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Product demonstrations and technical presentations from principals impress large crowd

On May 14, 2015, Exact Metrology held an open house at its Brookfield, Wisconsin facility and the event was attended by over 125 local area companies, comprising quality assessment, design engineering and management personnel from many of the leading manufacturers in the region. Hosted by company co-president Dean Solberg, the day included ongoing product demonstrations of the various metrology equipment brands offered for sale, lease and rental by Exact, as well as the testing procedures provided as a service by this unique metrology supplier.

IMG_20150514_103401

Services on display at the Brookfield open house included 3D scanning, reverse engineering, quality inspection, instant scan-to-CAD comparison and a full suite of PolyWorks software solutions. Equipment shown at the event included Aicon 3D systems, Breuckmann 3D scanners, Leica Geosystems, Romer and Hexagon brands of scanning devices and related hardware, all of which were available for hands-on use by event attendees.

A new product of great interest to attendees was the Breuckmann steroScan, a flexible scanning system for precise 3D digitization and metrology. Applications for this product include quality inspection, reverse engineering, rapid prototyping, deformation analysis and digital documentation. Because of the adjustable focal length of the scanner, products from small components up to large sections of automotive and aircraft parts can be scanned with high resolution and accuracy. Breuckmann is a company of Aicon 3D Systems.

During the event, technical presentations were made by Aicon, PolyWorks by InnovMetric and Exact personnel on the newest advancements in 3D scanning technologies. The presentations were given to a “full house” of interested attendees.

As Dean Solberg commented, “We seek to find the right combination of equipment and services to suit the applications and challenges presented by our customers. In some cases, it’s a matter of matching the right standard equipment to the job, while at other times we bring custom solutions and services to our customers, whether they buy, lease, rent or simply use our services to achieve the desired results on projects.” Solberg credited his staff of metrology engineers, technicians and customer service personnel for their hard work, dedication and adaptability in seeking their correct solution to all customer challenges.

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Exact Metrology is an ISO 9001:2008 Certified Company.

For more information on this new system, please contact:

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

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. 

Siemens announced today the release of its new single-axis Sinamics V20 AC drive, frame size E, with both Low Overload (LO) and High Overload (HO) ratings.  The V20 family features easy setup and operation with excellent cost and energy efficiency.  With a power rating ranging from 1/6–40hp at 480V AC, Sinamics V20 drives are available in five frame sizes and are ideal for material handling, conveyor, pump, fan and compressor applications.Sinamics V20 | Siemens

This compact drive can be connected and installed the conventional wall-mounting method or, optionally, mounted with heat sinks pushed through the enclosure wall.  Since no additional modules or add-on options are required for operation, installation time is minimized.

The integrated Basic Operator Panel (BOP) enables trouble-free commissioning and operation on-site.  Besides the universal serial interfaces that allow for easy connection to Simatic programmable logic controllers (PLCs), a Modbus interface is also included for communication with third-party controls.  Pre-built connection and application macros are used for facilitating application-specific settings.  For units with power ratings higher than 10hp, a braking resistor can be connected directly to the integrated braking chopper.

Operating the Sinamics V20 drive is just as easy as commissioning.  Parameters that have been optimized for one application can easily be transferred to other drive units using SD cards via the Basic Operator Panel or the battery-operated Parameter Loader.  The built-in display has the ability to list only those parameters changed from the factory default values rather than having to scroll through all of them.

Tailored inter-connectivity and application macros (i.e. for pumps, fans and compressors) provide the correct settings for the particular application.  The Keep Running Mode automatically adapts the V20 drive to the power supply to achieve higher availability when operated on unstable networks.  In this mode, line fluctuations are compensated for internally and error messages are acknowledged autonomously.  Thanks to enhanced cooling and coated PCBs and electronic components, the Sinamics V20 is extremely rugged, making the unit reliable even in harsh environments.

The demand-driven regulation of the motor speed also provides increased energy savings even for many applications. The Sinamics V20 is equipped with an energy-optimized control mode (ECO-mode) for increased energy efficiency.  ECO-mode automatically adapts the magnetic flux in the motor to the optimum operating point.  The DC link coupling enables efficient energy utilization of drives grouped together.  The Sinamics V20 can also be set to hibernation mode, which prolongs the service life of the motor and also reduces system component wear (i.e. pumps).  Additionally, by displaying real-time energy consumption on the operator panel display, the operator always has the drive’s energy and cost efficiencies in focus at all times.

For more information about the Sinamics V20 drive, please visit:

www.usa.siemens.com/sinamics-v20-pr

 

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

Green coil coater also provides coil cleaning services, now at substantially reduced cost to mills, service centers, fabricators and OEM’s  

Effective immediately, the following pricing matrix is effective until December 31, 2015 for Chemcoaters coil cleaning services, according to Mike Tieri, Director of Sales & Marketing for the company, a leading green coil coater based in Gary, Indiana.

Sheet Steel Coil Cleaning Pricing Matrix
Pricing Good 4/7/2015-12/31/2015

Pricing Matrix  4.7.2015 - 12.31.2015

* Matrix for coils up to 45,000#
* This price includes standard VCI wrap
* Single Paper Wrap $100 / Double Paper Wrap $200

Subject to Individual Pricing

Subject to Individual Pricing

Subject to Individual Pricing 2

Intercoat ChemguardHome of   Intercoat™ ChemGuard

All coil cleaning is performed on the processing line at the company’s main location in Gary, Indiana and comprises hot wash, chem rinsing and hot air drying, followed by careful recoiling and packaging for delivery back to the customer or other specified recipient.

Based in Gary, Indiana, Chemcoaters, Inc. is a leading supplier of green coil coatings, as well as traditional prepaint and protective coil coatings such as dry film lubes and other RoHS-compliant coatings.  Virtually no VOCs or HAPs present in the process.

The company’s patented InterCoat® ChemGuard 300 coating is formulated with trivalent chrome vs. hexavalent chrome, making it environmentally friendly in all building, architectural, transportation  and consumer appliance applications.   InterCoat® ChemGuard 300 coating has superior corrosion resistance, as well.  Chemcoaters offers a presentation that evidences this fact to all interested parties.

For more information, please contact:

Mike Tieri
Director of Sales Marketing
Chemcoaters, Inc.
700 Chase Street
Gary, IN 46404
Phone:  877-411-2905
Email:  miket@chemcoaters.com
Website: www.chemcoaters.com
Connect with Chemcoaters online: yt twit gplus fb li

The Customer’s Challenge:

Significant new business, order intake
New customers
Steeply rising monthly production rates
Building/Facility space constraints

Solution: The Bertsche Two-in-One P5 Mill

P5 Dual Mill | Bertsche

Bertsche’s Dual P5 Mill allows dual work chamber manufacturing, independent or simultaneous, thereby saving considerable factory floor space for their aerospace customer.

 

Our aerospace customer was faced with the choice of either building a new facility to house two new milling machines or splitting their production between two manufacturing sites. Bertsche developed a new machine concept that offered the customer the productivity (throughput)  of two machines and the floor space footprint requirements of one machine, thereby saving the customer the cost of  building a 2nd facility and moving all production to a larger facility.   The Bertsche Dual P5 Mill has all the benefits associated with having two machines, namely independent but linked CNC’s,  two 5-axis machining modules ( A-side, B-side) each with separate machining chambers, the ability to machine two different parts at the same time and yet the overall machine is nearly the same size as a previously supplied single 5-axis P5 Mill.   Based on the daily production requirements, the machine is operated A-side only, B-side only or A and B side together.  Twin integral vacuum fixture tables are designed to accept a variety of different vacuum workholding fixtures that can be quickly changed at a moment’s notice, with a high degree of repeatability.  To assist the operator loading parts, each table has retractable datum surfaces that swing into place to edge locate parts and then swing back down, when machining.  Thick-walled composite structures (up to 0.625”) are milled, scalloped, edge trimmed and drilled on all sides.  High accuracy hole patterns and datum holes are drilled for determinate assembly and then probed for accuracy.  Parts are machined complete in a single setup and manufactured one-off to meet user ship-set kitting requirements.

With the growing trend towards cutting composites wet, flood coolant cutting was added and composite debris is flushed into a full bed length flume system.  Flood coolant is constantly circulated throughout the machine for greater machine thermal stability. High volume mist collection hoods, integral to the machining compartment, collect and vent mist.  A special sealing system is employed on linear ways to protect precision surfaces from very aggressive (detergent type) coolant fluids that must be used with composite materials. Multiple temperature sensors on the bed and X-axis slide accurately capture data for dynamic thermal compensation.  To reduce the amount of filtration media, coolant is continuously filtered using a cyclonic filtration system.

P5 Dual Mill | Bertsche

Bertsche’s Dual P5 Mill allows dual work chamber manufacturing, independent or simultaneous, thereby saving considerable factory floor space for their aerospace customer.

 

Benefits:

  • Very efficient use of available floor space with 2x the productivity compared to a previously installed machine
  • Lower operating costs due to greater efficiencies
  • Flexibility to better match daily production demands to available machine capacity
  • Operate as single or twin machine
  • Easier to manage work area
  • Labor cost savings
  • Longer tool life due to wet cutting composites
  • Better air quality due to wet cutting (dust management)
  • High response 2-axis head and spindle
  • Thermal growth control
  • Thermal growth compensation
  • In machine probing, calibration and position verification (bore ring, sphere)
  • Part drying provided as part of post machining operations

For more information on this story, please contact:

BERTSCHE ENGINEERING CORPORATION
711 Dartmouth Lane
Buffalo Grove, IL 60089
Phone:  847-537-8757
Fax:  847-537-1113
Web:  www.bertsche.com
Email:  info@bertsche.com
Attention:  Rich Bertsche or Erich Bertsche

High precision 3D mapping supports installation of a new beam transport line for scientific research

Fermi National Accelerator Laboratory (Fermilab), America’s premier high-energy particle accelerator laboratory, in Batavia, Illinois, collaborates with scientists from around the world to perform pioneering research, operate world-leading particle accelerators, plus experiment and develop technologies for science supporting U.S. industry.

In 2014, Fermilab contracted Exact Metrology to work on a project known by its location as “Main Injector Ring Section MI-10.” Horst Friedsam, Head of the Alignment & Metrology Department at Fermilab, led the week-long project with Exact Metrology, which involved 3D mapping of existing equipment in order to yield data to support the placement and installation of an additional beam transport line.

Exact Metrology performed the scanning in section 10 of the Main Injector Accelerator, which is situated in a tunnel about 10 m below ground with a circumference of approximately two miles. The Main Injector accelerates a proton particle beam, arriving from the 8 GeV (Giga-electron-Volts) Booster, to 120 GeV and subsequently blasts it into a stationary target to generate the world’s highest intensity neutrino beams.

Recently, Fermilab has been working on a new Deep Underground Neutrino Project (DUNE) to provide a neutrino beam to the Homestake Mine in South Dakota. This project features access to research facilities 2 miles below ground, which is ideal for neutrino experiments requiring shielding from cosmic ray events. In order to deliver a neutrino beam to the DUNE, a new beam transport line that fits within the existing beam line infrastructure was required. As a result, data scanning, full CAD modeling and photo overlays of a large section of the currently installed Main Injector equipment was needed. The collected data were crucial for the design of new beam elements and visualizing interferences with existing components.

3D Map will help Fermilab install a new beam transport line

3D Map will help Fermilab install a new beam transport line

The Alignment & Metrology Department maintained a high precision control network throughout the laboratory complex. For the scanning process, a Leica ScanStation P20 ultra-high speed 3D Scanner was used in conjunction with special laser scanner targets, modified to fit within the existing control network points. Exact Metrology’s Leica ScanStation P20 was chosen for its combination of high accuracy and low scan noise, plus its industry-leading environmental specifications for industrial as-built documentation. The software chosen to aid the process was Leica Cyclone, producing TruView—a web-enabled panoramic point viewer allowing the user to view, pan, zoom, measure and mark up point cloud data over the web. Additionally, RSL300 laser scanner target markers from Berntsen International Inc. were mounted concentric to 1.5” radius steel half spheres interfacing with Exact Metrology’s laser tracker nests. The coordinates of the control network, determined at the millimeter level, were provided to Exact Metrology to globally register all scans relative to Fermilab’s system. Thus, the end product provides information for all scanned objects in the common coordinate system used for the entire Fermilab site.

Fermilab has a long-existing relationship with Exact Metrology, having purchased and rented equipment from their instrument pool plus contracted for metrology services as on-site work, such as this scan.

Exact Metrology is an ISO 9001:2008 Certified Company.

ExactMetrologyLOGOExact 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.  

For more information on this new system, please contact:

EXACT METROLOGY, INC.
11575 Goldcoast Drive
Cincinnati, Ohio 45249
Phone:  513-831-6620
Toll Free:  866-722-2600
www.exactmetrology.com
stevey@exactmetrology.com
Steve Young, President

Or

EXACT METROLOGY, INC.
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Phone: 262-533-0800
Local: 866-722-2600
www.exactmetrology.com
deans@exactmetrology.com

Or

FERMI NATIONAL ACCELERATOR LABORATORY (FERMILAB)
1117 N Washington Ave
Batavia, IL 60510
Phone: 630-840-2787
Horst Friedsam

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.