Used to keep the ultrasonic signal centered on the track, Exlar® actuators from Curtiss-Wright deliver outstanding performance for Sperry Rails, a leader in high speed railway track inspection systems, located in the United Kingdom. Find out why Sperry Rails uses Exlar.
APPLICATION CHALLENGE
Colpitt is the leading machine builder for automated production of blood bags. Their machines for welding the bags historically have used pneumatic or hydro-pneumatic cylinders to perform this motion. Colpitt wanted to install an electric servo system through which all the motion required for this process could be controlled through PLC programming and provide better control of the sealing process.
EXLAR SOLUTION
By using a Exlar® GSX servo actuator with its integrated roller screw and servo motor, Colpitt was able to achieve a quick transfer motion combined with a controlled low speed move for pressing at the end of each move. This allowed Colpitt to maintain a high cycle rate, while still achieving the accurate pressing control that their application requires. The integrated nature of the GSX Servo actuator allows both force and speed to be set very precisely resulting in an accurate and easily controlled process. The actuators run 24/7 without any interruptions. Utilizing the flexibility offered by the motion control system, Colpitt has been able to reduce their duty cycle and increase the throughput of blood bags that they are able to produce. The shorter cycle time combined with the reliability gives Colpitt customers a significant competitive advantage.
EXLAR PRODUCTS
GSX40 and GSX50 servo actuators were used in this application. The flexibility offered by servo actuation provided Colpitt the ability to manipulate motion parameters instantaneously, via an operator interface panel, eliminating the need for setting switches or changing offsets. The GSX series actuators provide high speed, accurate movement and the convenience of an integrated design in a very compact package.
The Exlar Linear Actuator Advantage with Planetary Roller Screw Technology
APPLICATION
Machines that fill containers with yogurt or other similar products.
CUSTOMER
Osgood Industries, located in Oldsmar, Florida, is a leading manufacturer of machinery for filling applications. They produce machines for a variety of different industries from food and beverage to medical and personal care.
CUSTOMER CHALLENGE
Osgood Industries used a variety of methods, from air cylinders to servo motor/gearbox combinations, to control the nozzles on the filling mechanism. These mechanisms took up a large amount of space and made it difficult to control the exact amount of product loaded in to each container. As such, Osgood was looking for an alternative solution which would allow for more precise filling of each container. They also needed a compact solution because of the limited space in their filling machines. Osgood wanted a product that would eliminate the need to purchase multiple components and reduce assembly time. Finally, Osgood needed a motion control system that would operate for 10 years without replacement.
SOLUTION
Exlar’s GSX series actuators provided an ideal solution for Osgood Industries’ requirements. The GSX actuators allowed for very precise control of the volume of product loaded into each container. Furthermore, Exlar’s GSX series actuators are very compact, which allowed Osgood to actually reduce the amount of space in the machine for the motion control solution. With Exlar’s GSX actuators, Osgood did not have to purchase various components such as motors, actuators, and mounting hardware, reducing the amount of time they had to spend on engineering. Moreover, with a reduced component count assembly time was reduced and reliability increased. In addition, Exlar’s actuators have proven they will last, running for up to fifteen years in other similar applications.
RESULTS
CUSTOMER
Research institute located in Germany, local German Exlar distributor (IGAS)
APPLICATION
Material fatigue testing
CUSTOMER CHALLENGE
The customer was attempting to use a hydraulic solution, but it could not provide the necessary combination of speed and precision. In addition, the hydraulic solution was complicated to commission and generated a significant amount of noise during operation. After a short period of time the customer started experiencing issues with leaking hydraulic fluid that were problematic to resolve.
SOLUTION
The Exlar® GSX30 and GSX40 were selected based on their force ratings and small package size. IGAS was able to secure the order by offering a complete motion solution package including the Exlar actuators.
The actuators apply a sinusoidal load to each test specimen according to the following profile:
10 Hz +/- 1mm more than 2 Mio. Cycles
3-5Hz +/- 3mm more than 2 Mio. Cycles
Other electric solutions were considered, however, the Exlar roller screw actuators were the only electric solution capable of providing the required combination of force, speed, package size and life.
RESULTS
The Exlar GSX can be optimally controlled even at high speed, which was critical to the validity of the test results. The Exlar GSX models have been running at 130% of catalog rating for over six months without issue, a testament to their robust design.
CUSTOMER
Oil & gas producer located in the East Texas Basin in Kilgore, Texas
APPLICATION
Control the operating pressure on a compressor using a four inch Kimray®suction pressure reducing valve and an Exlar® electric actuator.
CUSTOMER CHALLENGE
The producer was using suction throttling for capacity control of a compressor from Exterran. The original control was through a high bleed high pressure control valve that was gas actuated. To better control the compressor at lower capacities, the producer needed better suction pressure accuracy, and preferred a solution that also eliminated all methane emissions. They wanted to keep the original Kimray valve, but eliminate the pneumatic actuator and controls.
SOLUTION
The existing four inch high pressure Kimray valve was retrofitted using an Exlar® Tritex II™ actuator. The 12 VDC Tritex II was able to be placed onto the Kimray valve in the field in a short amount of time. A 4-20 mA signal from the Altronic compressor controls replaced the original pneumatic controller allowing precise position control by the new actuator. All pneumatic piping and regulators were also eliminated. While other electric actuators were considered, the Tritex II was chosen for its speed of response, high turndown capability, and its proven record in oil & gas production applications.
RESULTS
The retrofit of a Tritex II electric actuator provided much better pressure ratio control of the compressor. In addition, all methane emissions were eliminated and the natural gas that used to be vented is now used put back into the revenue stream.
APPLICATION
Liquid petroleum products and liquid natural gasolines are transported via pipelines from refineries and terminals to end users. To overcome the pressure drop that occurs when transporting liquids over a long distance in a pipe, numerous pump stations are located along each pipeline to boost the line pressure to an acceptable level. Each pump station requires exceptional control of the process, as many are near populated areas. A key contributor to providing precise and stable pressure control at each station is the valve control system, particularly the actuation of pressure control valves used to control the back pressure of the liquid. Proper and precise pressure control at the pump station is critical, as fluctuations at one pump station can be amplified at downstream stations.
CUSTOMER CHALLENGE
Hydraulic actuators have traditionally been used in these pressure control applications due to their stiffness and response rates. The customer was experiencing significant maintenance and performance issues with their existing hydraulic system which included a large 25 gallon hydraulic fluid tank, filtering system and supply lines in addition to the cylinder itself. The hydraulic systems were deemed unreliable due to the frequency of required maintenance. Potential hydraulic fluid leaks were also a major concern, as the EPA requires a hazard recording each time there is a leak.
While other hydraulic-based solutions were considered, the customer preferred an all-electric solution to simplify control and reduce maintenance. The challenge was finding an actuator that would match the capabilities of hydraulics, but with higher reliability, precision, and less maintenance.
SOLUTION
The Exlar® GSX60 electric actuator was chosen to replace the existing hydraulic solution. Exlar actuators use a roller screw to convert the rotary motion of a servo motor directly to a linear force. This unique design provides high force and fast response needed for the application, as well as long life to minimize maintenance. Controls for the actuator were provided by Rockwell Automation, seamlessly integrating the Exlar valve actuator into the overall pump station control. The control scheme also includes continuous diagnostic capabilities; providing information on the health of the valve as well as the actuator
RESULTS
The result is an all-electric actuator solution that provides more control flexibility, higher speed, faster response, lower energy consumption, and longer life than any hydraulic actuator alternative available today in a compact, easy to install package. Control was optimized and significant reductions in operating costs were achieved with the low maintenance package. Risk was alleviated by the elimination of all hydraulic fluid.
Customer
Commodore Technology, Bloomfield, NY
Application
The customer’s thermoforming equipment was using two opposing vertical hydraulic cylinders that came together to compress polystyrene sheets into foam trays at a high rate of speed. These trays are commonly found in grocery stores mainly in the meat department for meat and fish, fast food containers (Big Mac), restaurant take out containers, etc.
Customer Challenge
The customer wanted a “green” solution that eliminated the undesirable traits of hydraulics – such as mess from hydraulic fluid leaks, constant maintenance, etc. They were also seeking a higher production rate and improved product consistency.
Solution
The Exlar industrial electric actuator proposal consisted of an Exlar® FT35-0410 with high capacity screw, 2:1 parallel mount, oil ports with site gauge and a Schneider servo motor / drive. Since the Exlar system met or exceeded all specifications for the application, and it was viewed by the customer as the leader in rod style electric actuators, no other alternatives were considered.
Other factors that influenced the customer’s decision were Exlar’s industry experience, the FT Series high load capacity and long life, and that Exlar is a domestic manufacturer.
Results
The Exlar actuation solution significantly increased thermoforming production, nearly doubling the production rate from 20 cpm to 37 cpm. It also provides significantly better consistency of the finished product.
Future
Now that Exlar has been established as a solid supplier, and the FT35 has exceeded all performance expectations, Commodore is looking to use the Exlar GSX60, an integrated motor / actuator on new applications.
Customer Challenge
Our customer is a machine builder in Germany. They were looking for less maintenance and better performance than they were achieving with their current hydraulic cylinder. Specifically, they wanted to eliminate hydraulic fluid leaks and the use of oil in general.
Solution
They chose the Exlar® FT60 & FT80 due to the long life and robustness offered by our roller screw technology. The customer also considered ball screw-based electric actuators from a competitor, but the life they offered would not meet the customer’s requirement.
Results
In addition to eliminating oil from their production process, the high precision offered by the Exlar FT actuators increased part quality and the significant reduction in maintenance led to increased part production.
Our customer develops customized high-tech products and equipment in the areas of carbon technology and ceramics, environmental simulation technology and climate technology, sintered metal technology and ultrasonic welding technology in Germany.
Press filling coal sticks for electric motors. The actuator moves a bin containing powdered coal dust into position above a mold. The powdered coal material is then deposited into the mold where it is pressed into the finished part.
Customer Challenge
The existing hydraulic cylinder was not fast enough to meet the customer’s production requirement. In addition, the dusty environment contributed to accelerated wear and premature failure of the actuator.
Solution
The Exlar® GSX20 was selected for the application because of its speed and IP65 environmental protection. The customer also considered another brand of electric actuator, but it did not have the required environmental sealing.
Results
The customer initially used a GSX20 with a single stack motor, which was faster than the hydraulic cylinder used previously. Eventually the customer settled on a double stack GSX20 which significantly increased both speed and acceleration relative to the hydraulic solution.
