White Papers
Case Study - G3 Ethernet: Ethernet is an open architecture, high-level communication network
Control Storage - One of the most misunderstood concepts in a compressed air system is control (wet) storage
Investing in Condensate Drains Can Help Keep Your Money Out of It
Dispelling the Myths Surrounding Compressed Air Storage
Custom Fluid Power and Pneumatic Solutions to Fit Your Needs
Why consider an oil-sealed liquid ring vacuum pump system?
Modular Frames that Adjust to Fit Virtually Any Industry and Application
Select the Right Dryer and Lower Operational Costs
Small Cylinders Lead to Large Savings
The Best Kept Secret Surrounding Compressed Air
Does your facility's fluid cooling system really require chilled water?
Photo Optic Sensors - Keep and Eye on Efficiency
Air Flow through an Orifice
Low-Cost, High-Performance Electric Actuators and Robots
New Compressed Air Piping System Results in Lower Costs and Big Savings
Dual audit air compression and fluid cooling
processes take on operating costs
Compressor Controls - Innovation + Imagination = FLO-TROL
Consistent use of air delivers new sports technology
Case Study - G3 Ethernet
Ethernet is an open architecture, high-level communicaton network
A leading manufacturer of custom automation and high-precision specialty equipment contacted John Henry Foster (JHF) to assist in the redesign of an existing printer plate insertion machine. The goal was not only to increase reliability, but to simplify and speed up the production capability of their current product offering.
Challenges
Printing processes, such as offset lithography, use printing plates to transfer images to paper or other substrates. Printing facilities are very interested in equipment that not only prints faster, but also decreases the machine's setup time when changing plate size. In the past, this was a very time consuming process resulting in higher printing costs. After thorough review of the current machine operation, automation specialists from JHF concluded that the primary issue revolved around the varying thicknesses of the existing printer plates and the need to apply consistent pressure regardless of thickness. These varying thicknesses resulted in a load resistance that was not consistent and would ultimately result in inaccurate positioning.
Solutions and Benefits
After reviewing possible solutions, two types of components were identified – electric and/or pneumatic.
Since each option had its advantages, JHF determined that a combination of both pneumatic and electric components would be able to address all the issues in a cost effective and simplified fashion. In order to achieve the goals of the project, the new approach would require the control and monitoring of all the individual components including 40 pneumatic actuators, 8 electronic regulators and 80 sensors with cables. The magnitude of the design dictated the need for an Ethernet capable open architecture, high-level communication network that provided high-speed, high-throughput capabilities with built-in flexibility.
It became obvious that the only solution able to accommodate the high level of control and flexibility required, would be through the application of G3 Ethernet Fieldbus technology. The G3 air valve technology with its high level of diagnostic and control capability, along with the modular design and advanced wiring concept, would successfully integrate both the pneumatic and electrical requirements. A G3 fieldbus valve stack consisting of 28 solenoids, 40 input connections, 40 output connections, 8 analog communication ports was selected. Key features of the G3 Ethernet Fieldbus technology is the built-in plug-and-play wiring concept and multiple monitoring screens that incorporate built-in digital diagnostic capabilities. These features greatly simplify the design and reduce overall set up time.
Results
The G3 valve technology exceeded all expectations of the redesign project. The advanced control and monitoring capabilities made it possible to increase production rates and simplify the operation, resulting in reducing operational costs along with increased reliability and quality improvements. Additional benefits of the G3 valve technology included the flexibility to allow for future modifications and enhancements necessary to meet the demands associated with high performance requirements within the printing industry.
For further information regarding G3 valve technology, please contact us at 651.452.8452 or visit www.jhfoster.com.
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Control Storage
One of the most misunderstood concepts in a compressed air system is control (wet) storage
When evaluating a compressed air system and the proper application of storage, one of the most misunderstood concepts is control storage. It is often referred to as wet, primary, or in some cases demand storage; however, the term control storage is more reflective of its main function - to maximize the effective operation of the compressor control. For the purpose of this article, I have limited the definition of control storage to; any storage created between the air compressor discharge and before any cleanup equipment, i.e. filters and air dryers. While one can argue that control storage shares some commonality of purpose with the more commonly applied demand (dry) storage (storage created after cleanup equipment and before demand regulation), it differs in the location of the storage and its functionality. It is not that unusual in compressed air system design to integrate both control and demand storage taking into account the primary function of both.
While control storage was originally an integral component of a reciprocating air compressor installation, this article will only briefly explore that application. The content of this article will focus instead on rotary screw installations since the rotary screw air compressor has essentially replaced the reciprocating as the compressor of choice in industrial applications. It should also be noted that in compressed air systems where reciprocating and rotary screw air compressors are operating together, control storage should always be utilized.
The reciprocating air compressor, up until the 1960's, was the air compressor of choice and utilized extensively in general industrial plants. Control storage was always an integral part of a reciprocating air compressor installation; whether it was a tank mount configuration for 25 hp or smaller units, or a stand-alone vertical or horizontal configuration for larger hp.
Three main reasons determined why control storage was always used in conjunction with reciprocating air compressors:
- Reduce the pulsations from the compressor discharge
- Provide condensate removal through condensation and settling
- Eliminate short cycling of the compressor controls
Starting in the 1960's with the universal acceptance of rotary screw technology (both oil-flooded and oil-free), the reciprocating air compressor has virtually been replaced within the general industrial market. The demise of the market for reciprocating air compressors has led to a misunderstanding of when and how to apply control storage. This lack of understanding seems to have coincided with two major advantages inherent in rotary screw design - the elimination of pulsations at the compressor discharge and the development of alternative control schemes such as modulation, variable displacement and variable speed.
Over the last 30 years, there has been a perception that control storage is no longer required, as its function has been replaced by the flexibility of the modern compressor controls. Therefore, the question becomes "Is control storage an outdated concept?" The answer is no, control storage is not an outdated concept; however its role has become more application specific. The discussion now becomes "Where should control storage be applied and is it a required component of an air compressor system regardless of control type?" While there is not a clear yes or no answer, there are a few general principles that can be applied when taking into account the four basic types of compressor controls offered on rotary screw air compressors:
- Modulation Control
- Load/No Load Control
- Variable Displacement
- Variable Speed Drive (VSD)
Modulation Control
Rotary screw compressors with modulation control do not necessarily require control storage. While modulation control is not the most efficient control at partial compressor loads, its smooth control reaction to changes in compressor load minimize the need for control storage. The only exception would be very low demand loads, where the compressor would operate for a sustained period of time outside of the modulation range. It should be noted that in reality this is a very uncommon occurrence.
Load/No Load (On-Line/Off-Line) Control
Load/no load (also referred to as on-line/off-line) control, which is predominant in oil-free and some manufacturers of oil-flooded rotary screws, does require control storage. Without the proper amount to control storage, the short cycling of the controls will occur causing premature wear and failure of the compressor control system. This is exhibited in rapid loading and unloading of the air compressors at less than full load conditions, sometimes misdiagnosed as a high load condition. Most of the load/no load controls are set at a 7-10 psig differential, which is monitored at the compressor discharge. When a load/no load compressor is piped into a compressed air distribution system, the control differential of the air compressor is reduced by the pressure drop across the clean-up equipment. Essentially any pressure drop created by filters, dryers and piping will subtract from the controls differential. This could easily result in a true controls differential of 2-7 psig instead of the normal 10 psig and result in a short cycling in the compressor controls. Properly applied control storage will create a buffer between the sensing point of the compressor controls and clean-up equipment providing time to smooth out the compressor controls reaction. Optimally, a control storage ratio of 3-5 gal./cfm output is recommended.
Variable Displacement
Variable displacement controls are similar to modulation in the fact that as long as the plant load stays within the operational range of this type of control, then control storage is not necessarily required. However, it needs to be understood that the control range of a variable displacement control is narrower than that of a modulation control. Variable displacement control will only operate at loads of 50% or higher. Below 50%, the compressor operation will revert to a load/no load or modulation control. Should the compressor operate below the 50% level, control storage (3-5 gal./cfm output) should be applied.
Variable Speed Drive (VSD)
Variable speed drive controls are also similar to both modulation and variable displacement in that as long as the compressor operation is within the operational range of the VSD, a case can be made that control storage provides little benefit. As with the case of the variable displacement control, the operator must be aware of the turndown capability of the VSD, which can vary from manufacturer to manufacturer and even within models of a manufacturer's product line. If the compressor operates below the turndown range of a VSD compressor, then control storage should be applied (3-5 gal./cfm output).
The rational of utilizing control storage solely as a liquid knockout tank on compressor control schemes that otherwise would not normally require control storage is problematic. In order for control storage to be effective in condensate removal, sufficient cooling and a reduction in velocity of the compressed air would have to take place. While some condensate will be discharged from the system at this location, if the sole function is just condensate removal, the cost of high quality separators and condensate drains on the compressor would be more effective and will produce a much better ROI.
As is the case with all types of storage, knowledge of the compressed air system is required to maximize the value it would add to a compressed air system. Without application knowledge, the benefits of storage can be greatly compromised. Control storage is a tool that can significantly improve the reliability and operation of an air compressor system, but needs to be properly evaluated.
It is not possible to cover all the aspects regarding the application of control storage within the contents of this article. There are other specific applications that can arise in the design of compressed air systems that may require the use of control storage. For questions concerning control storage or any other types of storage and related applications, please contact us at 651.452.8452 or visit www.jhfoster.com.
Ron Nordby
Vice President, Sales and Marketing
John Henry Foster
651.681.5724
ron.nordby@jhfoster.com
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Investing in Condensate Drains Can Help Keep Your Money Out of it
The most vulnerable point in a purification system is the condensate drain system.
Where there is compressed air, there is water. Condensation is the moisture that drops out of an air flow as it cools and is therefore a constant threat to cause expensive problems in a compressed air system. Condensate drains are necessary to keep water, dirt, wear particles, bacteria out of your system. The problems get worse if you operate lubricated reciprocating or oil flooded rotary screw compressors - which is just about everyone. Compressor oil makes its way into the distribution system with the compressed air. The mixture of oil, water, and dirt tends to build up a sludge that will ultimately jam or clog production equipment, air tools and drains.
How big of a problem can this be? That depends on the ambient conditions at the compressor intake. The amount of condensation generated will change according to fluctuating temperatures and the relative humidity of the inlet air. For example, it would not be unusual for a 25 hp air compressor to ingest between 8 and 24 gallons of water a day during the summer season depending on site conditions.
This means that condensate management is a critical step in supplying clean, dry compressed air to your tools, equipment and system processes. The task of condensate drains is to remove the condensate from the pressurized air system safely and at low expense. The typical compressed air system is designed to have condensation removed at strategic locations. There are drains installed at the after cooler separator, receiver tank, air dryer, in-line filters and at drain points in the piping system. The diagram reflects a basic compressed air system with the amount of condensate removed at key points of the after cooler separator and a refrigerated air dryer.
Condensate drains should be considered based on reliability and energy efficiency, not on initial cost. The most vulnerable point in a purification system is the condensate drain system. When installing condensate drains, zero air-loss automatic drains with large drain ports should be utilized. They are full pressure drains, which do not consume compressed air and tend to be very reliable.
Key Benefits of Zero Air-Loss Condensate Drains
- Saves energy (no air consumption)
- Very resistant to clogging
- Removes risk of condensate carry-over
- Automatically adjusts to condensate levels
- Long service intervals with safe, easy maintenance
Contact Rich Dean, Air Systems Product Manager at 651.681.5749 or email rich.dean@jhfoster.com
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Dispelling the Myths Surrounding Compressed Air Storage
Compressed air storage is a critical component when considering efficiency gains
With today’s ever increasing emphasis on improving manufacturing efficiency and reliability, all aspects of the manufacturing process are being examined. Energy audits of manufacturing plants have readily shown that compressed air systems rank very high in potential for efficiency gains. In particular, one area of the compressed air system has consistently proven to be a critical component in achieving this goal - Compressed Air Storage.
When applied correctly, compressed air storage has been an excellent tool in the effort to increase the efficiency, performance and reliability of a compressed air system. Compressed air storage has the potential to supply large amounts of mass flow at an increased rate, which in turn reduces the reaction time required of the system components to demand events. This results in the ability to stabilize system pressure and reduce online power, thus lowering operational and maintenance costs.
Despite these facts, compressed air storage is still one of the most misunderstood and misapplied aspects of a compressed air system. Here, we address some of the more common misconceptions surrounding compressed air storage and how to apply it.
Myth #1
Useful storage can be created by simply adding
storage tanks.
Installing air receivers in a compressed air system without defining the purpose and expected results is a prescription for failure. Poorly applied compressed air storage is very common and while it may not negatively impact the operation of a compressed air system, it will most certainly result in little if any efficiency or performance gains. In order to maximize the effectiveness of compressed air storage, it is essential to measure and verify the performance characteristics of the compressed air system from both the supply side and the demand side. Simply adding additional storage volume, such as an air receiver without the intentional creation of a useful differential would create very little storage and serve no useful purpose. For example, a 10,000-gallon air receiver with only a 2 psi differential would only create 180 cfm of useful storage, while a 10 psi differential would create 900 cfm of useful storage for the same size receiver.
Myth #2
The more compressed air storage the better.
There is some truth to this statement since excessive compressed air storage is very seldom detrimental to the operation of a compressed air system. In fact, excessive storage applied to a compressed air system has the potential to reduce pressure fluctuations by increasing the reaction time available to the supply side of the compressed air system in relation to demand side requirements. However, the downside to over sizing storage in a compressed air system is the increased costs, which will invariably extend the pay-back period and may result in an unfeasible project. As stated earlier, it is always beneficial to measure and verify the performance characteristics of your compressed air system in order to maximize the benefits and improve the return on investment. This can best be accomplished by having a quality compressed air system audit performed.
Myth #3
System piping replaces the need for air receivers.
System piping (headers, sub-headers and drop legs) provide very little useful storage and is not nearly as cost effective as utilizing air receivers. For example, as you can see from the table included, 1,000 ft of 4“ piping has the volume equivalent of a 400-gallon air receiver. Obviously, it is far more cost effective to install a 400-gallon air receiver rather than 1,000 feet of 4” piping. It is also very difficult to create a meaningful pressure differential across system piping, when you must rely only on the natural pressure drop to create this differential. As mentioned previously, the small pressure differential that can be created results in very little if any meaningful storage. Air receivers by contrast, when coupled with Demand Regulation, provide a great opportunity to maximize useful storage by allowing a much greater pressure differential to be created.
Myth #4
Certain types of air compressors do not require storage.
First of all, it is necessary to differentiate between the storage requirements of a particular compressor controls verses that of the compressed air system. When addressing the needs of a particular compressor control, it is true that some controls require less storage than others. For example, when operating at high load levels, some compressor controls such as modulation, variable displacement, and variable speed benefit very little from what is considered control or wet storage. Control or wet storage is considered storage between the compressor discharge and any clean up equipment. However, when these same types of controls operate at lower load levels (certainly below their turndown), control (wet) storage becomes critical to preventing short cycling. Compressor controls such as load/no load do require control (wet) storage, at virtually all load levels to reduce the possibility of short cycling, excessive oil carryover and to increase the efficiency of operation.
When addressing the needs of the compressed air system, the fact is that the compressed air system will always operate more efficiently and reliably with storage properly sized and applied. The permissive of the compressor control and the compressed air system requirements are different and should be considered separately when considering the implementation of compressed air storage.
This article is the first in a series where we will discuss aspects of the creation and application of compressed air storage.
To support your productivity and efficiency needs with this innovative product, please contact us at 651.452.8452 or visit www.jhfoster.com.
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Custom Fluid Power and Pnematics Solutions to Fit Your Needs
Custom solutions are designed to meet the demands of changing markets and are established for customers whose project requirements cannot be met by the off-the-shelf products of most manufacturers. Our goal is to match customer demand with sound solutions to improve their performance and efficiency needs.
Representative Applications
Spline Cylinder
For a labeling application, a printer needed to extend a part with very little rotation in a tight space. It was modified from its original line construction and included a spline within the cylinder to keep it from rotating. The cylinder achieved rotational tolerance of only +/- 1/2° and kept the customer from having to use a bulkier linear thruster.
Rate Control Actuator
A food service company needed a cylinder to provide rate control on a spring-loaded cover. A unique rate control actuator was developed to deliver smooth, consistent velocity control. This fluid-filled cylinder was designed to provide free flow in one direction and controlled flow in the opposite, or controlled flow in both directions.
CASE STUDY - Air-Driven Adjustable Double-Finger Toggle Clamp
A window frame manufacturer needed a way to hold multiple boards, in a fastening application, without using multiple manual toggle clamps.
The solution was to utilize an air cylinder to provide “1-stop locking”. Upon actuation, the cylinder rotates the clamping fingers into position. When pressure is released, a spring returns the fingers to the home position. This design gave the customer the ability to vary the locking force by simply adjusting air pressure. And, by using a rack and pinion design from a traditional rotary actuator, the clamping fingers can rotate over 90 degrees. This allows it to fully release away from the assembled frame via a spring returning design.
Are you looking for your own custom solutions?
Contact Rodney Janovec our Fluid Power Supervisor for more information.
Direct 651.681.5732 or 888.681.5732
rodney.janovec@jhfoster.com and visit jhfoster.com
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Why consider an oil-sealed liquid ring vacuum pump system?
Get maximum reliability under the toughest conditions
Oil-sealed liquid ring vacuum pump systems give maximum reliability under the toughest conditions. These highly efficient systems are known for their simplicity in design and low maintenance requirements due to the absence of wearing parts. Compared to other vacuum pump systems, these systems offer advantages of no metal-to-metal contact between the impeller and casing and also require no internal lubrication. By using specially formulated low vapor pressure sealing fluid, they can operate up to 10,000 hours or more without an oil change, while preventing corrosion and scale build-up. An additional advantage of oil-sealed systems is that the use of water – and the corrosion and waste associated with it – has been completely eliminated. The air/oil separator virtually eliminates oil carryover concerns and ensures the cleanest environment. Switching from water cooled to air cooled will also produce significant cost savings on water usage and reduce groundwater runoff contamination.
The oil-sealed vacuum pump is also very adaptable to the utilization of a Variable Frequency Drive (VFD). The VFD is applied in industries where ruggedness, reliability and cost-effective operation are of the utmost importance. When demand for vacuum decreases, the VFD will reduce the speed of the vacuum pump, which in turn significantly reduces power consumption. VFD’s are affordable and easy to install and are one of the most cost-effective ways to maximize efficiency and reduce operating costs – frequently saving up to 50% in energy costs.
Advantages:
- Low maintenance
- Durable
- Extremely quiet with soundlevels in the 75-80 dBA range
- High capacity for contaminants
- Can operate at low vacuum without overheating
- Available in single or two-stage pumps
- Available in air-cooled or water-cooled
- Available explosion proof
- Eliminates the use of water
Representative industries served:
- Hospitals
- Laboratories
- Biodiesel plants
- Remediation projects
- Printing companies
- Food industry
- Plastics
John Henry Foster is able to assess and recommend the most efficient and cost effective equipment on the market today. Contact us to find the best application for your vacuum pump solutions.
Richard A. Dean
Air Systems Product Manager
John Henry Foster
651.681.5749
rich.dean@jhfoster.com
www.jhfoster.com
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ModularAluminum Frames that Adjust to Fit Virtually Any Industry and Application
80/20 Aluminum Framing, Aluminum Extrusion, T-Slots, Frames, Structural Framing, Fasteners and Accessories
Modular aluminum framing systems have the capability to adjust to fit virtually any industry and application. These custom specific framing systems consist of aluminum profiles, fasteners and accessories and are fully equipped to handle projects ranging from light to heavy-duty. They provide secure and OSHA-approved guards, displays, workstations, or any other custom application needed. To help save time and money, services such as design assistance, custom machining, kit packaging and support to build your application are all available in addition to offering the necessary parts and pieces for your project.
New Key Products
Profiles
Currently, there are 88 profiles available. Options for these profiles include fractional and/or metric extrusions and weights ranging from light, ultralite or standard. Also added are three rounded profiles for the 40 series metric, along with four other additions to the 40 series line. These additions give a greater variety of options for designing.
Paneling
80% of all framing projects need one or more panels. Our manufacturer has nearly 100 existing and in-stock options to choose from and has recently expanded to include several new options.
These options include: mill finish aluminum plates along with clear polycarbonate panels both available in five thicknesses, wire mesh in two additional powder coat colors, and PVC coated wire mesh panels with 2” x 2” openings.
Structural Aluminum Applications:
- Machine tool
- Automation
- Material handling
- Manufacturing
- Retail systems
- Furniture
- Fluid Power
- Robotics
- Displays/Exhibits
- Medical
- Scientific
- Packaging
Structural Aluminum Benefits:
- No welding
- No priming or painting
- Lightweight and easy to machine
- Uses standard fractional or metric fasteners
- Less engineering time required
- Easy to fabricate – only simple hand tools required
- T-Slot technology is industry accepted
- Great aesthetic value
- No expensive fabricating equipment required
- Machine frames can be easily reconfigured for design changes
For more information on Aluminum Framing Systems, please contact Terry Flanagan or Tom Garding at John Henry Foster to learn more about 80/20 Aluminum Framing Systems at 888.681.5750.
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Select the Right Dryer and Lower Operational Costs
Why the Regenerative Dryer Might be the Best Option for You
It has been well documented that the presence of water in compressed air systems can have serious ramifications. Consider this: a typical 100 hp compressed air system at common ambient conditions can generate as much as 40 gallons of water in a 24-hour period. As a result, industries lose millions of dollars each year from lost production, increased maintenance costs, and a reduction in quality.
The solution to the problem is to install compressed air drying equipment. While that may seem simple, the key is choosing the appropriate type of drying equipment.
Initially, facility managers need to understand what degree of drying is required. This can be determined by consulting with compressed air system experts and is an important step because drying compressed air beyond the level necessary will result in higher initial and ongoing operational costs.
There are four (4) basic types of compressed air dryers available: deliquescent, membrane, refrigerated and regenerative. While there is very limited practical use of the deliquescent and membrane air dryers, both the refrigerated and regenerative air dryers are very common place. While refrigerated air dryers are by far the more frequently applied and well understood method of drying compressed air, this article will focus on the lesser known, yet equally important, regenerative type of compressed air dryer.
Regenerative Air Dryers
Many industries including medical, aerospace, food and beverage, and semiconductor, have applications that require very dry compressed air with pressure dew points approaching -40 pdp, even as low as -100 pdp. This is far beyond the range of refrigerated air dryer capabilities and can only be provided by applying some type of regenerative air drying technology.
While there are variations within the family of Regenerative Air Dryers, the five (5) basic regenerative air dryer types based on methods of regeneration include:
- Pressure Swing (heatless)
- Exhaust Purge (externally/internally heated)
- Blower Purge
- Vacuum Assist
- Heat of Compression
The 5 Basic Types of Regenerative Dryers
1. Pressure Swing (heatless) regenerative air dryers operate without a heat source and achieve low dew points by using dry purge air from the process.
Advantages:
- Low initial cost
- Ability to achieve low dew points (-40 pdp or lower)
- Lower maintenance requirements
- Simplicity of design
Disadvantages:
- Consumes process air for regeneration (15%)
- Higher cost of operation in large sizes
- Shorter cycle time
2. Exhaust Purge (externally/internally heated) regenerative air dryers utilize both a heat source and dry purge air from the process.
Advantages:
- Lower cost of operation in large sizes
- Ability to achieve low dew points (-40 pdp or lower)
- Longer cycle time
Disadvantages:
- Moderate initial cost
- Moderate maintenance costs
- Consumes process air for regeneration (7% - 8%)
- Consumes some electrical costs
3. Blower Purge regenerative air dryers utilize a heat source, blower and dry purge air from the process.
Advantages:
- Lower cost of operation in large sizes
- Ability to achieve low dew points (-40 pdp or lower)
- Longer cycle time
- Consumes a small amount of process air for regeneration (0% - 2% on average)
Disadvantages:
- Higher initial cost
- Moderate maintenance costs
- Possible dew point or temperature spikes at switchover (when process purge air is eliminated)
- 7% process air purge consumption when regenerating
4. Vacuum Assist regenerative air dryers utilize a heat source and vacuum blower.
Advantages:
- Lower cost of operation in large sizes
- Ability to achieve low dew points (-40 pdp or lower)
- Longer cycle time
- Eliminates all process air purge use
- No dew point or temperature spikes at switchover
- Multiple compressor capability
Disadvantages:
- Higher initial cost
- Moderate maintenance costs
5. Heat of Compression regenerative air dryers utilize heat from the air compressor.
Advantages:
- Lower cost of operation in large sizes
- Ability to achieve moderate dew points (+10 to -20 pdp)
- Eliminates all dry purge use
- No dew point or temperature spikes at switchover
Disadvantages:
- Higher initial cost
- Dew points vary with operating conditions
- Moderate maintenance costs
- Must be matched to a single compressor
- Can only be utilized on oil free air compressors
Due to the numerous variations of these types of regenerative air dryers, as well as in their applications, more detailed information may be necessary. For more information and assistance in making the appropriate selection, please contact us at 651.452.8452 or visit www.jhfoster.com.
Ron Nordby
Vice President, Sales and Marketing
John Henry Foster
651.681.5724
ron.nordby@jhfoster.com
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Small Cylinders Lead to Large Savings
Efficient energy usage cuts running costs and benefits the environment
At the forefront of every industry’s business plan are cost-saving solutions, beginning with energy efficiency. Now is the time to think small – at least as far as actuators go. As the next generation of cutting-edge technology emerges, John Henry Foster is partnering with Intelligent Actuator America, Inc. (IAI) to introduce the Mini-ROBO Cylinder®, a new motion control system that provides unique linear and robotic components.
ENERGY AND PRODUCTIVITY BENEFITS
- Improves overall energy efficiency
- Xcel Energy Rebates
- Reduces overall production costs
- Effective energy efficiency is as high as 80% - 90%
- Lower “down time”
- Versatility allows one actuator to perform multiple functions
- Green automation benefits the environment
Features of the Mini-Robo Cylinder
- Lower maintenance time
- Reduces costly air leakage
- Smaller and space-saving
- Easy-to-make adjustments
- Flexible
- Greater control
- Longer life
The Mini-ROBO Cylinder is designed with a smaller footprint. Similar to an air cylinder and easy to use, the small format makes the transition to electric seamless. The 24 VDC electric actuator’s controller package mimics the valve setup of an air cylinder. The difference - and advantage - of using an electric cylinder is that force and speed can be accurately adjusted. Those features, along with position feedback, make these products attractive to the user that’s looking for increased controllability in any application.
Types of Mini-Robo Cylinders
John Henry Foster offers various types of Mini-ROBO Cylinders, including slider, rod, table and linear servo.
Slider
The slide design enables a user to push or carry a load within the footprint of the actuator, which can be critical when work space is at a premium. In addition, because of its built-in support, the slider is capable of longer stroke lengths. Popular applications include part transfer and table indexing.
Rod
The rod design is beneficial for higher push force. Typical applications include pushing a guided load, clamping and press fit.
Table
The table design incorporates a guide to allow for greater overhang of a load and mounting versatility.
Linear Servo
Linear servo style actuators have a low friction design that allows for greater accelerations (2Gs) and longer cycle life. Applications where short cycle times are desired are well suited for this style of actuator.
New 2 and 3 Point Controllers
The new line of position controllers from IAI continues to incorporate the force and position control of previous lines but at a reduced implementation cost. These controllers are also sold with an IP53, dust-proof rating for installation on the work floor near the actuator, similar to the installation of an air valve
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The Best Kept Secret Surrounding Compressed Air
When it comes to deciding on air compressors, most people look at rotary screw types that are either lubricated or non-lubricated. This is justified when the horsepower of the compressor falls between 10 and 250 hp, but what about when the compressor is at or above 250 hp? Is the rotary screw the air compressor of choice or are there other options available?
If you are like the majority of people, the centrifugal air compressor is probably not on your list of options. For a compressor type that has been around for 50 years - longer than the rotary screw air compressor - the centrifugal air compressor is relatively unknown. It has been the main workhorse of the process, air separation and energy generation industries where oil-free large horsepower compressors were needed.
However, in the last 20 years, the centrifugal air compressor has been reengineered to meet the demands of the plant air compressor market. The best features of the centrifugal air compressor design were combined with modern electronic controls to interface with or replace rotary screw air compressors.
Centrifugal air compressor highlights:
Oil-free compressed air
The centrifugal air compressor is by nature oil-free. This makes it very adaptable for applications that require oil-free air, but it also reduces the filtration and maintenance requirements in applications that would not normally require oil-free.
Reduced maintenance
The centrifugal air compressor has the lowest maintenance requirement of any of the types of rotary screw air compressors either oil-flooded or oil-free.
Small package
No other air compressor delivers the volume of air per ft² footprint requirement than the centrifugal air compressor. In many cases the floor space required is ½ that of a comparable rotary screw air compressor.
Extended oil life
Due to the low operating oil temperature, normally 120 °F, and the fact that the oil does not mix with process air, the life of the lubricating oil can extend as long as 2 years. The less strenuous oil requirements not only allows for an increase in oil life, but also a decrease in oil and disposal costs.
Efficiency
When it comes to cfm/kW, no other air compressor technology can match the performance of the centrifugal air compressor.
Reliability
The non-wearing basic design of the centrifugal air compressor makes it one of the most reliable compressor available and the compressor of choice for industries where reliability is of utmost importance.
For more information on centrifugal air compressors please contact us at 651.452.8452 or visit www.jhfoster.com.
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Does your facility's fluid cooling system really require chilled water?
Over the last 25 years there has been a heightened awareness to reduce the consumption of both water and energy. Federal, state and local laws, rising costs of water and energy, and a growing need to reduce operational costs have pushed this awareness to the forefront of all industries. Most companies are trying to cut expenses and become more efficient. It’s smart business and it’s urgent.
Water and energy are not an unlimited resource. And as regulations concerning the use and disposal of water have intensified, industrial applications that utilize both resources have come under scrutiny. One such application is industrial fluid cooling, which consumes as much as 7 percent of the energy and 15 percent of America’s water consumption (excluding the energy-generation industry).
While this high water usage makes industrial fluid cooling a prime target for energy and water conservation, the rush to reduce or eliminate it has in many instances actually increased energy consumption. Inappropriate fluid cooling, particularly the misapplication of chillers for cooling many industrial processes and equipment, has led to a large increase in fluid cooling costs and widespread inefficiency.
In the manufacturing industry, nearly all industrial facilities utilize chillers in some capacity, typically operating with an average water temperature ranging from 45°F - 60°F. But the question begs to be asked … is utilizing chilled water always the best choice? Creating a cold temperature, in general, is an expensive use of energy. Therefore, cooling temperatures below what is necessary has a direct relationship to an increase in costs.
By simply increasing the amount of water, it is well documented that many fluid cooling applications can operate successfully with cooling media temperatures between 70°F - 90°F. This temperature variance makes it possible to utilize other fluid cooling technologies, such as dry cooling or evaporative cooling, which would result in a reduction in energy costs, as well as a reduction or elimination of the use of water.
If a facility is to increase efficiency by reducing in energy and water usage, then fluid cooling applications need to be evaluated based on the highest allowable cooling media temperature. The increase in cost to supply additional water flow to an application would be quickly offset by either reducing the chiller load or eliminating additional chiller capacity.
Building managers can find out about alternative fluid cooling technologies and applications by simply conducting a fluid cooling audit. Engineers can evaluate how to maximize the performance, reliability and efficiency of a fluid cooling system. As experts examine each application, they can also determine the suitability of utilizing higher-temperature fluid cooling media.
Every single degree costs money. By learning how to improve efficiencies through an energy audit, businesses can reap the rewards of taking charge of their facility costs.
Ron Nordby
Vice President, Sales and Marketing
John Henry Foster
651-681-5724
Ron.Nordby@jhfoster.com
www.jhfoster.com
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Photo Optic Sensors - Keep and eye on Efficiency
In today’s business environment, there is unrelenting pressure to manufacture products faster, more precisely and at a lower cost per unit. Industrial manufacturers are charged to find new ways to increase production rates, while eliminating any unnecessary costs, including line downtime, scrap and rework. In order to meet these demands, factory automation has become, and will continue to be, a top priority.
One of the key elements of efficient factory automation is photoelectric sensors, which allow machine designers to measure, monitor and control machine functions quickly, precisely and reliably. The high-tech sensors become the eye of the machine, generating specific inputs to control its function. They are also the latest and most innovative way to optimize automation requirements, particularly sensing surfacing and distance performance.
Types of Photoelectric Sensors and Applications
A photoelectric sensor is simply an optical device that detects a visible or invisible light beam and responds to a change in received light intensity. The light source is either an LED (light emitting diode) or laser, depending on the requirements of the application.
Photoelectric sensors are available in numerous sizes, sensing modes and configurations that provide solutions to virtually any application in industries such as packaging, food processing, semiconductor and material handling.
LED Sensors
LED sensors are one of the most widely applied with the most versatile range. They are cost effective and adaptable to virtually any application.
Applications:
Sensing objects from opaque to transparent
Sensing parts in clean to contaminated environments
Counting parts
Sensing small parts that are not in a repeatable position
Sensing parts of varying reflectivity and ignoring backgrounds
Sensing parts in a defined depth-of-field
Laser Sensors
Laser sensors offer excellent repeat accuracy and performance, especially in applications where long-sensing range and narrow beams are required. Laser sensors can be used in the same applications as LED sensors, plus they are very effective in high-accuracy measurement requirements.
Fiber Optic Sensors
Fiber Optic sensors offer superior performance where the sensing environment is harsh and extremely confined.
Applications:
High vibration and shock tolerance
Applicable in high heat, wet and corrosive environments
Compact design for tight sensing locations
Complete immunity to electrical noise
Explosion proof design EMI and RFI
Sensing very small objects
Furthermore, the photoelectric sensors are relatively inexpensive and operate well in challenging environments. They perform tasks that other “more conventional” sensors can’t such as color identification, distance and thickness measurement. These highly sensitive sensors can be programmed to read an extremely specific and limited area, ensuring the highest accuracy. And because they are usually impervious to noise/dust/false signals, they are very long-lived.
Improving industrial performance is a top objective. High-precision photoelectric sensors help manufacturers optimize productivity, while helping their customers improve their products and their processes.
James J. Lavota, CFPS
Electro-Pneumatic Automation
John Henry Foster
651-681-5729
Jim.Lavota@jhfoster.com
www.jhfoster.com
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Air Flow through an Orifice
See chart
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Low-Cost, High-Performance Electric Actuators and Robots
Continuing John Henry Foster’s (JHF) mission to promote a progressive culture by seeking opportunities for cutting edge technology, we are excited to announce the addition of the Intelligent Actuator America, Inc. (IAI) product line.
IAI designs and manufactures a complete line of motion control systems providing linear and robotic component solutions to businesses around the world. These markets include automotive, consumer products, electronics, food, medical, inspection and examination, to name just a few. They are the world leader in linear actuators and low cost, high performance SCARA robots, as well as a leading source of advanced plug and play automation throughout North America.
With the recent introduction of the ROBO Cylinder® linear actuators product line, IAI has become a standard in cost effective, low maintenance, and fully programmable electric cylinders. The ROBO Cylinder® linear actuator was designed to accomplish the simple tasks usually assigned to air cylinders, but with greater flexibility and custom control over position, speed, acceleration, deceleration and torque.
Our goal at JHF continues to be our dedication to serve our clients with the most cutting-edge products available on the market. We bring customized client solutions in consistency, reliability, and profitability, while continuing to demonstrate our tradition of the latest industry trends and solutions in world-class compressed air automation. Specializing for over 70 years in air compressors, electrical motion controls, and aluminum framing systems.
Our team of experts in our Electrical Engineering Department are positioned to support your productivity and efficiency needs with this innovative product and can determine how best to fill your automation needs. Please contact us at 651.452.8452 or visit our website at www.jhfoster.com if you have any questions or would like further information regarding the IAI product line.
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New Compressed Air Piping System Results in Lower Costs and Big Savings
To be cost effective, compressed air needs to be delivered with enough volume, appropriate quality and pressure to properly power the components that require air to operate. Unfortunately, a poorly designed compressed air distribution system can increase energy costs, promote equipment failure, reduce production efficiencies and increase maintenance requirements. That’s the bad news.
The good news is that John Henry Foster has a solution – one that is quick to install, energy efficient and provides long-term savings: Transair® Aluminum and Stainless Steel Piping System.
Transair® Piping System is available for use on compressed air, inert gases and water in various sizes up to 4”. Its innovative technology is effortless to install and easier to modify than either black iron or copper piping. The push to connect and unique clamping systems provide airtight and secure connections with a minimum of assembly tools. Transair® requires no threading, soldering or gluing and once the connection is made it is ready to be pressurized.
Components are reusable and interchangeable, and allow for immediate and easy layout modifications. Alterations of an existing system such as adding a new drop or moving an existing drop, requires very little expense or downtime. The large number of connectors, pipe sizes and piping accessories available within the Transair® Piping Systems make it possible to accommodate even the most complicated of piping designs.
Optimum efficiency of the compressed air distribution system is assured with the airtight, full flow and corrosion resistant properties of the Transair® Piping System. The corrosion resistant characteristic of Transair® allows for consistently clean process media to be delivered to system components. Due to its ability to deliver high quality process media, downstream components such as air valves and cylinders are able to deliver long service life and reliable operation.
Overall savings
Perhaps the most attractive measure of the Transair® piping system is the overall savings it provides. Typically, any additional money spent improving a compressed air piping system will pay for itself many times over. Transair® piping system is no exception, offering sound solutions for all compressed air, liquid and inert gas applications.
For further information on Transair® Piping System or Installation information, please contact us at 800.582.5162 or visit our website at www.jhfoster.com.
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Dual audit air compression and fluid cooling
processes take on operating costs
A large printing company contacted JHF’s engineering department to perform an energy audit of its compressed air and fluid cooling systems. The goal of the audit was to evaluate the existing compressed air and fluid cooling systems to improve performance, reliability and efficiency.
Challenges
Fluid Cooling System:
Reduce demand on the current chiller system. The chiller system was operating at maximum capacity. With the addition of a new printing press a capital expenditure of $300,000.00 for an additional chiller would be required.
Reduce operational costs.
Reduce production dependence on chiller system.
The chiller system cooled virtually all process equipment supporting production and any loss of chiller capacity would result in a partial or complete shutdown of production.
Compressed Air System:
Increase system efficiency.
Stabilize system air pressure level. The current system demand is handled with on-line horsepower resulting in the system going dynamic. This allowed the system pressure to fluctuate at approximately 25 psig.
Reduce operational costs by lowering system pressure levels.
Solutions and Benefits
Fluid Cooling System:
It was determined that the air compressors, air dryers and vacuum pumps could be separated from the chiller system and cooled by a more efficient dry cooling system. The implementation of a dry cooling system reduced operational and maintenance costs, as well as removing 120 tons of chiller demand from the existing chiller system. The reduction of chiller demand resulted in the ability to assume the chiller load needed to operate the new printing press, eliminating $300,000.00 in capital expenditures. The separation of the air compressors and vacuum pumps from the chiller system also reduced the dependence of process equipment on the chiller system.
Compressed Air System:
Data logging of the compressed air system during the audit process revealed that the maximum demand could be handled with current compressor horsepower. It also identified areas of the compressed air system that could be changed to improve system efficiency. One area is the installation of demand regulation and 3,000 gallons of general storage which would allow the reduction in system pressure from 113 psig to 88 psig, as well as eliminate the wide system pressure swings, reduce leakage rate and power costs by 12%. The other area would be the installation of a Centralized Compressor Control System which would automatically maintain compressor horsepower necessary to match demand requirements.
Results
Fluid cooling system:
Savings of over $53K in yearly operational and maintenance costs.
Reduced dependence on chiller system.
Eliminated a $300K capital expenditure.
Immediate payback on the cost of required modifications.
Compressed air system:
Operational and maintenance costs reduced by $40K annually.
Stabilized plant pressure.
Increased reliability of compressed air system.
Return on Investment realized in approximately 1.2 years.
For further information regarding compressed air efficiency auditing, please contact us at 651.452.8452 or visit our website at www.jhfoster.com.
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Compressor Controls
Innovation + Imagination = FLO-TROL
The Department of Energy has estimated that 10% of all electrical energy use in the United States is consumed in the generation of compressed air. This has added significance since 70% of all manufacturing facilities utilize compressed air in some aspect of their manufacturing process. These facts highlight the reason why companies with compressed air systems have a compelling reason to investigate the potential for energy savings.
While there are a number of areas within compressed air or vacuum systems to analyze for energy savings, centralized control systems for multiple compressor installations is one that provides a great opportunity for significant savings. Energy savings of 30% can be realized on multiple compressor systems that currently do not have some form of centralized control system. Energy savings of 10-15% can be realized even with multiple compressors systems utilizing the cascading pressure band system, which is probably the most common control scheme.
Flo-Trol, the industry’s first flow-based centralized compressor control system was developed to address this issue. Flo-Trol eliminates many of the limitations that currently exist with compressor control systems offered by compressor manufacturers. Some of Flo-Trol’s advantages include:
Flo-Trol is non proprietary, using off the shelf components.
Flo-Trol is able to control and monitor all types and manufacturers air compressors and vacuum pumps.
Flo-Trol eliminates the need to designate a lead compressor or establish a cascading pressure band system.
Over the last 15 years and 200 installations, Flo-Trol has evolved into a very powerful and sophisticated control and monitoring system. Our Electro-Pneumatic Control department has applied the expertise and knowledge, gained through experience to develop a complete family of U.L. Listed controllers under the Flo-Trol name. We are utilizing state-of-the-art hardware and software such as Allen Bradley’s MicroLogix and CompactLogix controllers and Panelview touch screens to provide our customers with all the benefits this new technology has to offer. John Henry Foster is also well versed in the integration of Flo-Trol with Building Management Systems. We have extensive experience with Local Area Network technologies, such as Ethernet.
Today Plant Managers are looking to not only control their systems, but are looking for data such as energy, pressure, temperatures, dew point and flow measurements, which Flo-Trol provides. This information has become instrumental in analyzing and benchmarking system performance which is critical in maintaining and documenting the quality and cost of these systems. In many instances they are looking for this data to be incorporated into their own building management systems and formatted for internal and external use. Flo-Trol was designed to be customized to any level of sophistication required. We realize that individual requirements can vary tremendously and we are committed to providing whatever expertise is required.
If you would like further information regarding Flo-Trol and how we can assess your Company’s potential energy saving opportunities, please contact Ron Nordby.
Ronald K. Nordby
Vice President, Sales & Marketing
Direct 651.681.5724
ron.nordby@jhfoster.com
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Consistent use of air delivers new sports technology
JHF becomes engineering tool for Airborne Athletics
In 1997, Doug Campbell and his brother Jeff decided to start their own business. Doug was an avid volleyball player and wanted to develop a product that would provide him with a convenient way to train on his own. Doug asked Jeff for his engineering expertise and together in their garages they designed a volleyball throwing machine called AirCAT. The Campbell brothers knew that other volleyball machines existed but most lacked consistency, caused ball wear, and none were operated with the help of an air system. This was the beginning of Airborne Athletics.
“Our goal when developing the AirCAT was to improve player’s skills by allowing the coach freedom to coach rather than being a ball tosser. With our patented ‘Consistent Air Technology’, the AirCAT will deliver with consistency, up to 1100 volleyballs per hour automatically for all types of drills,” explains Mr. Campbell.
The AirCAT volleyball machine was introduced in 1998 and with JHF’s help has become very popular within the athletics industry.
Over the past 11 years, there has been constant communication between JHF’s account manager, Chris Garding, and Airborne Athletics. Being a small company, Airborne Athletics has utilized the expertise of JHF in the product development area. JHF has been providing Airborne Athletics with several innovative design and product suggestions since the very beginning and continues to assist by streamlining Airborne’s purchasing, staying deeply involved in engineering changes and developing new product ideas.
In 2003, building on the success of AirCAT, Airborne Athletics decided to take advantage of the growing popularity of basketball and create Dr. Dish, a basketball game simulation machine. Currently about 60% of Airborne Athletics sales are in the basketball industry, and 40% are in the volleyball industry. This is mainly due to the larger amount of basketball programs available and the greater popularity for both genders in schools.
Over the years, Airborne Athletics has gone from two employees to twelve and plans to keep expanding in the future.
Through JHF, Airborne Athletics continues to look to Chris Garding for new products and engineering expertise to improve their current designs. The relationship between Chris and Airborne Athletics is truly a mutually beneficial partnership that will continue into the future.
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