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Product demonstrations and technical presentations from principals impress large crowd

On June 25, 2015, Exact Metrology held a tech event at the Horseshoe Casino in Hammond, Indiana for local companies, to demonstrate its new 3D scanning equipment. Cleverly titled “Don’t Gamble with Your 3D Scanning,” the event was attended by local area industries, including steel, oil & gas and power gen “players”.

Exact Metrology Tech Event 2

Hosted by Dean Solberg, Exact Metrology co-president, the day included presentations by Leica GeoSystems and Hexagon Metrology, business partners of Exact, plus product demonstrations featuring the newest technology in 3D scanners. Several scanners were demonstrated and available for hands-on use by the attendees, including the Romer Absolute Arm, the Leica Absolute Tracker and the Leica T-Scan.

Attendees were impressed by the ease of use, speed and accuracy of the demonstrated models, with scanning capabilities of over one million points per second. Bruce Bowditch of Leica described them as “a survey total station on steroids.”

Exact Metrology Tech Event - Romer Arm

Attendees could be heard discussing their excitement and one steel industry engineer commented, “That specific type of scanning can be applied to a lot of what we do. Pumps need to be scanned to assure proper fit. The Romer Absolute Arm is definitely quicker and more accurate. Our current process is so cumbersome; there’s just no comparison.” After trying out the Leica Absolute Tracker, one attendee in the oil industry stated, “Speed and accuracy is what we’re after. We have a model that does about half of what this can do. A lot less field time…hoping to get one. We’re excited.”

Exact Metrology offers a complete line of portable scanning and measurement technologies as well as contract measurement for 3D laser scanning services, reverse engineering services, non-contact inspection, metrology services, 3D digitizing and training.

See all the photos from the event on Facebook, here.

For more information on any of the systems discussed or to arrange a demonstration, please contact:

Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600

Exact Metrology, with facilities in Cincinnati and Milwaukee and affiliated offices throughout the Midwest, is a comprehensive metrology services provider, offering customers 3D scanning, reverse engineering, quality inspection, product development and 2D drawings.   The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements. 

Sequenced changeover of all process control parameters yields successful implementation of system upgrade with minimal downtime

Lisle, Illinois – Synergy Systems, Inc., a consulting engineering firm and Recognized System Integrator for Rockwell Automation, today announced the completion of a successful upgrade on the main blast furnace and stove control system at a major Midwest steel producer. Unique to this 18-month project was the absence of production downtime experienced by the client, during the transition from legacy control system elements to a Rockwell Automation ControlLogix and Wonderware-based HMI platform. Synergy Systems termed its protocol on this project the System Transition Execution Plan (STEP). During the implementation of STEP, the client experienced no interruption in overall blast furnace or stove control system operations, as it transitioned from an older DCS (distributed control system) to the new system, which was entirely designed and installed by Synergy Systems engineers, working onsite at the steel mill with client personnel.

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At the heart of the concept, according to Synergy Systems VP Marc L. Hunter, “We developed our strategy around a core principle that targeted zero downtime during the changeover. Essentially, we created a building block operation, in which each control input/output on the old system was upgraded with parallel monitoring of performance values and system readouts. Only when each new component was functioning properly and the signals were inline with the existing monitored values did we execute the changeover of the control strategies, which was then integrated loop-by-loop into the new process LAN.” Utilizing this strategy, Synergy Systems enabled the client to maintain full production at the mill, throughout the entire project. Client engineering confirmed their complete satisfaction with the performance on this major project.

The STEP upgrades included all the following procedures: replacement of legacy PLC hardware with AB ControlLogix, replacement of DCS/PLC interface, movement of I/O from DCS to ControlLogix, deployment of Wonderware HMI, movement of control from DCS to ControlLogix, Wonderware historian integration and finally Level 2 interface via Wonderware HMI. Essentially, the control scheme for each system element was installed in parallel to the legacy control, then connected to the new ControlLogix processor and monitored on a channel of the client’s overall process control LAN for comparison to the older output.

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Using this STEP approach, minimal process impact occurred and there was a significant savings realized for the client, both in operational expense and total project cost. As Hunter explains, “This project, because it happened in steps, so to speak, could be costed as a maintenance, not a capital, expense. The major capital expenditure diminished, owing to our strategy of loop-by-loop cutover and a gradual evolution of the graphical user interface, plus a progressive integration with the plant historian software. Collateral benefits to the client included a gradual weaning away from the legacy system, which allowed our team to thoroughly familiarize our client’s operational and maintenance personnel with the new hardware and software, as the changeover progressed.”

The determination to upgrade this system had resulted from numerous factors, according to the client. The I/O had become obsolete and the legacy system was UNIX-based, so many of the client’s current engineering staff onsite were not familiar with it. However, because a need existed to retain overall control strategies and functional client knowledge of system operations, Synergy Systems devised this STEP protocol to make the transition more gradual and self-teaching.

According to the client’s plant production & technologies manager on the project, “The blast furnace and stove control systems needed to be upgraded from a legacy DCS (Distributed Control System) to a Rockwell Automation PLC (Programmable Logic Controller) platform, with Schneider Electric Software Wonderware human machine interface and historian, along with statistical reporting mechanisms. Synergy Systems was challenged with cost-effective project deliverables requiring a proven transition plan, zero production outages, minimal risk implementation with no impact to production or product quality, improved technology with future expansion capabilities, improved process controls, enhanced operator interface, significant improvements to system reliability and stringent budgetary guidelines. This project required verification and movement of nearly 2000 I/O points, installation of new workstations, network communication upgrades, development of over 60 HMI screens with built-in diagnostics and alarms, extensive PLC programming, system functional documentation development and drawing approval, historian upgrades and onsite training. Finally, total project implementation and completion were required within a two-year period.”

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He continued, “Synergy delivered beyond our expectations on every challenge presented. The innovative approach, level of engineering delivered and tools selected ensured a successful transition without impact to our production or product quality. Synergy’s professional manner plus their willingness to listen and offer solutions always made it easy for our Operations and Automation team personnel to work with them. The upgraded control systems have been in operation for nearly a year now, with high levels of reliability and efficient operations realized. Synergy proved to be an extremely cost-effective yet resourceful company, with a focus on the future of our mill control requirements. Our plant now has the technology to further enhance the automation strategies and drive flexibility and productivity that were not available with the legacy automation platform.”

For more information on this application, please contact:

Synergy Systems, Inc.
1982 Ohio Street
Lisle, IL 60532 USA
Phone: 630.724.1960
Marc L. Hunter, VP

PLC, drive and motion-based functionality and architecture

There are several architectural strategies that can be considered for web handling drive system controls. Current industrial control platforms permit the web handling controls to be implemented in either a Programmable Logic Controller (PLC) (typically the same as the machine control), directly in the drive system, or through a motion controller.

PLC-based web control has long been a traditional choice for machine builders for a number of reasons. The PLC provides a single platform for both automation and drive control with a centralized control structure. PLC-based systems offer a suitable level of usability, however, they can be limited in high-end performance capability and in their options for process-level programming.

Drive-based control typically offers distributed control architecture, peer-to-peer networks and an increased level of performance due to faster processing times. Graphical engineering tools are common for drive-based systems and are a preferred programming environment due to their ability to visualize and document the web control processes.

Motion controllers offer the highest level of performance and functional flexibility. Their inherent capability of providing position data can help increase web handling performance on several fronts. Motion controllers also permit the line integration of axis motion functionality such as positioning, electronic gearing and cam functionality in the common web controller. They are not limited by memory constraints and typically utilize the full range of programming languages.
This paper will review the merits of these three control architecture options in detail under the criteria of usability, functionality and performance, and also touch on the related topics of drive safety and remote diagnostics.

Overview / criteria

Usability defines the control system’s ease of use in the areas of engineering, commissioning, and maintenance. The following points apply to each of the control system options, PLC,
drive-based and motion control.
A common engineering tool utilizing a common database for machine and drive control is
recommended. Individual engineering tools for each controller (PLC, drives, etc.) should be
avoided. The engineering and programming connection to the system should be though a
single point with efficient routing to each drive or controller location in the system.
Additionally multi-user editing is an important feature for complex and large projects.
The programming language used for the web control should be considered for usability. The
programming language should be sufficient for implementing the critical tasks, easy-to-use
and understand. We find that the ideal programming language for the web control or drive
processes to be graphical function chart. Web handling control is a process and a graphical
programming editor offers the most efficient method to develop, visualize, support the
process and produce the system documentation.
The engineering platform should offer efficient and common diagnostic and troubleshooting
tools that include integrated online monitoring capability, time and frequency-based trace tools
and a drive axis commissioning control panel.
Control and drive hardware platforms that store programs on removable media are ideal.
The Compact Flash cards permit the easy swapping of hardware without the requirement
of program or parameter file downloading and retain current machine settings.

Download the brochure/PDF HERE.

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to:

Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit

A. Roger Guillemette, 81, of Narragansett, Rhode Island, died Friday, June 5th. Born in Providence, RI, he was the son of the late Joseph Arthur and Yvonne (Roy) Guillemette, both Canadian born.

Roger graduated from Coventry High School and served as a machinist in the US Army, 600th Engineering Aviation Maintenance Co. He was stationed in Family, Friends and Industry Mourn Loss Of Roger GuillemetteKorea and Mineral Wells, Texas.

He and his wife Claudette raised their four children in the village of Phenix, RI where they hosted many a sing-a-long around their piano. Among the many other things in life he thoroughly enjoyed, Roger loved playing Skip-Bo with his family and friends.

An entrepreneur, he established several businesses throughout his lifetime, creating long-term steady employment opportunities for many people. Guill Tool & Engineering Company was established in 1962 and remains in operation today, as a global leader in extrusion tooling. Until recently, Roger was very active as the CEO and always an inspiration to his employees, as his passion for engineering quality products and customer solutions never waned. He had been a fierce advocate for U.S. manufacturing on local and national levels; participating in many organizations as well as advocating for STEM education in the state of Rhode Island.

Professionally, Roger was SE MA Chapter past President of NTMA-RI and a longtime member of the Wire Association and Society of Plastic Engineers. Guill Tool, as a result of Roger’s leadership and drive, remains active in the Rhode Island Manufacturers Association, National Association of Manufacturers, National Institute of Manufacturing Skills, the Rhode Island STEM Center and other local endeavors for the betterment of the industry and community.

Memorial contributions may be made to The Johnny Cake Center of Peace Dale, 1231 Kingstown Rd., Peace Dale, RI 02879. Visit for online condolences.

For more information, please contact:
Rich Guillemette
Guill Tool & Engineering
10 Pike Street
West Warwick, RI 02893
Phone: 401-828-7600

No. 901 is a 1200ºF (649ºC), electrically-heated walk-in oven from Grieve, currently used for heat treating at the customer’s facility.  Workspace dimensions of this oven measure 48” W x 60” D x 72” H.  120 kW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 12,500 CFM, 10-HP recirculating blower provides horizontal airflow to the workload. 901 electrically-heated walk-in oven from Grieve, currently used for heat treating | Grieve Corp

This Grieve high-temp walk-in oven features 10” thick insulated walls, comprising 2” of 1900ºF block and 8” of 10 lb/cf density rockwool; inner and outer door gaskets with the inner gasket sealing directly against the door plug, while the outer gasket seals against the front face of the oven; doors equipped with expansion joints on the inner face to guarantee uniform sealing at all temperatures; aluminized steel exterior; Type 304, 2B finish stainless steel interior; 7” insulated floor with truck wheel guide tracks and a 2000 lb. capacity stainless steel shelf oven truck with shelf supports on 6” centers.

Controls on No. 901 include a 325 CFM stainless steel powered forced exhauster with motorized dampers for cooling, manual reset excess temperature controller with separate contactors, recirculating airflow safety switch, 10” diameter circular chart recorder, digital indicating and programming temperature controller and an SCR power controller.

For more information, please contact:

500 Hart Road
Round Lake, IL  60073-2898
Phone:  (847) 546-8225
Fax:  (847) 546-9210
Attention:  Frank Calabrese, VP