TempTrak Transmitters - Binsfeld Engineering Inc. - Rotary Temperature Transmitters

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New RT406-2C Transmitter is "Invisible Operator"

Binsfeld Announces New RT406-2C Temperature Transmitter for Neumag S5 and NPT Machines
Binsfeld Adds Representation in India with Inditech International

Achieving Better Quality and More Production from Existing Extrusion Lines

Binsfeld Announces New Sales Representative in Turkey, INNOVA TEKS

Binsfeld Secures Large Order from Shanghai JWELL

Binsfeld Chooses Comhaire International for Northern Europe Sales

Binsfeld Introduces First Rotary Transmitter on New Platform

Eye on Quality: Binsfeld Technology Pays Off For Oriental Weavers

Binsfeld Solution is Key at Extruded Fibers Inc.

Binsfeld, Welantech Join Forces In Asia

For Godet Temperature Transmitters It's All About Precision And Reliability

NEW LIFE FOR OLD GODETS
Top Quality from Yesterday's Machines at a Fraction of New Machine Cost

Binsfeld Solution is Key at Extruded Fibers Inc.

Extruded Fibers Inc., Dalton, Georgia has built a reputation for producing high-quality yarn for its customers, who include the major carpet manufacturers. The company is owned by Bob McEntire, who built other fiber producing facilities including the Fiber One plant that is now Mohawk Carpet�s McFarland plant.

The company uses Italian-made machinery to produce a mix of nylon and polypropylene fiber for the carpet industry. �In general, we have been satisfied with our Italian machines. They were a good value and have performed well for the products we run on them,� said Mike Legg, maintenance manager at Extruded Fibers. �If you understand their strengths and weaknesses, you can use a systematic approach to maintenance and keep things running pretty well.�

Extruded Fibers� Mike Legg and Binsfeld�s Mike Kawiecki after solving crippling transmitter problem

Crippling Problem

While Mr. Legg admits some frustration in getting spare parts from overseas, he recognizes it as a necessary evil and one that is manageable. Allowing plenty of time for delivery is vital, and that means staying ahead of predictive maintenance.

When Extruded Fibers began experiencing higher-than-acceptable failures of the Italian-supplied godet temperature transmitters, the result was a significant loss of production. Positions were frequently down because one of the transmitters failed. And while the machinery supplier attempted to provide free replacements (the transmitters were still within the 1-year warranty), the company�s production continued to suffer.

Each failure of a temperature transmitter would shut down a position until the motor could be pulled and the transmitter replaced. This is a time-consuming project. Even when spare transmitters were in stock, run time was lost on the machine during repairs. Other maintenance suffered as technicians spent excessive time pulling motors and replacing transmitters. Eventually a larger problem developed. The Italian supplier ran short of replacement parts and long deliveries left problem positions idle for extended periods, severely impacting production capabilities. What had been an annoyance suddenly became a crisis.

When it became clear that the Italian machinery supplier could not solve the problem, Extruded Fibers began looking for an alternative source for temperature transmitters.

Searching for Solution

The company looked to Binsfeld Engineering for a possible solution. Binsfeld specializes in designing drop-in replacement transmitters on existing godet roll motors. �We visited Extruded Fibers and reviewed their situation,� said Mike Kawiecki, vice president of temperature transmitter sales. �We asked them what they suspected was the cause for the frequent failures of the OEM transmitters.�

They focused on two issues. A narrow 1 mm gap between the rotating and stationary sections of the transmitter was difficult to set; too close and the transmitter rubbed; too far and there was no signal communicating across the gap. The technicians at Extruded Fibers suspected poor power transfer was requiring a very close positioning and that subsequent rubbing or impacting was a cause of some of the failures.

The second issue was heat-related failures when the ambient temperature became elevated. They didn�t feel the ambient temperature was unreasonable, but rather that the OEM transmitter was not meeting its temperature specification.

A third concern related to poor precision and intermittent performance as the transmitters progressed toward failure. A position would get tripped out of service for a bad temperature signal and would test fine when the problem was explored. Yet it would repeat the trip-out again after a short return to operation. Extruded Fibers advised Binsfeld that it had four critical requirements for a replacement transmitter:

� It needed to be a mechanical drop-in replacement; they did not want to modify the roll motor assembly.
� It had to work with the existing process control system.
� It had to be robust and, therefore, failure free.
� There had to be ready access to spares in the event that a failure did occur.

Modifying Existing Configuration

Binsfeld was able to meet all four requirements. They could easily modify their existing mechanical configuration to accommodate a drop-in replacement on the Italian motors. �We do this all the time,� said Mr. Kawiecki. �We have designs to fit most manufacturers� roll motors, and we continue to develop for others.�

Working with the existing control system was fairly simple. A discrete process controller was being used and it was easily configured for the 4-20 mA temperature signal proportional to 0-300� C RTD output.

The Binsfeld design is known for robustness. Featuring a full 5-year warranty (the only such warranty in the business), Binsfeld�s popular TempTrak� transmitter is designed to last a long time. Using a tuned resonance power system, it operates with a gap of 9 mm �3 mm to minimize burdensome positioning requirements and eliminate possible rubbing or bumping between rotating and stationary parts. Combined with live transmitter power regulation accomplished via its digital communication scheme, the transmitter is always powered properly, never under� or overdriven. Venting in the stationary housing allows the transmitter to run as cool as possible, yet it is rated to 100� C.

The main stationary circuit is located up to 30 meters away from the hot motor in any convenient control cabinet where it will operate worry-free for years. If a failure does occur in the stationary electronics, a replacement unit can be installed without removing the roll motor. This is an important advantage in order to quickly return the position to production. Regarding the issue of spare parts, Extruded Fibers was assured that Binsfeld would keep spares on hand, despite the fact that it was unlikely that any would be needed, which has proved to be the case. Extruded Fibers was convinced and ordered transmitters to fit the roll motors on their first machine. Binsfeld was on-site the day of the installation and everything went flawlessly. �We like to be there when our customers first install a Binsfeld system,� said Mr. Kawiecki. �It�s new technology to them and we want to make sure they don�t run into problems or delays getting it up and running. When we see fiber running on the machine, we know we are leaving a satisfied customer.�

Satisfied With Solution

Based on the initial success, Extruded Fibers soon ordered more transmitters for other machines in the plant. And when it came time for expansion, they ordered more Italian machines, but specified Binsfeld transmitters as a requirement of the order.

After several years of operation without a transmitter failure, Extruded Fibers is confident they made the right decision. They also gained a more stable process control as the Binsfeld transmitters control temperature at set point without drift or frequent calibration.

�We�ve never had to adjust the calibration,� said Maintenance Manager Mr. Legg. �I can go out there and shoot any godet with the IR gun right now and it will be right on.� What had been an ongoing and aggravating problem was completely solved by upgrading to the Binsfeld temperature transmitters. The machinery is running continuous, high quality production. The maintenance schedule and budget are back on track. And Extruded Fibers is focusing on yarn production instead of spare parts and repairs.

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Binsfeld, Welantech Join Forces In Asia

Discussions at the recent ITMA Show in Birmingham, England have lead to an agreement between Binsfeld Engineering Inc., Maple City, Michigan, U.S.A. and Welantech International Co. Ltd., Nan-Kan Vollage, Lu-Chu Hsiang, Tao-Yuan County, Taiwan 338, R.O.C. Under the terms of the Agreement, Welantech will offer technical sales and support for Binsfeld products in Mainland China and Taiwan.

Michael Binsfeld, President of Binsfeld Engineering Inc. voiced enthusiasm for the arrangement. �This is a great opportunity for both our companies. Welantech has developed an excellent customer base in China and Taiwan. They have already generated serious inquiries for our TempTrak transmitters. We are excited to be partnering with them in the Asian market.�

Mr. Anthony Feng, Mr. Michael Binsfeld, and Mr. Thomas Feng cement relationship at ITMA Exhibition in the UK.

Anthony Feng, President of Welantech said he anticipates swift success with the Binsfeld line. �We pursued Binsfeld at ITMA because our customers are asking for these products. The performance of the Binsfeld transmitter system is exceptional in precision and reliability. It comes with a five-year warranty. We are delighted to be able to offer this level of quality to our customers.�

Binsfeld Engineering Inc. manufactures rotary temperature transmitters for heated godet roll motors used in the manufacture of synthetic fiber. Welantech International Co. Ltd. sells instrumentation and technical equipment to synthetic fiber producers in China and Taiwan.

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For Godet Temperature Transmitters, It's All About Precision And Reliability

When it comes to godet temperature transmitters, precision and reliability are essential features. Ask anyone from the plant manager to the technicians in the motor shop and they will all agree. It doesn't matter if it's made by Barmag or Toray, Neumag or Plantex, whatever the machine, whatever the transmitter, it needs to be precise and it needs to be reliable.

Binsfeld Engineering manufactures drop-in replacement transmitters. When our clients upgrade their old godet temperature transmitters they demand a step improvement in precision. And it goes without saying that the new transmitters better run consistently without failure. Over the years, we've learned what works and what doesn't in transmitter designs. Here's an overview of what you should know when you shop for your next godet temperature transmitter.

Digital Precision

Consistent yarn properties (color, tenacity, stiffness, etc.) require precise godet temperature control. So, how do you make a temperature transmitter that maintains its precision without requiring frequent calibrations? A key element is the use of digital electronics and digital communication. Unlike analog electronics, digital electronics are immune to output errors (drift) caused by temperature changes and elevated temperature over time.

Most older transmitter designs rely on analog electronics. Here's how they work. On the rotating godet, the temperature sensor output is measured as a voltage and then amplified. Next, the amplified signal is measured and manipulated (perhaps converted to a frequency signal) and then transmitted across the rotating-to-stationary interface (perhaps by a blinking LED).

Now, the transmitted signal is measured again on the stationary side (frequency is counted) and converted back to a voltage.

In simple terms, the critical temperature data goes from the sensor to the final output through a path of "measure-and-send", "measure-and-send", "measure-and-send" steps - each of which can introduce error.

New transmitter designs use digital electronics and digital communication to eliminate all the intermediate "measure-and-send" steps. With the digital method, you measure once - at the sensor.

The sensor output is immediately converted to a digital word (e.g., 00101011), which is immune to offset and gain errors. This digital word is transmitted across the rotating-to-stationary interface, read on the stationary side (notice I didn't say measured) and converted to the desired output. The result is that the temperature is measured only once, at the source. The measured value is then processed as a word in digital language all the way to its final output. That's why digital systems maintain calibration over time and temperature.

Here's an illustration of how analog differs from digital:

Children play a game called "telephone." One child thinks of a phrase and whispers it to the next, who turns and repeats it to the next, on down the line. The last child calls out the phrase. Inevitably, it is different from what was first whispered and everyone laughs. Somewhere along the line of "measure and send" someone heard it differently or repeated it inaccurately. This game of "telephone" models how an analog signal is processed and transmitted. Errors can be introduced at every step along the way.

Here's how to play "telephone" the digital way:

The first child writes the phrase down on a piece of paper and passes it to the next, who passes it to the next, on down the line. At the end, the last child reads the written phrase out loud. It comes out exactly as first written. Granted, the game is not as much fun when played this way, but it sure is precise!

Digital Precision: How long is this screw? Images, like temperature measurements, can be distorted in processing. Measuring at the source and transmitting the value in language maintains precision immune to distortion.

You may wonder how the digital word gets transmitted across the rotating-to-stationary interface. It uses a technique similar to how a computer sends digital data over phone lines. This technique is called Frequency Shift Keying (FSK).

All digital words consist of an "alphabet" of zeros and ones. FSK uses two frequencies (e.g. a low frequency for zero and a high frequency for one). Communication from rotating-to-stationary (or from one computer to another) is accomplished by sending a series of high- or low-frequency pulses, spelling out the digital words. A predetermined communication protocol is used so that the transmitter and receiver send and receive at the same speed. Note that this is different from transmitting a range of frequencies proportional to the temperature (e.g. analog) in that the reader only has to distinguish between high or low rather than to precisely measure the exact frequency being transmitted.

Digital error checking is used to verify that the sent data matches what was received. One example of digital error checking is parity. With parity checking, the last letter (bit) sent with a digital word (byte) indicates if the sum of the other bits in the word total an even or odd number. On the receive side, the bits are counted (evaluated for odd or even) and compared with the transmitted parity bit. If the parity doesn't match between sent and received data, the receiving side knows the data sample is erroneous.

It's easy to see why digital signal processing and its inherent stability are advantageous for making precision measurements. Using FSK communication techniques allows true digital reproduction of the transmitted signal across the rotating-to-stationary interface. Employing these technologies in godet temperature transmitters ensures consistent, repeatable precision temperature measurement that can be maintained without frequent calibration or adjustment.

Transmitters that Keep Going

In today's competitive fiber industry it is critical to produce as much fiber as possible on each machine. Lost production equals lost income that can never be recovered. When intermittent, inaccurate or failing transmitters idle production positions, fiber production stops and the extruded polymer is aspirated to be recycled or scrapped. With four or five heated rolls per position, if you have reliability problems with the temperature transmitters, the odds quickly stack up against you in the battle to maximize fiber output.

Robust: A sturdy shaft attachment combined with fully potted electronics protect the transmitter circuit from vibration, centrifugal force and contaminants such as spin finish.

How do you get reliability in a godet transmitter?

Start by making it mechanically robust. It's a hot, harsh, spinning, vibrating environment on the back of a godet roll motor assembly. The rotating transmitter needs to be rugged and it needs to hold on tight.

A strong connection to the shaft is the first step to transmitter survival. If you skimp on the mounting fixture you jeopardize your design before it even gets a chance to work. We've learned that a compression clamp provides a very secure and user friendly mounting. It can be quickly installed with a high level of confidence on most any shaft - and it doesn't let go.

Given a robust mounting attachment, the next concern is mechanically stabilizing and protecting the electronic components.

Potting the rotating electronics in a solid block of epoxy works well. It secures and protects the electronics from vibration and gravitational forces. It also shelters the entire circuit from contaminants such as spin finish.

Obviously, only high quality electronic components should be used in the rotating transmitter circuit. Industrial- or military-grade components typically have higher operating temperatures so they will perform better and survive longer in this hot application. Still, elevated temperature environments can shorten the life of any electronic component.

Most godet transmitter designs seal the rotating transmitter inside a solid stationary housing that holds in the heat. A better design incorporates holes in the housing to let the heat escape. This, combined with a rotating transmitter designed to pull air into the stationary housing, effectively cools the entire assembly as it rides on the hot shaft. Even though the high-grade components are designed to operate hot, we know they will run longer if they are not.

To further reduce the unnecessary impact of the hot environment on the electronics, locate the stationary support circuits in a nearby instrumentation cabinet instead of packing them inside the stationary housing on the back of the roll motor. Binsfeld houses these electronics in a separate controller interface that can be located up to 100 feet away from the transmitter.

Extended Life: Ventilation holes aid in cooling shaft mounted electronics and generous clearance between rotating and stationary parts helps survival during bearing failures.

Sensor connections need to be of high integrity. Intermittent connections are frustrating in that they repeatedly shut down a position yet can be difficult to find during a repair cycle. We recommend crimped and soldered ring lugs on the sensor leads secured to the transmitter contacts with small socket-head cap screws that won't come loose from heat and vibration.

Loose or failing motor bearings can cause movement and wobble in the motor shaft. Low-clearance transmitters will suffer from interference (rubbing and/or impacting) between the rotating and stationary parts, causing catastrophic failures. Look for transmitter designs with generous clearance between rotating and stationary parts to avoid this.

Godet transmitters that utilize tuned resonant power induction offer greater separation between the stationary coil and the rotating coil. In addition, tuned resonant coils work well with FSK digital data transmission, eliminating the need for a separate optical data link (another potential failure point).

Incorporating all of these techniques in a transmitter design will certainly provide strong reliability. But there is more that can be done. Including simple, clear error indicators help point to the source when a problem does occur. DIN-rail mounted controller interfaces that can be interchanged without affecting transmitter performance (they perform a digital handshake when connected to the transmitter) allow rapid on-the-fly troubleshooting and problem resolution. Quickly isolating and correcting a problem this way shortcuts the repair cycle. The position is soon returned to production with confidence that it will remain in operation.

Of course, keeping your draw stands running takes more than just good temperature transmitters. But upgrading problematic transmitters with precise, reliable ones can make a noticeable difference in production quantity and quality.

The ideal godet temperature transmitter is one you never need to think about. Or maybe a better way to put it is to say the ideal godet temperature transmitter is one you think about before you get it, so you don't ever have to think about it again. It's all about precision and reliability.

Article originally appeared in the International Fiber Journal.

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NEW LIFE FOR OLD GODETS:Top Quality from Yesterday's Machines at a Fraction of New Machine Cost

Fiber producers today face a double-edged sword. To capture new business, and keep existing customers, they must beat the competition on quality. But how can they invest in quality improvements when their profit margin is being squeezed by low prices? One answer is to leverage existing capital machinery with updated technology. And the best technology bargains are in instrumentation. Here's why.

First, electronic circuitry has leap-frogged ahead at lightning speed, thanks in part to digital circuit design, driven by the computer industry. Just look at how fast today's top dog PC becomes yesterday's news as faster, more sophisticated designs are introduced. Second, unlike capital intensive machinery investments, instrumentation investments are much smaller, and much less painful on tight budgets.

Instrumentation upgrades not only improve machinery performance, they extend the useful life of the machinery, postponing the major capital investment for new equipment. And instrumentation upgrades can be integrated quickly into the production process, minimizing the downtime and maximizing the return on investment.

Rotary temperature transmitters are excellent targets for instrumentation upgrades on existing spin draw machinery. Aging analog transmitters frequently hamper the process control system by inaccurately transmitting roll temperatures, reducing product quality. And their higher-than-acceptable failure rates decrease production capacity.

If you are running rotary temperature transmitters that are even 5 years old, you are likely missing a significant opportunity to improve your process control and ultimately, your product quality. If your transmitters are over 10 years old, the combination of lower maintenance costs and increased production capacity will payback an upgrade in as little as 18 months.

What's so special about the new generation of transmitters? The introduction of digital electronics provides higher precision and most importantly, long term stability for these circuits, even in the harsh, hot vibratory environment of a fiber plant. Stability (and therefore repeatability, a critical requirement for consistent yarn) is the greatest benefit of digital designs. Digital transmitters don't drift over time or with temperature changes like analog transmitters do.

Upgrading the rotary temperature transmitters on a spin draw line is a minor expense compared to installing a line of new machinery. And that makes it an acceptable investment for today's tight budgets. The result is improved yarn quality, required to stay competitive in the marketplace. And the short payback quickly converts investment to profit.

An added benefit of upgrading the rotary temperature transmitters is the extension of the useful life of the machinery. Investing a little money on instrumentation now can postpone the major capital investment of new machinery until the economic climate is more favorable.

Conclusion:
In the current market of low prices and depressed margins, fiber producers are reluctant to make the large investment new machinery requires. However, smart manufactures will invest smaller amounts to update instrumentation because it decreases production costs and increases quality and production capacity, restoring their margins and competitive edge in the market.

Typical Cost of Rotary Transmitter Failures

$200.00 - Lost Production: Includes faulty yarn generated during onset of problem

$100.00 - RTD Sensor Replacement: Sensor is often replaced while machine is down for transmitter maintenance

$100.00 - Field Maintenance: Manpower and equipment required to respond to failure

$100.00 - Shop Maintenance: Manpower and equipment required to evaluate and confirm failure is transmitter related

$250.00 - Repair Cost*: Manpower and equipment required to troubleshoot and repair failed transmitter

$50.00 - Transmitter Checkout: Manpower and equipment required to confirm proper operation of repaired transmitter

$100.00 - Transmitter Installation: Manpower and equipment required to reinstall transmitter on motor and verify performance. May include cost to dynamically balance motor with new transmitter

$100.00 - Motor Reinstallation: Manpower and equipment required to install updated motor into production line

$100.00 - Yarn Requalification: Manpower and equipment to sample and test yarn to verify acceptable quality

$1,100.00 - Total Approximate Cost of Transmitter Failure

Article originally appeared in the International Fiber Journal.

*Replacement cost for non-repairable transmitter is $1000.00-2000.00. This does not include hidden costs such as shipping to (possibly overseas) suppliers.

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