You have an application – we have your tailor-made solution. We develop and manufacture customized products in the fields of drive, positioning and pressure measurement technology.
Positioning systems from halstrup-walcher have all the components required to function as an independent cyber-physical system – sensors for determining position (absolute encoder), actuators for moving the positioning objects (gearbox, motor, motor control unit) and on-board decentralised intelligence (embedded system).
This ensures optimum integration of the cyber-physical positioning system into the machinery processes. Once the target position has been specified by the machine control unit, the positioning system runs to this new target position and reacts to any unexpected conditions (self-monitoring). For example, the positioning system can independently recognise the difference between an obstruction and dirt and responds accordingly (accelerates if the problem is dirt, stops for a genuine obstruction). The positioning task consumes only minimal machine control unit resources. It is executed independently and with optimum accuracy to the specified target. Positioning systems are therefore one of the central elements of factory automation as understood by the Industry 4.0 model: Self-monitoring support with outstanding flexibility.
Volume flow measurement
In order to convert the volume flow into a differential pressure, so-called primary elements are installed in the air duct or process. The sum of the static and dynamic pressure is measured and recorded (pitot tube, flow tube, Wilson flow grid) at one or several points and the static pressure subtracted. The latter group of primary elements offer the advantage that there is only a minimal loss of pressure – which noticeably reduces operating costs!
Luftmeister® from halstrup-walcher provides the missing link at the interface between energy management, air-conditioning technology and facility management: the world‘s first air meter and air energy meter (presently in preperation for 2016) records air consumption and energy flows within air-conditioning and process air systems based on high-precision mass flow and enthalpy sensors. The new instrument is factory-calibrated and thus offers maximum accuracy.
Luftmeister® provides a number of advantages depending on the application:
Luftmeister® provides continuous flow through data based on accurate mass and volume flow measurements at all measurement points. This allows the operator to perform the following operations at any time:
2. Distribution of costs based on consumption
Luftmeister® allows operators to calculate a precise total for air consumed (in m³ or kg) as well as the delivered useable energy per zone (in kWh). Energy input (e.g. heating) and output (e.g. cooling) are recorded separately. The result is that the person / company responsible for each zone can be billed for a fair share of the costs based on actual consumption.
Studies into the consumption of a wide range of media have clearly demonstrated that such measures can stimulate changes in behaviour, which result in savings of 10-30 %. As these consumption values can be officially calibrated and verified if necessary (commercial real estate, air contracting), the costs also have a clear and legally secure basis.
3. Record and optimise air-energy flows
Luftmeister® enables operators to record the transportation of energy in air ducts. So instead of just looking at the input energy of an air-conditioning system,they can analyse the complete energy contribution:
This data provides a base (available via Impulse, BACnet, Modbus or M-Bus) that effectively opens up an enormous range of possibilities for optimising the system. At long last, energy management can now be applied to air-conditioning and process air. As well as reducing operating costs, it is also possible to register the savings achieved. Precisely and transparently.
The halstrup-walcher company is known for its all-round expertise in the field of drive and pressure measuring technology.
We have cooperated closely with our customers to develop numerous useful solutions – many of which are customer-specific.
Others have a broader scope.
The following pages provide a look at a selection of these applications.
Moving logistics boxes
At -30°C, these boxes are stored and retrieved using fully automated processes. A conveyor carriage is dispatched to the specified storage bay where it extends its side arms under the box. Four N40x50P units turn a finger under each corner – and the box and carriage glide away smoothly to their destination.
Rotation drive in textile machines
Carding is a process that aligns cotton fibres to produce loose textile fibres (fleece). Brushes at the sides remove clumps and aggregations of material. The compact N64V30KG drive performs this task efficiently and is resistant to the microscopic dust particles generated in the immediate environment by the process.
Positioning drive for air intake flaps in furnaces
The N64V30IF positioning drive is exceptionally quiet and was developed for positioning furnace air intake flaps. In order to ensure that fuel is burned with maximum efficiency, a precisely defined volume of air is allowed to enter during each phase of combustion. The absolute position is measured using a potentiometer. Communication is via an RS485 interface. The drive must comply with the highest standards of safety and reliability as incorrect functioning can result in deflagration.
Entrance facilities designed to control flows of people in public areas frequently use turnstiles. The halstrup-walcher N72K allows the turnstile to rotate through an angle of 120°. The angle of rotation is released or blocked by mechanical stops. The turnstiles are activated using ticket readers that authorise ticket holders to enter. The N72K runs quietly and is notable for its powerful drive and rugged design.
Positioning of valves or pumps
Ball valves for use with water must be positioned reliably. In the same way, with membrane pumps it is necessary to adjust the flow rate. The N100P offers a powerful and robust solution to these tasks.
A powerful motor/gearbox drive unit propels a screw conveyor, moving pellets from a reserve tank into the combustion chamber of a pellet furnace. The speed (rpm), and therefore the quantity of fuel being delivered to the furnace, can be regulated according to the heat output required so the room temperature can be controlled flexibly and evenly. The halstrup-walcher N100W motor/gearbox unit runs exceptionally quietly and is notable for its compact, powerful design.
Positioning of industrial valves
The halstrup-walcher GT50 is primarily used for controlling flap valves in industrial heating applications for making steel, ceramics and building materials. By ensuring the optimum mixture of gas and air, it is possible to achieve an even temperature distribution in the oven atmosphere. The GT50 is a compact drive with a flat build and offers a wide range of torques and positioning velocities.
Positioning of smoke extraction dampers and windows
Smoke and fumes produced during building fires pose a hazard to people and damage property. Lawmakers therefore require the installation of reliable smoke extraction equipment. The N30x120 is exceptionally quiet and used to adjust the position of smoke extraction dampers and windows. The compact drive is reliable and complies with the highest safety standards. For example, the integrated brake guarantees a high self-holding torque.
Positioning colour zones in printing machines
The N22x65 drive adjusts the positions of the metal tongues attached to the printing rollers. A special fine manual adjustment feature is also provided. The distance between the metal tongues and the printing roller controls the quantity of ink applied. The N22x65 is reliable and notable for its compact size and long service life – an important factor in reducing service intervals and costs.
Automated cup supply
Revolving cup dispensers are frequently used in automated beverage vending machines to provide a compact and trouble-free supply of cups. The BK80 offers persuasive performance in this application with a compact, rugged design, and long service life.
Carding is a stage in the process of spinning yarns (or manufacturing fleeces). The fibres are thoroughly cleaned and then processed to form a web on drums fitted with sets of teeth. The teeth and flexible hooks on these drums face in different directions and straighten the textile fibres so they run in parallel. The resulting web is then wound into card sliver, which is finally spun into yarn after stretching. The distance between the cover of the carding machine on which the sets of teeth are mounted and the cotton fibres determines the quality of the fleece material produced. The robust and powerful TR130i drive provides highly reliable adjustment of this distance.
During combustion, the flue gas damper is open so that the flue gas can escape via the chimney. Once combustion is complete, the flue gas damper closes again to ensure that no heat energy escapes into the environment via the exhaust duct. The drive of the complete module is powerful, reliable and suitable for all safety-relevant applications.
The use of plastic and brass gear wheels together with a plastic housing ensures low noise emissions and excellent value for money. If required, we can also deliver the neighbouring module, e.g. the appropriate metal flaps.
Located directly adjacent to the ship‘s diesel engine or to its reversing gear, the SP72 spindle drive offers infinitely variable control of the setting range and stroke. It replaces mechanical rope, chain or cable pulleys from the ship‘s rudder to the engine. Electrical cables run from one or more navigating bridges to the SP72 spindle drive. The actuator provides infinite adjustment of the speed of the ship‘s diesel engine. The SP72 is approved by German Lloyd, certified resistant to seawater (protection class IP65) and consequently already used as standard in many ship systems.
Determining air conditioning usage in a way that is fair to consumers
With the P26 air consumption meter from halstrup-walcher
For rental spaces in buildings such as shopping centres and office complexes, air conditioning costs are typically billed by square meters (resp. square feet), a practice that is often the subject of debate. This is where the new P26 air meter from halstrup-walcher comes into play: the P26 works within the supply air for each rental space, where it adds up the actual amount of air consumed (in cubic meters or feet), making it as easy to track air conditioning costs as it is to track water or electricity costs.
The advantage for the building investor is that air conditioning can now be integrated into the building's energy management. This is a welcome innovation for building owners who rent out commercial space, as it helps improve their property’s sustainability and allows them to target specific areas for savings.
Regular calibration is a must for any pressure gauges used in HVAC applications, in clean rooms, in medical technology and mechanical engineering applications, or as service units. One way of doing this is to send these instruments to halstrup-walcher’s accredited DAkkS laboratory.
In order to avoid having to disassemble pressure gauges and send them to a calibration lab, however, more and more operators are having them calibrated on site. Mobile KAL series calibrators from halstrup-walcher support these efforts.
The advantages of KAL:
Interested in learning more about the on-site calibration process?
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The Volkswagen plant in Emden is a busy place. Located in the East Frisian region of Germany’s northwest coast, the facility and its over 8,000 employees will pass two major milestones this year, each of which would have produced considerable activity on its own: the new Passat B8 is on its way, and the plant will be celebrating its 50th anniversary in 2014. The atmosphere in the plant’s gigantic paint shop, however, is one of professional calm. The 1,200 cars that enter here each day leave as high-gloss versions of themselves in every conceivable colour.
Detert Ackermann, who helps maintain the finishing lines, proudly presents “his” finishing line. The clear highlights of the line are the curing ovens, which bake the finishing layer previously applied by painting robots. Vehicle bodies first pass through two radiant heating zones before entering the next three zones, where recirculating air produces a high-gloss finish that will last for many years.
“The painting process generates over forty percent of the energy costs at an automotive plant,” says Ackermann. “So this was where we focused our work with Crone Wärmetechnik, an equipment builder from Rhauderfehn, Germany, and with CVET of Clausthal, Germany. The collaboration produced huge savings in the curing and drying process!” From a technical perspective, the process has two outcomes: it provides the ovens with thermal energy, while eliminating the harmful substances in the oven waste gas that pose a hazard to human health and to the environment. The entire process must keep costs at a minimum without sacrificing the quality of the finish.
halstrup-walcher maintains the overpressure – to prevent contamination
Cleanrooms must be kept at a constantly higher pressure than their neighbouring areas in order to prevent infiltration of contaminated air from outside. This is not just required by the relevant standard ISO 14644-4. Every expert in this area knows hour air quality can quickly deteriorate if the overpressure falls by just a few Pascal even temporarily. In the area of semiconductors, dust particles and other pollutants threaten to compromise highly clean finished products. In the pharmaceutical sector, hazardous substances can penetrate highly critical medicines. Obviously, this must be prevented safely.
halstrup-walcher offers high precision pressure sensors, developed and manufactured on its own premises.
One of the company‘s specialist areas lies in the smallest measurement ranges such as those required in clean rooms. These sensors are integrated into three products, which cover every application: The P26 differential pressure transducer for mounting in control cabinets or wall mounting (from which pressure hoses lead to the clean rooms), as the PUC 28 panel version for direct installation in a clean room wall (where it is also possible to view readings for °C and %rF) and the high precision KAL 200 calibration device. This mobile calibration device powered by a rechargeable battery can be used to calibrate all pressure measurement locations regularly on-site and adjust them if required. A pressure generator inside the device generates the target pressure on-site and the internal sensor measures the pressure precisely for the calibration procedure. To ensure that contamination risks never occur in the future.
From on-site calibration to on-board compensation of pressure and temperature
The importance of volume flow measurements to air quality and operating costs has been underestimated for many years. Yet there is now a growing recognition that excessive volume flow in air conditioning and process air systems sends operating costs spiraling upwards. Not only do ventilator fans consume extra energy in moving the surplus air around the system but expensive air conditioning processes (cooling, heating, humidifying or dehumidifying) generate further costs by treating unnecessarily large volumes of air.
Operators and planners have recognized that too little volume flow also creates problems as it results in an inadequate air supply. Moreover, an insufficient volume flow can also lead to hygiene problems – from oxygen deficiency for humans to accelerating bacterial growth in moist, slow-moving air during production processes.
Control cabinet installation of the P 34 pressure transmitter, optimised for volume flowzoom
The measurement technology specialist halstrup-walcher identified this problem and responded immediately by offering a complete package solution:
The company supplies pressure transmitters, which are perfectly tailored to the requirements of volume flow measurement, such as the newly launched P 34 differential pressure transmitter.
Selection, delivery and (on request) installation of the appropriate primary element. The key is to find the correct compromise between the available budget and the accuracy required.
On-site volume flow calibration: we always offer and include on-site calibration for every volume flow measurement point (in accordance with DIN EN 12599). This takes into account and, for the most part, compensates for the individual deficiencies of the measurement location. Based on this calibration, the pressure transmitter is then adjusted to achieve optimum precision.
Volume flow calibration in an accredited laboratory (accreditation under way): In the future it will be possible to calibrate beside primary elements also balometers, ventilators and complete test sections.
Clearly, the difference lies primarily in being able to observe all the relevant aspects of the volume flow measurement as a whole. In practical applications, the accurate, stationary (permanent) measurement of volume flow is essential for maintaining air quality and keeping operating costs under control.
Changing formats with today’s machines – Preventive maintenance and batch size 1
"It‘s quality that counts!“ Whenever a purchasing manager in the furniture industry was going to buy a wood processing machine ten or twenty years ago, that was the advice his production colleagues gave him. Naturally the purchase price had to be right too, and not least the delivery time.
It‘s more complicated nowadays. Of course, the quality, price and delivery time still have to be right. But the production manager in a furniture factory must make sure of two things in particular: that he can change to new formats as quickly as possible (first "a slim cabinet, then a bulky chest of drawers, followed by a small table“) and that the expensive machine keeps running and doesn‘t stop suddenly.
With the halstrup-walcher PSE positioning system
When the operating managers of major breweries present their state-of-the-art bottling plant, they wash a large number of bottles very quickly. The visitor is amazed as these fragile vessels are propelled through the machine. However, an experienced manager knows the importance of speed when the bottles are not moving. This machine is designed so that changeover downtime is no longer significant and changeover precision does not vary. The plant can afford more frequent changeovers and support a more flexible operation. The example of bottle inspection machines makes this particularly clear.
Machines for inspecting empty bottles, such as the Linatronic 735 made by the bottling specialist Krones AG, monitor washed reusable bottles for dirt and damage. A reliable standard of bottle washing quality within the bottling plant translates directly into greater safety for the consumer – reusing bottles should not mean compromising on the hygiene and proper condition of the bottles!
At the same time, this requires a high level of flexibility as the bottle inspector must be capable of monitoring a wide range of bottle formats. For the operating manager, a hygienic design that can be adjusted automatically at the touch of a button to different bottle types equates to reproducibility and efficiency!
Modularity and monitoring for automated format adjustment
Most mechanical engineers have long recognized that the ability to switch machine formats automatically is a huge advantage, saving an enormous amount of time over methods using hand wheels. Plus, automation also minimizes the amount of material wasted, as the format adjustments are always precisely reproducible and autocorrecting.
A drive technology manufacturer specializing in positioning systems and format changeovers, halstrup-walcher has come out with a new generation of PSE/PSS/PSW products, adding two important items to the list of advantages that the company already offers its customers:
1. An extensive modular system allows mechanical engineers to adjust bus communication and the IP protection class to meet the needs of a given customer – all without changing relevant dimensions. This feature noticeably reduces the amount of work involved in making the changes and adaptations needed for meeting a customer’s specific machine concepts.
2. A large number of system parameters are continuously reviewed to support the machine‘s condition monitoring, a feature that results in improved availability.
The PSE, PSS and PSW positioning systems: Modularity for automated format adjustmentzoom
What makes this possible is an integrated product family designed for all three relevant IP protection classes: IP54 (PSE), IP65 (PSS) and IP68 (PSW). None of the models requires an additional, bulky bus distributor, because bus communication takes place directly on board in halstrup-walcher positioning systems. The need for bulky exterior packaging for higher IP protection classes is eliminated here as well – an important benefit for any mechanical engineer, given how tight installation spaces always are.
Modular positioning systems offer flexibility for machine tool builders– now also available with IO-Link
One modular solution for every machine conceptzoom
In contrast, halstrup-walcher, a global market leader in the area of positioning systems, puts its trust in extremely compact units, which are available in a very extensive range of modular systems:
The key advantage: when you change the IP protection class or the bus communication, all the relevant connection dimensions remain the same. This enables the machine builder to “convert“ an existing machine to the customer‘s wishes extremely quickly.
Of the field buses, IO-Link plays a particularly important role. Actually, IO-Link is not a bus communication but a “peer to peer“ connection which bridges the final metre between a field bus and the sensors / actuators. The purpose of this exercise is to be able to use the same communication (IO-Link) for the sensor and actuator in every version of the machine while the gateway permits the use of any
customer-specific field bus. This approach is an optimum solution for accommodating the wide range of sensors and actuators.
Until now, IO-Link has been used predominantly by sensor manufacturers. The inclusion of IO-Link in “PSE / PSS / PSW“ positioning systems makes halstrup-walcher the first supplier of decentralised actuator systems that also supports this concept. The system provides the best possible adaptability in terms of the criteria described above under “Level 2“ – and simultaneously offers optimum support for the fast, precision positioning tasks stated under “Level 1“. The following details will be of interest to practical engineers: