, iPod Touch or Android smartphone. Users are then ready to copy profiles to new pumps, generate installation reports, request status data, adjust pump settings and receive alarms and warnings. The GO also provides a live data feed from the pumps directly onto the screen, including duty points, historical data, power consumption, pump speed and temperature.

Learn more about the Grundfos GO here: http://us.grundfos.com/about-us/news-...

The Intelligent Grundfos MAGNA3

/

Designed to meet the global market's increasing demands for efficiency, intelligence and sustainability, MAGNA3 sets new standards for pump technology. The most energy-efficient line of circulator pumps on the market, MAGNA3 boasts the lowest energy consumption, most flexible range, easiest installation and most innovative functionalities on the market. From its improved hydraulics and rotor system to a built-in differential pressure sensor, every detail of MAGNA3 is designed to boost efficiency. In fact, it reduces energy consumption by up to 85 percent when compared to a typical circulator. Alongside AUTOADAPT technology, which continuously adjusts operation to changes in demand, the pump includes FLOWADAPT control mode to reduce the need for pump throttling valves.

Learn more about MAGNA3 here: http://us.grundfos.com/about-us/news-...