http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/RSS.ashxRefrigeration and Air Conditioning PagesSat, 30 Jun 2007 18:27:13 +0200http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=1http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=1Manufacturers nd ways to make more with less 2 Move over, waste Lean Production is here 5 The industrial chiller is one cool machine 6 Robust sensor keeps locomotive producer on track 8 The most ef cient parts painter in the world 10 Global OEM expects the right products at the right time 12 From pulp to precision, OEM integrates motion control 14 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=2http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=2Who in the world is only happy when he has zero to show for a full days work As a testing technician, Van Keyes has zero tolerance for defects. His motto is do it right the first time. And thats a good thing, because Van is the last person to touch our products before theyre shipped. Every day he submits them to a rigorous series of tests designed to weed out even the smallest possible issue. When it comes to quality control, hes our last line of defense. Take a look at himdo you think much gets by Van Ever since the companys beginning, the Danfoss name has stood for consistency and unwavering reliability. Quality control is never, ever taken lightly. Please visit us at www. northamerica. danfoss. com to see how our strict quality control helps customers keep their downtime close to zero. Who in your world delivers the dependability that fuels your success We do. Controls Compressors Condensing Units Gear Motors Adjustable Frequency Drives Valves Controllers Oil Pumps Thermostats Danfoss Dependable. Van Keyes, test technician2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=3http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=3Vol. 4 Issue 11Danfoss Dependable. CONTENTS Volume 4, Issue 1 The manufacturing sector is in a period of growth as the economy gets stronger and orders increase. At the same time, markets continue to put pressure on factories to raise quality, decrease costs, and speed up delivery. As production techniques and technologies advance, manufacturers are striving to get better and faster at what they do. In this issue of Solutions we feature some of the ways manufacturers are meeting market demands for improved processes and enhanced productivity. We hope you enjoy the articles and, as always, we welcome your comments. THE EDITORS, solutionsdanfoss. com www. northamerica. danfoss. com Manufacturers nd ways to make more with less . . . . . . . . . . . . . . . . . . . 2 Move over, waste Lean Production is here . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 The industrial chiller is one cool machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Robust sensor keeps locomotive producer on track. . . . . . . . . . . . . . . 8 The most ef cient parts painter in the world . . . . . . . . . . . . . . . . . . . . . . 10 Global OEM expects the right products at the right time . . . 12 From pulp to precision, OEM integrates motion control . . . . . 14 Product News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Jeff Duncan North America Motion Controls Jennifer Hutchins Corporate Communications Aneta Stephens North America Heating Lisa Tryson North America Air Conditioning and Refrigeration DANFOSS SOLUTIONS is published for the bene t of Danfoss customers. Information in the DANFOSS SOLUTIONS may be republished only with permis sion of editorial and always with credit to DANFOSS SOLUTIONS. Comments, suggestions, and contributions are welcome . This publication should not take the place of appropriate technical or legal advice related to companyspeci c circumstances. DANFOSS SOLUTIONS does not assume any liability of any kind whatsoever for the use or reliance upon the information contained in this publication. Design by Arista Advertising, Inc. www. Arista Advertising. com Dear Readers, Manufacturers nd ways to make more with less 2 Move over, waste Lean Production is here 5 The industrial chiller is one cool machine 6 Robust sensor keeps locomotive producer on track 8 The most ef cient parts painter in the world 10 Global OEM expects the right products at the right time 12 From pulp to precision, OEM integrates motion control 14 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=4http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=42Vol. 4 Issue 1Danfoss Dependable. Increased productivity in manufacturing leads to higher standards of living, indicate U. S. Department of Commerce statistics. Sixtytwo percent of RD performed in the U. S. comes from the manufacturing sector, according to ndings by the Commerce Department and National Foundation. Manufacturer research results in everything from Internet development to new vaccines. The relationship between manufactur ing and society is cyclicdemands from markets inspire factories to improve their capabilities, which in turn raises expectations for product diversity, global distribution, and speedy delivery. In response to these market demands and to intense competition, manufacturers constantly strive to do more with less. In the last decade, output by worldwide manufacturing enterprises has jumped 30 percent, despite employing 22 million fewer workers in the same period, according to a Department of Commerce 2004 report, Manufacturing in America. But increasing manufacturing ef ciency also creates jobs through what is known as the multiplier effect Every 1 of a manufacturing product sold to an end user generates 1. 43 of intermediate economic output, such as raw materials components and services. Anyway you look at it, manufacturers will continue to increase productivity. Global manufacturing has been fundamentally reshaped by the remarkable improvements in computing, communications, and distribution, states the Department of Commerce report. Taken together, the rapid changes in uence many of the trends that have most reshaped manufacturing from the shop oor to the loading dock to the nal customer. MANUFACTURING COVER STORY The success of factories impacts our lives in more ways than meet the eye. We depend on manufacturers not only to output products for modern living, but also to improve our society. Manufacturers nd ways to make MORELESSwith2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=5http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=5Vol. 4 Issue 13Danfoss Dependable. Manufacturers Invest in the Environment Despite a huge leap in economic growth, a rise in energy consumption and a growing population, air and water quality has dramatically improved, resulting in cleaner lakes and rivers and reduced pollution EPA data shows, for example, airborne lead emissions were cut by 98 percent Capital investments by manufacturers, many of them voluntary, stand behind these dramatic improvements. Enhancements in productivity and technology, as well as economic growth, contribute to these successes National Association of Manufacturers NAM2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=6http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=64 To increase ef ciencies manufacturers turn to the latest advances in tech nologies in areas from automation, networked communications and robotics to laser optics. However, it is semiconductor technology that has the biggest impact on productivity, since computing is at the core of so many other technologies. As Moores Law shows, computer chip power doubles about every 18 months. Although factory productivity has not moved at the same breakneck speed, computing continues to evolve in synergy with developments in elds such as precision mechanical engineering, electronic process control, and IT. As a result factories are making more products more ef ciently. Customers get speci c Mass production no longer means all products that come off a production line are the same. Today many products, from OEM factory equipment to consumer goods, are made with mass customization. To deliver high volumes of builttoorder variable frequency drives, for example, the Danfoss Motion Control Division implements advanced automation, tooling, and production techniques at its electronics factory in Denmark, which produces the VLT FC 300 Automation Drive. Mass customization not only produces FC 300 drives, but also bene ts from them. The modular drives are designed to increase manufacturing performance. The factor integrates customerspeci ed features to meet an array of demands in industrial motor control. As a single concept for a wide range of applications, the FC 300 Automation Drive can be applied across production, from general purpose AC induction motors to servo motors, which are often used in robotics. The exibility, adaptability, and communication of the motion control technology appeals especially to high performance automation in industries such as textiles, packaging, material handling and food and beverage as they strive toward higher productivity. Ef ciency means more options Food production, which comprises a sixth of the manufacturing sector, faces increased market demands for product diversity, quality, and safety. When consumers scan the supermarket shelves they dont see the factories productivity progress, but the changes are there in the increased diversity and quality of the products they choose. In addition to automation develop ments, advances in sensor, control, storage, IT, and transportation enable food manufacturers to produce high volumes of quality products in many variations for widespread distribution. Lean manufacturing techniques reduce product defects by an average of 20 percent, reduce leadtime by 70 percent, reduce inventory by 75 percent and increase ontime delivery by nearly 100 percent Source University of Tennessee, Manufacturing Extension Program Vol. 4 Issue 1Danfoss Dependable. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=7http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=7Vol. 4 Issue 15Danfoss Dependable. Danfoss provides controls and components for the industrial refrigeration sector and works with customers to develop ways to increase ef ciency of refrigeration plants. Cut the fat and add customer value In conjunction with technology, manufacturers use continuous improvement techniques to improve productivity and responsiveness to customers. More and more manufacturers are embracing continuous improvement in the form of Lean Manufacturing as they see the results. Lean techniques reduce product defects by an average of 20 percent, reduce leadtime by 70 percent, reduce inventory by 75 percent and increase ontime delivery by nearly 100 percent, according to a study by the University of Tennessee, Manufacturing Extension Program. The truly Lean enterprise doesnt just try to operate quickly to absorb overhead costs. Rather, it pays close attention to customer input and feedback to enhance performance. Across factories worldwide, Danfoss implements Lean Manufacturing to signi cantly boost productivity. This includes streamlining manufac turing processes, minimizing inventory at all production stages, eliminating waste, and shortening product cycle times. The goal is to constantly raise productivity at the factories and, in turn, raise customer satisfaction. When the Danfoss Calgary fabrication plant planned to double output two years ago it did not look for a larger premises, but instead introduced a Lean Production environment, like Danfoss operations worldwide. The Danfoss Calgary facility assembles prefabricated Zone Control Panels for oor heating, oor warming, and snow melting. The panels are prewired and ready to accept sensor and thermostat inputs. They are used to increase ef ciency and reduce installation time for hydronic heating systems. To think Lean, the factory had to view everything through the eyes of the customeranything that didnt add value to the product had to go. The team, led by Lean Champions, analyzed every single process. Nonvalue added practices were abolished, from under utilized space to excess inventory and wasted worker energy. Some changes were as simple as placing all tools and components required to do a task within reach of the employee. This eliminates a lot of downtime as people are looking for things or fetching them. Also a Kanban system was implemented to replenish inventory as it is needed to ll orders. Production lines abolished A more drastic change was virtually eliminating all nished goods inventory. The result is Justintime JIT productionthe panels are built as required within a minimal leadtime. To accomplish this, production lines were replaced with work cells. Work cells contain all staff, supplies and equipment needed to take a product from raw materials to a nished, tested product and no more. Now space previously used for nished goods and raw material inventory is dedicated to production. Stockouts on the production line are almost nonexistent. Production ef ciency is signi cantly improved and staff job satisfaction has increased, as Lean Thinking involves workforce empowerment to increase ef ciency. Most importantly, customers receive high quality products in shorter lead times. Transforming to a Lean Organization is a neverending process. It involves a culture of continuous improvement that pervades the factory and the organization as a whole. Lean Production is Here Move Over Waste Lean Manufacturing involves eliminating waste in every area from customer relations, product design, and supplier networks to factory management, labor and space. A Lean factory cuts inef ciencies anywhere it nds them. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=8http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=86Vol. 4 Issue 1Danfoss Dependable. Everyday items rely on temperature control From kitchen utensils to dashboards, injection molding produces many of the everyday items we use. The process is simple, but without correct temperature control would be impossible. The melted substance is forced under pressure into a mold, which is clamped shut due to the enormous pressure. The mold must be cooled to just the right temperature, usually by circulating water through it. Once the plastic cools, the mold opens, the part emerges, and the mold is ready for its next injection. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=9http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=9Vol. 4 Issue 17Danfoss Dependable. Danfoss is a principal supplier of critical components for specialized industrial chillers, particularly compressors and controls. Other manufacturing processes requiring careful temperature control are injection molding and extrusion to form plastic shapes. Plastic parts in automobiles, for example, are uniform, sturdy, attractive, easily installed, and carefully manufactured in temperature controlled processes. In many plants the industrial chillers that control the temperatures of the molds to make the parts are driven by Danfoss Maneurop hermetic compressors. Chillers every step of the way Cars and printing presses have more in common than one might think each contain parts precision machined to tolerances as close as a few ten thousandths of an inch. In addition to the inks and molds that need cooling in their processes, the machine tools that mill, grind, and drill those parts also need cutting uids that are constantly delivered to the cutting surface. These uids are delivered at temperatures controlled by industrial chillers. In fact, the compressors that power industrial chillers are themselves machined by tools whose cutting actions are cooled by industrial chillers. To optimize chiller capabilities, Danfoss provides industries, including chiller manufacturers, with Danfoss Maneurop compressors equipped with variable speed technology. Variable speed, when applied to a refrigeration compressor or one used for airconditioning is a highly energyef cient solution that constantly matches the compressor output to the demand for cooling. This ensures the compressor speed runs to reach the target cooling temperature, and no faster. This saves a lot of energy because the alternative is to introduce hot gas into the cooling circuit to control the temperature, which is simply not the most ef cient method. Variable speed compressors also save money in another way, because they run throughout the time the machinery is in use. Although it might seem that running equipment constantly would waste energy, the contrary is trueif little energy is used, or just the right amount, then running the compressor constantly actually extends its service life by eradicating the stresses of stopping and starting. In compressor operation, starting and onoff cycling are the most lifelimiting normal events. Danfoss is one of the worlds largest suppliers of hermetic compressors from 110 hp to 70 tons capacity and leads in the production of compressors for variable speed applications. Because variable speed makes possible energy ef ciency and extended compressor life, Danfoss enhanced the designs of many of its compressors to make them especially suitable for high ef ciency variable speed operation over an extended capacity range. Applications for these compressors range from water coolers to vending machines to home refrigerators and freezers, while other models serve in airconditioning and industrial process systems. One Cool Machine THE INDUSTRIAL CHILLER IS The Solutions you are reading was published in a printing plant in which the presses deliver inks, several colors or varieties at a time, at precisely controlled temperatures. Controlling the ink temperatures ensures machine ef ciency and high quality products. Printing is only one of many industries that require carefully controlled temperatures for processes andor input material. Typically industrial chillers create and maintain the target temperatures. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=10http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=10Danfoss Dependable. Vol. 4 Issue 18 THE LOCOMOTIVE IS THE MOST POWERFUL VEHICLE THAT MOVES ACROSS LAND, weighing hundreds of tons and moving at speeds up to seventy ve miles per hour. But the behemoth vehicles require a component weighing only a few ounces help to control and monitor it the pressure transmitter. Pressure transmitters, including pressure sensors, translate the low level output of a sensor or transducer to a higher level signal suitable for transmission to a site where it can be further processed. The manufacturers application was special, because the environment for the pressure sensors for the locomotive is harsh due to dirt, ne rock dust, wide variations in temperature and humidity, extreme shock and vibration, and major uctuations and spiking in pressures. In these very aggressive conditions, correct and accurate operation of the pressure sensors is essential to engine protection and safety. After locating the Danfoss website, the manufacturer began dialogue with industrial controls engineers at the company with broad and deep experience in pressure measurement for diesel engines for oil systems and coolant. Another suppliers pressure sensor used in the locomotives had an unacceptable failure rate due to overpressure and pressure spikes, e. g. transient high pressures. The potential customer wanted to know what Danfoss could offer to alleviate the problem. Danfoss engineers Recently a major locomotive manufacturer found a critical component through the Danfoss Industrial Controls website, www. danfoss. comusic. Through an online network of engineers, the producer of pulltrains and other large diesel vehicles, discovered that Danfoss produces pressure transmittersjust the critical component it needed. keeps locomotive producer on track ROBUST SENSOR A POWERFUL ENGINE The dieselelectric locomotives made by the manufacturer have enormous diesel engines occupying over half the interior of the vehicle. The remainder of the space in front of the engineers cab contains a generator driven by the diesel. The generator in turn supplies the energy to drive powerful electric motors on each axle. This provides power to pulltrains weighing thou sands of tons across America to deliver raw materials and nished factory goods of every conceivable variety. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=11http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=11Danfoss Dependable. Vol. 4 Issue 19 had solved a similar problem before, and had a 0100 psi transmitter that met the requirement. The engineers visited the locomotive manufacturers plant and discovered that the sensors that needed replacing just couldnt withstand the railroad environment. They were failing after only a year in service when the vehicle producer wanted at least two years. Because of connector issues with the old sensors, each individually mounted sensor was installed on a exible hose standoff to dampen the shock. The customer did not have any data to support the fact that this helped at all. Danfoss examined and tested two dif ferent engine applications. The small engine produced about 4000 HP. The other was reported to deliver 6000 HP. They concluded there were Danfoss sensors that would serve the manufacturers needs. And they put them to the test. Testing a product to death The potential customer had to be certain that the Danfoss sensor would actually perform, so HALT Highly Accelerated Life Time testing began. Manufacturing test engineers use the destructive HALT method to literally work a product until it fails, using special instruments to record events during the tests. As a result of their techniques, a component expected to endure for half a dozen years can have that lifetime compressed into a much shorter period so that a purchasing decision can be made as quickly as possible. Despite the rigorous testing, the customer was not able to break the Danfoss pressure sensor. A quick response by the Danfoss factory in supplying supplemental test data assured the sensors robustness, and the locomotive manufacturer selected Danfoss as the supplier of pressure sensors and transmitters. UNBREAKABLEManufacturing test engineers use the destructive HALT method to literally work a product until it fails, using special instruments to record events during the tests. Despite the rigorous testing, the customer was not able to break the Danfoss pressure sensor. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=12http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=12The Most Ef cient Parts Painter in the World PRODUCERS OF METAL INDUSTRIAL PARTS LOSE MULTIMILLIONS of dollars when an immense amount of very expensive industrial paint over sprays the intended target and spews paint across factory equipment. Overspray results in costly material losses, equipment stress, and poses a potential for re hazards. ITW Ransburg, a division of Illinois Tool Works, has devised a solution to virtually eliminate this overspray that plagues producers of metal parts, from lipstick tubes to aluminum extrusions and automobile parts. Danfoss Motion Control products are integral to the innovation. It is not an exaggeration to say the reciprocating disc sprayer is the most ef cient metal parts paint system in the world. It provides up to 90 percent transfer ef ciency, meaning most of the sprayed paint particles attach to the intended parts. Other systems tend to miss their target a lot. Hydraulic systems, the most popular used today, provide only from 60 to 75 percent paint transfer ef cient. Beyond the costly waste caused by overspray, companies face many other challenges in their applications processes, including achieving uniform coating for the parts. On a vertical line, some parts may turn out with a light coating of paint at the top of the component and a heavier coat at the bottom. There are also challenges in inconsistencies in paint nish, rejects and repaints, increases in production and dif culty tracking solvent use. Highspeed disk rotary atomizers like ITWs are an important technology for solving these problems. The high speed allows higher uid ow rates while maintaining the appropriate atomization levels of the paint to ensure proper coverage. The ITW system increases production, decreases errors, increases safety, and enables better process control. The operator uses a PLC system to set parameters for each batch of parts and between different batch runs for 10Vol. 4 Issue 1Danfoss Dependable. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=13http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=13maximum exibility in production, while maintaining tight system control to ensure the best quality painting. ITWs electrostatic reciprocating disc sprayer saves major costs, outputs higher quality products and prevents environmental danger. Used in coating applications from window frame painting and aluminum extrusions to auto parts, the system delivers signi cantly superior paint nish quality. In addition to the obvious thruput, ef ciency and product quality gains the advantages of the diminished overspray cannot be understated. Industrial paint is extremely expensive and wasted material plagues manufacturers, not to mention the price of coating errors. Besides the obvious money savings, there are also safety bene ts. When there is overspray during operations, the industrial paint can gather thickly on the paint booth walls and increase re hazard potential. In traditional spray systems, it is common that the overspray of paint collecting on the walls over the years can build up to be an inch or more thick. An ignition from a spark or electrostatic discharge could have violent consequences. Controlled complexity Industrial part painting is a rapid and complex process. In order to ef ciently and effectively coat components as they move through the paint booth, the conveyor and spray head systems must be synchronized and timed precisely. When ITW developed the improved system, it sought increased performance, higher coating quality and to minimize the environmental concerns. The disc sprayer, referred to as the bell, spins rapidly up to 40, 000 RPM to atomize the paint. The sprayer is sus pended on a column, which moves verti cally up and down inside an omegashaped booth. The stroke length and time of the sprayer bell varies depending on the appli cation. In aluminum extrusions, vertical distance traveled is typically in the area of 12 to 15 feet. The parts to be painted are suspended from an overhead monorail which enters one side of the spray booth, and progresses continuously in a horizontal movement through the painting booth. Paint is injected into the disc, which sends off electrically charged paint particles by centrifugal force. The spray pattern of the paint is shaped appropriately through the use of compressed air and the magnetically charged paint particles attach to the metal parts. Traditional parts spraying used hydraulics to accomplish the spray head movement and achieve the appropriate stroke duration and length, but this method has major limitations and concerns. Speed and reaction time are not precisely controlled and quality is compromised. Also, there is the problem of paint contamination due to the hydraulics uids. Danfoss VLT 5000 Series variable frequency drives and Danfoss Bauer geared motors are key to the system. In contrast to traditional system, the electronic solution allows better user control. It also eliminates contamination because there are no hydraulic uids. Also, maintenance of the equipment is signi cantly reduced because there is less paint buildup and less strain on the systems motor. And, the precision speed control of the VFD and geamotor provide a marked increase in overall system response and increased thruput productivity. The process of spraying metal parts demands precise timing, direction, speed, and pressure control. To accomplish this, the PLC interfaces with the Danfoss VLT 5000 unit equipped with the Sync Pos synchronizing positioning option. This option perfectly matches the drive with the precise application. The drives Sync Pos feature gets feedback from sensors above the parts position and coordinates the sprayer accordingly to paint the parts precisely. Overall system performance is increased by approximately 50 percent compared to the traditional hydraulic system. And, the Danfoss Bauer gearmotor provides durability in the harsh paint booth environment. For ITW customers, the combination of a Danfoss VLT 5000 and Danfoss Bauer gearmotor ensures that the sprayer provides pa2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=14http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=14Danfoss Dependable. Vol. 4 Issue 113 We passed TRANEs production quality standards with ying colors, says Shelley Ryan Carlson, Technology and Quality Systems Manager for NAMC. In the area of testing we surpassed the requirements on the initial evaluation. She explains that every Danfoss product undergoes rigorous testing, including fullfunctionality and thermal tests. To maintain the 100 percent product testing process while accommodating the high volumes for TRANE, Danfoss added an additional test chamber. This means the VFD unit line maintains production speed without sacri cing product quality. Control for Quick Response Although the TRANE TR1 drives are based on the same technology as the standard Danfoss VLT 6000 HVAC drives series, the TR1 VFD packages are customized in several ways. The control panels, for example require TRANE speci ed components and hardware designed for the customers airhandler speci cations. In addition to increasing testing capacity, Danfoss also added advanced tooling to the TR1 lines and established customerdedicated Lean Production lines for the TRANE TR1 units and panels. We have created a factory within a factory just for TR1 production, says Jayson Stemo, a manufacturing engineer on the TRANE control panel assembly cell. The area runs selfsuf ciently from the rest of the Danfoss panel production. This includes a TRANEdedicated production staff. Parts management through the use of a Kan Ban system cycles parts through the assembly line process, saving time and assembling errors. Parts, including many subassemblies, are kept within the immediate production area where orders are produced. The unwavering ef ciency of TR1 series production also allows the line to be exible so that it can output special requests, urgent orders, and short production runs. The majority of the TRANE TR1 units are in the 60 to 100 hp range, but the company also orders other power ranges. In fact, the customer requires the possibility of delivering hundreds of TR1 package variants within the same time frames. Key to achieving this exibility is an automated Shop Floor Control system, which allows the line to mass produce TR1 VFD units in more than three million possible variants. Once an order is placed, a bill of material enters the online system and sets in motion the assembling process, from materials acquisition to speci c work instructions for any given product variation. The TR1 lines also must easily adapt to new products and features. Product development and manufacturing at Danfoss work together closely to ensure smooth implementation of design changes. Many design ideas come directly from the shop oor, explains Stemo. For example, relocating 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=15http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=1512Vol. 4 Issue 1Danfoss Dependable. It takes high performance manufacturing to supply components for a global leader in indoor comfort systems. As the supplier for TRANE Companys TR1 Series HVAC variable frequency drives VFD, Danfoss North America Motion Controls NAMC produces more than 12, 000 VFD packages annually. This means ontime delivery of about 550 product variations to four TRANE factories and hundreds of eld sales of ces throughout North America. Danfoss buildstoorder the drives packages for TRANE facilities in Tennessee, Georgia and Kentucky. Meeting the demands of a large, worldclass manufacturer requires extremely ef cient and exible mass customization. Throughout the supply chain, Lean Production, Quick Response Manufacturing, and advanced automation and tooling output highvolumes for the customer. The VFD units for the TRANElabled TR1 packages are produced at the ISO 90012000 and 14000 certi ed Danfoss facilities in Loves Park, IL. and Milwaukee, WI. The TR1 VFD units are manufactured in Loves Park and from there they are transported to the Danfoss Milwaukee facility which is a ULcerti ed panel shop to be combined with control panels. The panels include the switchgear, fuses, and other devices as speci ed by TRANE. The TR1 VFD and control panel packaged units are then shipped to the appropriate OEM factory or sales company. TRANE integrates the TR1 packages into its commercial airconditioning and ventilation equipment to boost performance and energy ef ciency. Before selecting a supplier, the OEM conducted intense analysis of product quality, manufacturing and logistics. TRANE had a critical need to receive reliable products on time to meet its own high production and customer service standards. The timing of the orders is critical in the equation to deliver the products to the factories ontime, not before and not lateso TRANE can merge the units with their equipment in process. Expects the Right Products at the Right Time Global OEM A supplier OEM partnership involves strong cooperation, collaboration and dedication to ensure the customer can meet its own production and customer service standards. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=16http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=16OEM integrates motion control components from their traditional back panel mounting location to the panel door for easier and faster wiring evolved from an assemblers idea. Materials management also involves careful planning and smooth execution. As part of the factorywithinafactory concept, we have a planning process dedicated to the TR1 products, explains materials manager Brian Korrison. High performance manufacturing for an OEM requires not only ef cient systems but also a welltrained and motivated workforce. Training for assemblers and test technicians for the TR1 line takes a minimum of three months. Most of the staff on the TRANE assembly line are crosstrained and certi ed to ll any of the line tasks. Employee empowerment and teamwork ensure the factory runs smoothly regardless of order volume. Everyone working with the TRANE TR1 assembly knows that all matters is satisfying the customers demands and delivery expectations, says Michael Reckamp, material manager. The customers top priorities are quality and ontime delivery, so the entire process must be onehundred percent geared toward these outcomes. Supplying a worldclass OEM does not end in the factory. Customer Service is also equipped to handle the high order volumes and address all the customers requests and concerns. An online con gurator ensures accuracy and timeliness for all orders, regardless of con guration. But the foundation of the partnership and satisfying the customer is cooperation. Global OEM Continued from pg. 11 From Pulp Phillips, Wisconsin, a quiet place tucked away in the beauty of the Northwoods, is home to the builder of some pretty sophisticated machinery. Marquip Ward United was formed when three separate companies Marquip, Ward, and United merged in 2002. Each had a long history as a specialist in building machinery that handled part of the process of making cardboard now, together, Marquip Ward United builds machines that handle everything from producing corrugated cardboard, to cutting and stacking. 14Vol. 4 Issue 1Danfoss Dependable. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=17http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=17to Precision Vol. 4 Issue 115Danfoss Dependable. Corrugated cardboard consists of a uted layer of paper between two at layers. The uted layer is produced by a set of gearshaped rollers that crimp the paper into a zigzag pattern. A starchbased glue usually made from corn, wheat or potatoes is applied to the high points on each side of the uted layer, which is then sandwiched between the outer layers of paper and ironed at under steam heat and pressure. As the cardboard is being produced, it comes off the machine in a continuous sheet called a web, which then runs through a machine called a slitter scorer to cut it to whatever width is needed. Each slitter scorer has two stations with rotating blades, only one station is in contact with the cardboard at any given time. While one set is cutting the cardboard, a robot is placing the second set into position. When the width needs to be changed, the rst set of blades lifts up and the second set starts cutting, all without ever stopping the web. Next, the cardboard is cut to length by a machine simply called a knife, which consists of a large roller that has a curved blade running across it. The blade has to be curved because it slices across the cardboard as the roller spinsas opposed to chopping it offso it has to account for the fact that the cardboard is moving as it is being cut. Once the cardboard has been cut to the correct size, machines appropriately called stackers stack the cardboard for shipping or storage. The sheets of cardboard are moved along a conveyor, at the end of which is a platform called a lift table. The lift table, which can be raised and lowered, starts off slightly lower than the level of the conveyor. As each sheet reaches the end of the conveyor, it slides onto the lift table, which then drops by the thickness of one piece of cardboard in preparation for the next sheet coming down the conveyor. The result is a perfect stack of cardboard sheets. The Life of Cardboard M Marquip Ward United integrates Danfoss drives and Danfoss Bauer gearmotors into the machines they build. VLT 2800 Series drives control infeedout feed conveyors and vacuum blower motor tables that exert a slight downward force on the cardboard as it moves along the conveyor, allowing the rollers to grip it and move it along. VLT 5000 drives and Danfoss Bauer gearmotors provide the precision needed to perform functions like raising and lowering lift tables, onto which cardboard is stacked. Marquip uses approximately 3040 gearmotors per month in the production of their machines. About two years ago, the company started an upgrade program for their customers, in which they rebuild older machines using new drives, motors and components. These upgraded machines typi cally run about 30 percent of the cost of a new machine because they can retro t existing frames with the newer technology of todays drives. For example, the company recently upgraded a stacker unit originally built in 1992, replacing several competitor servo drives with VLT 5000 drives and permanent magnet motors with signi cant cost savings. Marquip Ward United is also saving costs by using Danfoss MCT 10 Software. According to Mark Bjork, Marquips Project Technician for Controls, the software allows parameter sets to be distributed to multiple drives from a central PC or control system. Without the need for manually entering parameter sets, drive swapouts are quick and errors are virtually eliminated. Setup procedures have also been greatly simpli ed, which makes their customers happy. Setup used to be an allday project, says Bjork. Now we can have them up and running in about ten minutes. In the future, he sees a signi cant role for the FC 300 Automation Drive in Marquip Ward United products. He and others at the company are excited about being able to offer the features of the new generation of drives in their machinery. 2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=18http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=1816Vol. 4 Issue 1Danfoss Dependable. PRODUCT NEWS Danfoss Bauers threephase BF Series helical geared motors are engineered to drive machines and equipment of all types. These threephase motors are available with power from 0. 075 to 50HP, with output speeds of 0. 3 to 230 rpm and torque range of 840 lbfin to 163, 700 lbfin. They are suitable for driving machines and equipment of all types in even the most challenging application environments. The robust, durable BF Series motors include stator winding of high quality insulated enameled copper wire, an aluminum die cast cage rotor and gear wheels made of high tensile and casehard steel. A stateoftheart, fully enclosed gearbox housing allows for reliable operation under harsh conditions, with protection from dust and water spray, as well as preventing lubricant loss and dirt buildup. The motors are IP65 sealed as standard, with optional IP66 protection. Gearboxes with an integral torque arm and hollow shaft as standard provide considerable time and cost savings during installation. Since 1927, Danfoss Bauer has been a leading manufacturer of quality gearmotor products. In 1999, they joined forces with Danfoss Drives to develop classde ning power transmission solutions. Danfoss Drives created the VLT name when they introduced the worlds rst massproduced Adjustable Frequency Drive in 1968, and the name has set the standard for quality adjustable frequency drives ever since. For more information contact Danfoss Bauer, 7324698770. New Gear Motors Series A new electronic controller from Danfoss that operates with various manufacturers EEPR electronic evaporator pressure regulating valves provides the tightest PID temperature control currently available. When electronic EPRs are well controlled, they are more ef cient than mechanical EPRs at maintaining closetolerance xture temperatures, and they allow multiple temperature setpoints on the same refrigeration circuit. Danfoss has applied for a patent on the unique software algorithm that resides in the new module and controls suction pressure based on the conditions in a refrigeration circuits most loaded xture. The Danfoss algorithm continually matches suction pressure to xture load, quickly adjusting for any pressure uctuation due to changes in load. The module is being introduced as a member of the second generation ADAPKOOL family, and is designated type AK2XM 208B. With this EEPR control module, xture temperature can be set at the controller or remotely, because the module is installed as part of the inputoutput network of a system based on a Danfoss rack controller. Each control module can serve up to 4 EEPR valves from Danfoss or major competitors. Conventional or loop piping may be used. In a typical installation, a 24foot lineup of multideck dairy cases using Danfoss controls shows temperature of 34F 0. 5 maintained over 24 hours, with quick defrost recovery. The target temperature set by the store owner was 34F for this period. For more information call 410 9318250. Electronic Control for Suction Stepper Valves EEPR2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=19http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=19Vol. 4 Issue 117Danfoss Dependable. PRODUCT NEWS New from Danfoss Heating A new Zone Control Panel supplying 30, 000 btu of mixed water for radiant heating or other low temperature applications is now available. This compact 13X12 inch panel contains a circulator, mixing valve, circulator control, and boiler contact. All internal tubing is stainless steel with union connections for easy servicing. The precoated steel enclosure protects the internal components and provides an attractive nish for the consumer. This new ZCP panel is one of a series of panels developed by Danfoss to simplify and enhance almost any hydronic installation. For more information contact 905 6766000. Danfoss is introducing an innovative patented family of weldin control valves for industrial refrigeration applications. The ICV family offers both servo and digital motorized versions. Both versions for a given capacity use the same valve body, with no internal bearing surfaces. The seat and all operating parts are contained in a replaceable function module. Singlepilot and threepilot bonnets are offered for servooperated versions. A servo valve can be upgraded to motorized function by changing the bonnet and function module. ICV valves perform as pressure regulating valves, solenoid valves, and as stepper motor controlled expansion valves. ICS servo version applications include suction pressure regulation in multitemperature evaporator systems and hot gas relief and solenoid function. Applications for the motorized ICM version include liquid injection into pump separators dry expansion liquid injection and hot gas liquid injection on high pressure PHE systems and liquid injection into closed economizers. Because of an extended working pressure range up to 725 psig 52 bar, ICS valves, can be used in CO2 systems as hot gas release valves. Promising new applications for the motorized ICM include use as an electronic expansion valve in DX ammonia systems use as a media temperature suction controller and as an electronic expansion valve for liquid injection on screw compressors. Danfoss supplies a variety of compact controllers suitable for use with the ICM valve. In the patented ICV family, the weldin valve body has no internal bearing surfaces, and will not require replacement during its service life. There is no bottom port. The seat and the entire valve mechanism are contained in a replaceable function module that is accessible by removing the valve bonnet. To order a servo valve, the user selects the body size, a function module, and a bonnet. Selection of bonnet and function module depends on whether the application requires a single pilot or up to three. ICM motorized valves have a body, a bonnetfunction module unit, and a motor. The motor is magnetically coupled to the function module, making it possible to remove or change the motor without shutting down the system. 420 m A, 020 m A, 010V, and 210V control signals can be used with the stepper driver that is supplied on the motor. The ICM valve motor also has a threedigit display, so that valve function can be continuously observed. Programming by three buttons on the stepper driver is passwordprotected. Alarms can be programmed, and their history is logged. All ICV valves are formed from low temperature steel, and are much more compact and less than half the weight off traditional ductile iron valves. ICV connection dimensions are in accordance with DIN, ANSI, SOC, SA, and FPT standards. For more information call 410 9318250. Patented Control Valve Family for Industrial Refrigeration Winner of the AHR 2005 Innovation Award2007-06-30T18:27:13+02:00http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=20http://danfoss.ipapercms.dk/refrigerationandairconditioning/RA/Solutions/US/SolutionsVol412005/?Page=20January Pro Mat MHIA Material Handling Industry of America Show January 1013, 2005Mc Cormick Place, Chicago, IL. Danfoss booth 1153 February Air Conditioning, Refrigeration, Heating Expo February 79, 2005 Orange County Convention Center, Orlando, FL. Danfoss booth 4110 March 37th ACCA, Air Conditioning Contractors of America, Annual Conference Indoor Air Expo March 912, 2005 Renaissance, Austin, TX IIAR International Institute of Ammonia Refrigeration March 1316, 2005Fairmont Acapulco Princess, Acapulco, Mexico IFPE International Exposition for Power Transmission March 1519, 2005Las Vegas Convention Center, Las Vegas, NV April IARW April 29May 5, 2005Las Vegas Convention Center, Las Vegas, NV CALENDAR OF EVENTS Please mention that you read about the event in Danfoss Solutions HOW TO CONTACT DANFOSS BALTIMORE, MD 7941 Corporate Drive Baltimore, MD 21236 4109318250 Fax 4109318256 www. acr. danfoss. com www. danfoss. comusic Refrigeration Air Conditioning Industrial Controls Components for Oil Burners Heating Controls GLENS FALLS, NY Danfoss Flomatic Valves 15 Pruyns Island Drive Glens Falls, NY 12801 8008332040 Fax 8003143155 EMail omatic omatic. com www. danfoss omatic. com Water Controls LOVES PARK, IL Danfoss Drives 4401 N. Bell School Road Loves Park, IL 61111 8156398600 Fax 8156398000 www. namc. danfoss. com Drives Industrial Sales MILWAUKEE, WI 8800 W. Bradley Road Milwaukee, WI 53224 4143558800 Fax 4143556117 www. namc. danfoss. com www. na. water. danfoss. com Danfoss Graham HVAC Danfoss Water Wastewater Nessie Water Hydraulics MISSISSAUGA, ONT 7880 Tranmere Drive Mississauga, ON L5S 1L9 Canada 9056766000 Fax 9056760279 www. danfoss. ca Heating Controls Motion Controls SOMERSET, NJ Danfoss Bauer 31 Schoolhouse Road Somerset, NJ 08873 1212 7324698770 Fax 7324698773 www. danfoss. comdrivesus Gearmotors For More Information To nd out more about Danfoss North America, contact us viaemail at solutionsdanfoss. com Keep updated on all the latest news about Danfoss products and your industry at www. northamerica. danfoss. com Log on today2007-06-30T18:27:13+02:00