Bytes

Gauge Testimonial: Monadnock Paper Mills, Inc.

 
 

PROJECT SITE

Bennington, NH

COMMISSIONED

May 2020

MCS TEAM MEMBERs

Mahlo America, Inc.

Teknikor Automation

Teknikor Contracting

 

Our Involvement


 

Measurement and Control Solutions served as commercial and project coordinator for Teknikor Controls automated oven moisture control, Teknikor Contracting electrical and mechanical installation and Mahlo Gauging measurement and control system.

 
 
 
Start-up performance far exceeded all of our expectations as the line just started right up with technical support from Mahlo and the Teknikor install team!
— Ian Hamilton, Monadnock Coater Manager and Process Engineer
 
 
 
We are achieving our projected ROI for this project in a shorter time frame than we expected.
— Bob McDonald, Monadnock VP of Manufacturing
 


About Coordinated Drive Systems

 
Drive System Enclosure

Drive System Enclosure

Industrial electronic motor controllers are commonly referred to as “drives”.  A drive in its simplest form is a variable speed or torque controller used to power (drive) an electric motor.  Drives are most commonly used in stand-alone variable torque rated applications like controlling a pump or fan speed for energy conservation.  Alternatively, drives can be used as part of a constant torque rated “coordinated drive system”, more commonly referred to as simply a “drive system”.  In drive systems, each drive is interdependent upon another drive for a speed, torque or position reference as part of its unique role in sectional control of the line.  Ultimately, multiple drives in the system are engineered to work together as a team to control a machine or line’s proper operation.

Drive systems are used in most any industry where products are manufactured in a roll or sheet form.  One example is the converting industry, that can utilize various combinations of paper, plastic film or sheet and foil compositions in their final product construction.  Converting industries commonly start with an unwound substrate material and change/convert its properties through intermediate coating, laminating, cooling, stretching, slitting, calendaring or other operations and then wind the final converted product into finished roll(s).  Drive systems are also used in printing lines where a multiple print stations are registered to one another to create the final color image.  Other drive system applications are for the fabrication of juice containers where different plastic polymers are extruded as a molten plastic sheet onto unwound carton stock or for juice boxes where extrusion laminated papers/foils are used to create flexible, yet robust, containers that protect contents from spoilage.  Even sheeting lines used to make pizza cartons or corrugated boxes use drive systems. 

DC Drives

DC Drives

AC Drives Inverter/Vector Duty Drives

AC Drives Inverter/Vector Duty Drives

Drives technology has evolved in power electronics used.  DC Silicon Controlled Rectifiers (SCR) drives that convert AC into DC voltage and feed a constant torque DC input motor were historically used for drive systems.  AC inverter insulated-gate bipolar transistor (IGBT) variable frequency drives were once used for only variable torque applications but now are designed to also perform closed loop vector control. The key attribute of DC motors that made them ideal for web handling systems use was their constant torque operation from zero to base speed.  Vector control inverter drive algorithms allow control of an AC motor to mimic the speed versus torque curves of DC motors.  AC vector control has added benefits of improved speed and torque regulation and near unity power factor over the entire speed range of the AC motor.  AC motors also are lower cost to purchase and less expensive to maintain compared to DC motors.  These key features combine to make AC Vector the dominant technology for new drive system design while DC drives still have a place for some regenerative applications and retrofitting older drive systems without needing to change-out existing motors.   

Specialty servo motors and amplifiers have an important niche for multi-axis control for robotics, machine tool and pick and place markets.  Servos are also incorporated in traditional drive systems where quick and accurate response is required. The specialty nature of servo motors/cabling/feedback and their cost, especially for higher HP requirements, don’t allow servos to economically replace all AC induction motor applications.  However, there are AC inverter drives that can be used to power servo motors, so an end customer can work with one type of drive to power both AC vector and servo motor applications.

Common Bussed AC Vector Drives

Common Bussed AC Vector Drives

Drives core electronics “smarts” have evolved from analog to being almost exclusively digital microprocessor based.  Multi-drive systems offer peer-to-peer deterministic speed reference communications as well as data communications to tell the outside world about the process.  Motor speed feedbacks can be measured in parts per million for a single motor revolution when required for precision applications. Less precise applications, that historically required a motor mounted tachometer, today need no feedback device to mimic speed control performance.  Drives incorporate Proportional-Integral-Derivative (PID) control, analog and digital inputs and outputs, and application specific control macros that eliminate the need for ancillary custom circuit boards of old.  No need to custom design/trouble shoot systems with new control algorithms.  Reduced system implementation risk is achieved by using drives with pre-engineered macros that are already proven for: non-linear acceleration/deceleration ramp rates, loadcell tension trim, dancer position control, draw control, load sharing, speed/position electronic line shaft, center-driven diameter compensated unwinds and winders and position camming.  The internet has come to digital drive systems with browser based diagnostic capabilities that provide for secure remote location access to drive and process information for added support. 

Drive Configuration Software

Drive Configuration Software

Measurement and Control Solutions can assist you in taking the complexity out of drive system specification, supply, commissioning and support.  Our system proposals detail all items and their function so there is no ambiguity in the scope of supply, nor project responsibilities.  All drive systems proposals are for completely engineered and documented control solutions to match the customer project needs.



Retrofitting Eurotherm LINK Drive Systems

 
LINK1_MCS.png

In 1988 SSD (subsequently Eurotherm Drives and now Parker-Hannifin) introduced the LINK drive system product line.  The LINK drive system was a market disruptor.   When LINK was first introduced, most existing drive systems used analog technology.  Custom discrete boards were sold by drive manufactures to perform PID functions, summing and basic math needed for coordinated drive system control.  Speed reference signals between drives were discrete hardwired analog references.  Most operator stations that interfaced to drives consisted of discrete pushbuttons, potentiometers, analog meters.  The machine logic interface from a central PLC to the drive system was hardwired and there was no distributed remote I/O for field process inputs.   LINK completely changed the integrated drive system paradigm.

LINK was a fully digital, distributed coordinated drive system that utilized noise immune fiber optic peer-to-peer 2.7 MBaud communications between its nodes.  LINK nodes originally were DC drives, operator CRTs, analog and digital remote I/O modules, with data interfaces for SCADA systems and PLCs. Later, AC vector drives were added to LINK.  If you needed to add processing power for complex functions you simply added a LINK EEPROM processing within another node.  LINK’s Configuration Editor programming software was object oriented that made it intuitive to use by control engineers and service personnel.  You did not need to be a software programmer to use LINK effectively.  Drive software function block macros were designed to create a control library for loadcell tension trim, dancer position trim, cascade draw, unwind and winders, electronic line shafting and torque regulation applications.  These standard control macros ensured standardization between projects for design, startup preparation and maintenance support.   Key LINK benefits were less costly installations, fasters startups, improved control and improved support.  These system attributes made LINK the likely choice of many OEMs and end users drive systems.

LINK systems were the gold standard of their era but, some 30+ years after inception, all LINK components are no longer fabricated by Parker Hannifin.  This leaves end users that still have operational LINK lines extremely susceptible to failures of difficult to find replacement component parts.

MCS can greatly assist you in the replacement of your existing LINK drives systems.  Depending upon the type and age of your LINK system, sometimes this upgrade can be done in a staged approach, sometimes it is best for a wholesale change-out of the entire drive system.  In either case, we can assist in the supply of needed components, engineering, installation and commissioning services to make the upgrade as straight forward and cost effective as possible to dramatically improve the reliability and support of your operation.



Discontinued LINK Component Parts

 

In 1989 SSD (subsequently Eurotherm Drives and now Parker-Hannifin) introduced the LINK drive system product line.  Below are LINK parts that have been discontinued for sale by Parker.  Please contact us and we will do our best to provide immediate emergency sourcing or cross reference these parts.  All used parts we source are confirmed previously operational when they were taken out of service.  We also provide LINK system upgrades and field support services.

Discontinued LINK Components_MCS.png
CATALOG # LINK Drive Type
570L570L Series - DC LINK Drive
590L590L Series - DC LINK Drive
620L620L Series - AC Vector Drive
591SPL2706AA5 Hp Digital Single-Phase Non-Regen Drive 230v 27a Chassis
591SPL2706BA5 Hp Digital Single-Phase Non-Regen Drive 230v 27a Protective Chassis
590SPL2706AA5 Hp Digital Single-Phase Regen Drive 230v 27a Chassis
590SPL2706BA5 Hp Digital Single-Phase Regen Drive 230v 27a Protective Chassis
955SPL-4N51590SP LINK DRV Digital Non-Regen 230v, 27a, 5hp, Ip20
955SPL-4R51590SP LINK DRV Digital Regen 230v, 27a, 5hp, p20
CATALOG # LINK Three Phase Control Boards and Techboxes
590LD/00/000 590 LINK Control Door Assembly - Old Style
590LDC/00/001 590 LINK Control Door Assembly - New Style
6053-L-00 LINK Techbox for 690+ Frame B Drives
6055-L-00 LINK Techbox for 690+ Frame C-J Drives and all 590+ Drives
CATALOG # LINK I - Modules
L5201-2-02Stand-Alone: LINK Analog I/O Module - 5 Input / 1 Output
L5202-2-01Stand-Alone: LINK Digital I/O Module - 12 Configurable I/O
L5203-2-00Stand-Alone: LINK Serial I/O Module - 2 Channels, RS-232/422
L5207-2-00Stand-Alone: LINK Processor Module - Being Phased Out
L5209-2-01Stand-Alone: LINK Digital Input Module - 12 Digital Inputs (24dc)
L5206-2-00LINK Repeater: Acrylic Fiber to Acrylic Fiber
L5206-2-01LINK Gateway Repeater: Acrylic Fiber to RS232 (DD-25 Pin) For PC Interface
L5206-2-02LINK Repeater (Acrylic/Glass): Converts Acrylic Fiber To Glass Fiber
L5514LINK Modem For LINK 2 Hardware
CATALOG # LINK II - Modules
L5300 LINK Rack: 4-Slot Rack with Power Supply, Processor (RTN LinkCard Required)
L5301 Remote LINK Rack: Remote 4-Slot Rack, Limited Processor (RTN Linkcard Required)
L5392 LINK Station: 6" Color LCD Touchscreen / LinkRack, Processor (RTN LinkCard Required)
L5311 LINK Rack/Station Mounted: Rtn LinkCard (Acrylic) - Fiber-Optic Communication Card
L5312 LINK Rack/StationMounted: Firewire Communication Interface (1 Per Rack Only)
L5321 LINK Rack/Station Mounted: Serial LinkCard - RS 485 Serial Communication Card
L5331 LINK Rack/Station Mounted: Digital LinkCard - 16 Configurable Inputs/Outputs
L5341 LINK Rack/Station Mounted: Analog LinkCard - 8 Inputs, 2 Outputs, Bi-Polar, 13Bit+Sign
L5351 LINK Rack/Station Mounted: DeviceNet LinkCard
L5352 LINK Rack/Station Mounted: Ethernet LinkCard Modbus TCP or A/B Ethernet IP Protocol
L5353 LINK Rack/Station Mounted: Profibus LinkCard
L5354 LINK Rack/Station Mounted: ControlNet LinkCard
L5355 LINK Rack/Station Mounted: Modbus Plus LinkCard
8000/LK/00 LINK RTN Comms for TS8000 - Self Contained Processor/Memory Module


Gauge Testimonial: Haartz Corp.

 
 

PROJECT SITE

Acton, Mass.

COMMISSIONED

2013-2018

MCS TEAM MEMBERs

Mahlo America, Inc.

 

Our Involvement


 

Measurement and Control Solutions is the Mahlo Technical Sales Representative for Haartz - serving as commercial and project facilitator for each of Haartz’s 15+ Mahlo gauging system installations.

 
 
 
Lots of companies sell scanners that could probably meet our needs. The real difference for us was the technical aptitude and service attitude of Mahlo’s people.
— Haartz Senior Process Engineer
 
 


Gauge Testimonial: Impact Plastics, Inc.

 
 

PROJECT SITE

Putnam, Conn.

COMMISSIONED

2012

MCS TEAM MEMBERS

Mahlo America, Inc.

 

Our Involvement


 

Measurement and Control Solutions is the Mahlo Technical Sales Representative for Impact Plastics - serving as commercial and project facilitator for Impact Plastics multiple Mahlo gauging system installations.

 
 
 
From quality to delivery times, everything Mahlo commits to do, they do. Though they are not always the least expensive alternative out there, they are the best value. We found the Mahlo sales team to be extremely market savvy about plastics and how our business works.
— Impact Plastics Technical Director