PLC Control and Color Touch Screen Added to Conair EP2 Portable Chillers for Simpler Operation, Monitoring

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The newest EP2 Series portable chillers from Conair now include PLC control and a 7-inch color touch screen HMI as standard equipment. Theses chillers – available with air-cooled, water-cooled, or remote air-cooled condensers – use a new sloped top electrical panel that places the large touch screen on the front of the unit at an ideal height and angle for easy viewing and operation.

New capabilities made possible by the EP2 chiller PLC control system include digital pump pressure display, compressor/pump/fan running hours, and performance trend charts for key operating parameters such as process fluid temperatures. The new controls also include Modbus RTU communications as standard to allow easy integration of the chillers with injection-molding machine controls or plant-wide process monitoring systems. In addition, the new control system is fully compatible with the SmartServices™ platform — Conair’s cloud-based Industry 4.0 solution for auxiliary equipment monitoring, management, and analysis.

An optional, premium EP2 control system provides an expanded PLC system that provides additional communications capabilities like:

  • Modbus TCP/IP
  • BACnet MS/TP
  • BACnet/IP
  • LonWorks
  • OPC/UA

The Conair EP2 chillers include many industry-leading design features. They are among the most energy-efficient chillers on the market, incorporating standard high-efficiency stainless steel brazed plate evaporators, stainless steel pumps, and Scroll compressors. For maximum flexibility and efficiencies under varying part-load conditions, the EP2 chillers offer variable-speed Scroll compressors technology options on 5-, 10-, 15-, 20-, and 30-ton water-cooled and air-cooled chillers. By automatically adjusting the compressor speed, the optional variable-speed chillers work only as hard as necessary to provide optimum performance with significantly reduced power use.

EP2 air-cooled units are equipped with generously sized micro-channel condensers designed for industrial environments. Water-cooled units use cleanable shell-and-tube condensers and include a condenser-water regulating valve to provide constant head pressure. Remote condenser units are available to direct all heat outside the building.

All EP2 chillers meet severe-duty industrial cooling needs and provide additional resistance to harsh fluid conditions and operating environments. They feature stainless-steel pumps, stainless-steel evaporators, and a process-fluid circuit with corrosion-resistant materials to prevent rust and ensure clean, dependable operation for many years.

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New Coil Strapping System for Conair ATC Series Coilers Protects Extruded Tube and Simplifies Handling

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A new coil strapping system, now introduced by Conair for its ATC Series tube coilers, automatically and securely straps finished coils of small-diameter extruded tubing. Handling coils up to 24 in (61 cm) in diameter, the system prevents tube damage or unraveling and making the coils far easier to grasp, handle and move. It uses roll-fed PP and PET strapping and is FDA compliant for medical-tube applications.

The optional system comes in two pieces: The first piece is a separate steel stand that holds two large strapping rolls, which is positioned approximately three feet from the end of the ATC Coiler.  The second piece is the automatic strapping head unit, which is mounted on a sturdy steel base that attaches directly to the base of the ATC Series coiler on the coil-outlet side. This consists of a strap guide roller, an alignment arm, and a combination strap cutter/welder head that affixes, cuts, and welds the strap material onto the coil. The strapping system control integrates directly with the ATC coiler control via a secure Ethernet communications connection.

In operation, the strapping system is actuated by a signal from the ATC coiler that a full coil of extruded tubing has moved into position. The alignment arm of the strapping system extends to check the coil position, followed by the cutter/welder head. The head attaches one end of the strap to the tube coil, which is then rotated until the wrap is completed. Then, the head cuts the strap material and ultrasonically welds the finished coil strap before retracting. The system can apply one, two, or four straps to a tube coil, based on user selection. (Note: Ultrasonic welding is a vibratory joining process that does not heat or distort finished tubing.)

The strapping system is fed by two 12,700 ft rolls of PE or PET strapping material, each of which contains enough to wrap up to 4,400 coils with one strap or 1,100 coils with four straps. Should strapping material run out, the ATC Coiler’s automatic in-line accumulator ensures that tubing production continues while new strapping rolls are loaded. No line shutdown is required.

The strapping system is available as a factory option for new ATC coilers or as a retrofit for existing units. Conair introduced the dual-spindle automatic cut-and-transfer ATC Series coiler in 2013 to provide tensionless, high-speed winding of small-diameter flexible tubing in sizes from 0.040 inch (1 mm) to 0.5 inch (12.7 mm) on coils up to 24 inches (61 cm) in diameter. The coiler fully automates transfer of tube winding when a coil is full, eliminating the need for operator involvement or process disruption.

Additional ATC Coiler features, including automatic unloading, conveying, and wrapping of strapped coils, are planned by Conair for future release.

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Sepro Group Scaling Back Fakuma Plans

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Sepro Group, La Roche sur Yon, France, has announced that it plans to substantially curtail its activities at the Fakuma plastics fair, should it be held as scheduled October 13 to 17, 2020. Sepro has recently made the decision not to display any robot solutions or automation systems and will consequently reduce staff attendance on the fair.

“Even if Sepro operates today at a normal level, the global Covid 19 pandemic continues to create a global atmosphere of uncertainty. We think that the potential to endanger the health of our employees and customers remain. The global context can also limit opportunities for Sepro’s customers for travel and for face-to-face interactions,” explains Xavier Lucas, Chief Sales Officer of Sepro Group. “Already we have seen that many major industry players have announced they will limit their participation at Fakuma and we expect attendance, especially from outside Germany, will be substantially reduced.”

“Our motto these days is ‘safety first’,” Lucas continues. “As the lockdown in France has softened, we have returned to full production while implementing strict hygiene practices, including the mandatory wearing of masks.”

As an alternative, the company is looking into offering injection molders the opportunity to learn about recent developments in its globally recognized range of 3, 5- and 6-axis robots and automation systems by participating in e-meetings, webinars and other socially distanced activities that have already been successful these past few months.

Information about on-line meetings and other ways that customers and stakeholders can engage Sepro sales and technical experts will be posted on the company website (www.sepro-group.com ) in the near future.

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New Sensor Kits Enable Non-Computer Controlled Auxiliaries to Connect to Conair SmartServices™

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New SmartServices™ sensor kits from Conair now make it possible to connect operating, performance, and alarm data from non-computer controlled auxiliary equipment to the SmartServices platform, Conair’s cloud-based Industry 4.0 solution for auxiliary equipment monitoring, management, and analysis.

The user-installed sensor kits are now available for use not only with Conair auxiliaries, but with a range of competitive auxiliary equipment including:

  • Temperature control units (TCU),
  • Positive-displacement vacuum-conveying pumps
  • Single- and dual-stage regenerative vacuum pumpsd
  • Portable loading/conveying systems
  • Desiccant dryers

These kits were created by Conair so auxiliary equipment that does not utilize computerized controls could be equipped with digital sensors and communications capabilities and linked to the cloud-based SmartServices platform with the same ease as newer equipment. Each user-installed kit contains common digital hardware, plus fluid-system fittings, sensors, and wiring specific to the equipment type. Digital hardware includes a SmartServices expansion box that receives sensor inputs via wiring and a SmartServices hub that securely exchanges data, via the facility’s local network, with the cloud-based analytics platform.

After installation, the new sensors monitor the performance and operating/maintenance status of each auxiliary, collecting data and operating information specific to the auxiliary type.  For example, sensors on the TCU can monitor coolant pressure, temperature, and flow rates, while those on vacuum pumps and conveying systems will monitor air flows and speeds, vacuum levels, and the like. At the same time, sensors will also monitor for operating alarms, track maintenance alerts, and observe the vibration and temperature status of motors for anomalies that could signal possible problems.

“Adding a SmartServices sensor kit to an auxiliary unit that doesn’t have a computerized control dramatically simplifies monitoring and saves maintenance,” explains Alan Landers, a Conair Product Manager. “Consider maintenance of a vacuum pump, for example. With SmartServices, you can establish a norm for pump vibration, then build high and low limits around that norm. The system will then track vibration automatically, offering regular reports or sending a text or e-mail alert to designated personnel if the level begins moving out of limits. Timely data like this can help save preventive maintenance by clearly indicating when maintenance is required. The alternative is to manually observe, measure, then guesstimate when preventive maintenance is needed. Or, you could wait for a breakdown.”

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Le groupe Sepro propose une formation robotique en ligne

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Alors que la pandémie mondiale continue de limiter les opportunités de voyages et d’interactions, Sepro Group, basé à la La Roche sur Yon, un important fabricant de robots pour le moulage par injection de plastique, a commencé à proposer une gamme de cours de formation gratuits à ses clients, en utilisant des systèmes de « classes virtuelles ».

Les cours sont adaptés aux niveaux des participants, depuis les débutant jusqu’aux utilisateurs de robots les plus expérimentés, qui souhaitent revoir ou élargir leurs connaissances. 4 cours sont destinés aux débutants et présentent le fonctionnement de base du robot, la création et la modification du déchargement simple de pièces, le diagnostic des problèmes courants. Pour les niveaux plus avancés, 9 cours permettent d’aborder en profondeur des sujets comme la programmation complexe, l’optimisation des mouvements du robot, la gestion des libellés ou des retours origines, la réalisation d’un rangement régulier et la connaissance des organigrammes

Chaque cours dure environ une heure et est planifié périodiquement selon la disponibilité des instructeurs et des participants. Les cours sont donnés en français. Les personnes intéressées peuvent s’inscrire sur : https://bit.ly/37hjY1v .

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Sepro America Offering ‘Virtual’ Robot Training

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As the global pandemic continues to limit opportunities for travel and face-to-face interactions, Sepro America, a leading manufacturer of robots for plastics injection molding located in Warrendale, PA, has begun offering free training webinars to its customers using online meeting systems.

Five webinars are offered, covering:

  • Basic use of the control pendant
  • Simple pick and place programming
  • Editing a program
  • Work zones and the IMM interface
  • Optimizing the robot cycle.

The webinars, which can be conducted in English, Spanish or French, range in length from 1 to 1.5 hours. They are open to current and new customers using robots with Visual 2 or Visual 3 controls. Participants need a PC with microphone, speakers and webcam and must have internet access with Google Chrome browser. Webinars are limited to 6 students and will be scheduled periodically depending on the availability of instructors and participants.

For more information or to register, visit https://bit.ly/2MMh6QI.

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Conair TrueRate® System Automatically Tracks Changes in Resin Inventories, Simplifies Resin Dispensing

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The new TrueRate® intelligent inventory tracking system from Conair automatically tracks changes in the inventories of up to 500 different user-specified resins or flowable powders in a processing plant. Developed as an alternative to the use of single-component batch blenders for resin inventory measurement, the new TrueRate system utilizes highly accurate gravimetric measurement.

The TrueRate system is available in two sizes, consisting of an 8-inch weighing ring equipped with two load cells, or a 12-inch ring equipped with three. Both configurations connect to a separate electrical control panel containing a PLC. The weighing ring is mounted below a material loader or receiver but above a container or bin, where it uses resin information provided by the user to precisely calculate the change in weight of the loader/receiver before it discharges the material through the ring and into the container.

The system can operate in two modes:

  • In default or “totalizer” mode, the TrueRate system continuously and automatically measures the total resin flow through the receiver to a bin or container below. While doing so, it can display the weight for each load cycle, tabulate a running total (in lbs or kgs), and calculate the total throughput rate for a period of time (lb/hr or kg/hr).
  • In job (active) mode, the system adds an optional discharge valve to the weighing ring. This enables the TrueRate system to meter and dose a specified amount of material from the receiver mounted above into a bin or vessel located below. The system senses the amount of material accumulating in the vessel and uses a pneumatic cylinder to close the discharge valve as soon as the correct amount has been dispensed. The cylinder reopens the valve and the receiver cycle resumes when the TrueRate is ready to measure the next batch.

The system can be programmed and controlled in three ways: with an optional 4.3-inch touchscreen built into the system’s electrical control panel, with a Windows-based PC running a virtual network client viewer connected via Ethernet cable to the panel, or with both. Mode selection and programming is very simple. So too is connecting the TrueRate system to SmartServices, Conair’s cloud-based Industry 4.0 solution for auxiliary equipment monitoring, management, and analysis. All that is needed is a SmartServices hub and an Ethernet cable connected to the TrueRate system’s electrical control panel.

“TrueRate is a new and elegant way to track and regulate the receipt, flow, and usage of valuable resins and flowable powders throughout a plastics processing facility,” says Alan Landers, Conair’s Product Manager for Blending. “In totalizer mode, the system can, for example, accurately measure and validate the quantity of resin conveyed from a process bin that was loaded from a silo. Or, it can track the dispensing of that resin to the plant, leaving the processor with an accurate, running inventory,” he explains.

“In job mode, an operator can program the system to measure out a precise amount of material into a bin. For example, you can unload 400 pounds of material into a Gaylord, 25 pounds into a mixer, or 65 pounds into a container that is used to manually fill a rotational mold. Just put the container in place beneath the TrueRate system, and input the desired weight on the control interface. The system will dispense exactly the right amount and stop, so there’s no need for manual weighing and no guesswork or error in tracking the total throughput.”

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Sepro, Labotek Agree on India Distribution Pact

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Sepro Group, La Roche sur Yon, France, has signed a distribution contract under which Labotek A/S, Frederikssund, Denmark, will sell Sepro robots in India. The agreement is expected to strongly develop the commercial presence of Sepro Group in India, while expanding Labotek’s portfolio of auxiliary equipment for plastics processing.

The contract signing, which took place remotely due to the current Covid-19 confinement situation, was completed on 14th of April 2020.

Robots will be sold under the Sepro brand name by Labotek Plastics Auxiliaries India Pvt. Ltd., the local sister concern of Labotek A/S headquartered in Pune, Maharashtra. Commissioning and service of Sepro robots in India will be handled by Labotek technicians who will be trained at the Sepro factory in France. Labotek maintains a showroom in Pune where robots can be demonstrated and where user training will take place.

“Sepro is serious about growing our business in Asia as part of our strategy to become the world leader in robots for injection molding,” says Xavier Lucas, Chief Sales Officer. “Until now, Sepro has been mainly present on the Indian subcontinent through its large, multinational customers but the distribution agreement with Labotek will give our products much broader exposure.

Yann Laurent, who is responsible for overseas markets, including India, added “We see a lot of opportunity for growth in India, The market for injection-molding machines has grown by more than 17% in the last three years, with the primary markets being automotive, where Sepro has a particularly strong reputation, and also in infrastructure, household goods, agro-food, health and packaging. We expect the demand for automation to increase as local companies strive to increase in production rates and raise the level of quality demanded by increasingly affluent customers.”

For Labotek, the agreement creates an opportunity to offer a more complete package of auxiliary equipment to injection molders, which already includes plastic material storage and handling equipment, dryers, dosing and mixing systems, chillers and mold-temperature control units. The Indian subsidiary maintains sales offices in most major cities and serves customers throughout the country. Labotek India was founded in 2014.

“Labotek India has long been searching for an industrial automation company in order to offer our customers a complete package of auxiliary equipment, for the benefit of time savings and better utilization of their capacity. After researching the market, the choice fell at the Sepro Group due to their outstanding, flexible and innovative solutions and not least: Their 40 years of experience in the market” says Managing Director Jasveer Singh Grewal, Labotek India. ”I look very much forward to our cooperation and to introduce the Sepro robots to our customers”.

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Hybrid Vacuum Pump Combines Quiet Operation with Long-Distance Conveying Power, Energy Savings

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The multi-stage regenerative impeller design of the new Conair HRG Series vacuum pumps is the key to developing deep vacuum power for conveying plastic pellets over long distances, while keeping noise levels comfortably low. An optional variable-frequency drive is available to save energy and makes the new pump ideal for use in Conair Wave Conveying™ systems.

“Until now, processors have had to accept various trade-offs when selecting a central vacuum pump,” explains Rich Shaffer, VP Product Development. “Single-stage regenerative pumps are quiet and inexpensive but limited to short- and middle-distance conveying applications. Positive displacement pumps have been the workhorses of conveying — powerful and reliable but the low cost versions don’t handle long distances and are noisy. Long-distance pumps (LDP) are special positive displacement pumps that convey over long distances, at high rates, with low noise levels, but they can be quite expensive. Conair’s new hybrid regenerative pumps offers many of the best features of previous designs at a price that is about 30% lower than a comparable LDP unit.”

The secret is in the three-stage pump design, with regenerative impellers that smoothly cut, capture and compress the air with minimal draft or vibration. Like twin turbo chargers on automobile engines, the vacuum becomes deeper and more powerful at each stage allowing the HRG Series pumps to convey material up to 1000 linear feet. Vacuum levels below 12 inches of mercury are possible.

Hybrid regenerative technology makes the HRG pumps extremely quiet. Operating at 60 Hz, the average sound level ranges between 74 and 77 dBA, a comfortable range that does not require hearing protection.

VARIABLE-SPEED OPTION

Equipping the HRG pumps with a variable-speed drive (VFD) motor makes them ideal for use with Conair’s patented Wave Conveying System, which previously required a more costly LDP pump.

Instead of moving plastic materials at 5000 ft/min or more, creating dust, angel hair and equipment wear, Wave Conveying uses controlled speed conveying (300 to 2800 ft/min) to move material in compact slugs, waves or streams.

The VFD also saves energy by allowing the pump to operate using only the amount of power necessary to achieve the desired material speed and throughput. In fact, an HRG pump, running in a Wave Conveying System, was shown to save as much as 50% on energy compared to similarly sized positive-displacement pump at equivalent throughput rates. Even in standard (non-Wave) operation, savings of up to 25% were observed. In addition to energy savings, the VFD option extends pump life by only running at the capacity necessary.

The pumps are available in three different sizes: the HRG-10 has an 11.5-hp motor and is intended for 2.5-inch conveying lines; the HRG-15 (16.9 hp) and the HRG- 30 (42.9 hp) service up to 3-inch line sizes.

The new HRG pumps are also virtually maintenance free. The direct-drive system eliminates drive belts that wear and require constant adjustment. No lubrication is required.

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Portable Multi-Hopper Drying System from Conair Provides Economical, Flexible Solution to Central Drying

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Simple enough for the most basic applications or upgradable to a fully featured drying solution, the new Conair Multi-Hopper Cart (MHC) delivers the ultimate in value, portability, flexibility and productivity.

The MHC features up to four dependable Conair CH Series mass-flow hoppers mounted on a lightweight, yet durable, caster-mounted push cart. Even with the largest hoppers mounted, the cart is only 35 inches deep saving valuable floor space and making it easy to maneuver down narrow aisle ways and through doorways. Material can be dried off-line and then wheeled where it is needed or stationed remotely to supply material to multiple machines at once.

There are two basic configurations available: The simplest has hoppers only with an insulated integral welded manifold system for supply and return of dehumidified air from a central dryer which, for smaller applications, can also heat the material. For larger throughput applications or applications requiring higher temperatures, supported by a Conair D Series Carousel Plus dryer with the DC-C Premium control package, the cart can be wired for power and individual heaters added to each hopper. This allows many convenient features, including the ability to dry at different temperatures in each hopper, Temperature Setback to prevent over drying, as well as Dewpoint Monitoring and Dewpoint Control. It can also be integrated into Conair’s SmartServices central monitoring and control platform, providing real-time alarm displays, a key performance indicator (KPI) dashboard, machine view with real-time readouts of setpoint and actual temperatures as well as condition indicator lights. The system can also display trend lines for key measurements in real-time.

Seven different hopper sizes are available ranging from the smallest, which has a 0.5-cu.-ft volume and a nominal capacity of 18 lb., to the largest with 6 cu. ft. of volume and 201 lb capacity. Carts are built in two sizes: a large version that can accommodate up to four hoppers (depending on hopper size) and the smaller cart can be mounted with up to three hoppers (again, depending on size). A slide-gate discharge port prevents material leakage but facilitates easy hopper draining.

Available in carbon or stainless steel, all hoppers are fully insulated from top to bottom in order to preserve heat and save energy. All are designed for easy cleaning with a large clean-out door (with sight glass) and a removable air-diffuser cone. The mass-flow hopper design ensures that all materials is evenly exposed to dry air and heat. Funnel flow and material hang ups are eliminated for superior drying. Each hopper is equipped with an isolation valve so that it can be taken off-line without disrupting operation of the other drying hoppers.

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