�ǳ�web Knowledgebase - custom

Resolving Plasma Cutting Challenges for a Welding Equipment OEM

Rachel Desenberg — Tue, 25 Jun 2024 15:49:23 +0000

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A welding equipment OEM was experiencing poor leak rates with their plasma cutting systems. Learn more about how �ǳ�web's solution significantly increased the performance and efficiency of their system.

Problem:

Welding equipment OEM faces high operational costs and poor leak rates

A welding equipment OEM was experiencing a number of challenges with their plasma cutting systems. The systems traditionally consume over 100W of power, leading to high operational costs and inefficiency. Additionally, poor leak rate performance can waste expensive gases. Limited gas blending and pressure control capabilities were another issue that was impeding the cutting process. The lack of effective feedback mechanisms was hampering the regulation of cutting gas pressure and the maintenance of the gas shield around the cutting arc.

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Solution:

�ǳ�web develops a comprehensive solution that enhances efficiency, reduces costs, and improves control

�ǳ�web designed a comprehensive solution that significantly improved the performance and efficiency for the OEM. The new system integrated 14 ES valves to pilot MJV cartridge gas control valves and five compact pressure sensors within three custom manifolds. This solution enhanced the system's energy efficiency by 90%, lowered operational costs, improved leak rate performance, and reduced the weight and size by 50%, making it more adaptable and easier to integrate into various industrial setups. Enhanced gas blending and pressure control capabilities optimized the cutting processes, while advanced feedback mechanisms ensured accurate regulation of cutting gas pressure and maintained the gas shield, thereby improving the quality and consistency of the cutting process.

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Custom Solutions

Custom Refrigerant Valve for Monopolar RF Equipment

Rachel Desenberg — Tue, 25 Jun 2024 13:43:50 +0000

Category:

Applications

A cosmetic surgery OEM was experiencing challenges with the valves in their monopolar RF equipment. To address the issue, �ǳ�web developed a custom electronic valve with high-performance seals to meet the specific needs of the OEM's unique application.

Problem:

Valve leak issues undermine performance in OEM's monopolar RF equipment

An OEM of monopolar RF equipment for collagen regeneration required a specialized valve capable of withstanding high pressures and preventing refrigerant leakage. The existing valves were unable to maintain a low leak seal under the elevated pressures necessary for the application, and standard valves were not compatible with the R-134 refrigerant media.

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Solution:

�ǳ�web develops custom valve to meet OEM's specific application needs

�ǳ�web developed a custom electronic valve that incorporated high-performance seals suitable for the media and was specially engineered to meet the performance requirements of the application's high-pressure conditions. In this application, RF energy is transmitted to penetrate the skin, heating cells to promote new growth and improve elasticity, thereby restoring skin vitality. The valve precisely controls the flow of refrigerant media to cool the skin during this process, preventing surface burns. By collaborating closely with the OEM, �ǳ�web ensured that the valve achieved ultra-low leak rates and compatibility with noise and power requirements, providing a reliable solution that enhanced the equipment's performance.

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Custom Solutions	DR-2 Series Precision Regulator	ES Series Electronic Valve

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10 mm & 15 mm Valve Customization Options

Rachel Desenberg — Thu, 25 Feb 2021 17:08:48 +0000

Category:

Videos

Learn more about customization options for �ǳ�web's 10 mm and 15 mm electronic valves in this video from Mike Kettering, Electronic Valves Product Manager.

Video filmed at �ǳ�web in Cincinnati, Ohio

VIDEO TRANSCRIPT:

Hi there, I’m Mike Kettering, Electronic Valve Product Manager for �ǳ�web. �ǳ�web has many standard options for 10 and 15 mm valves. However, I understand that standard options aren’t always the perfect fit for every application. Today, I would like to share with you some of the custom valves that we’ve done in the past. I know customs can sound scary to many customers, however, half of �ǳ�web’s business is customs.

Here are a few examples of our custom valves that we’ve done.

Here’s a really simple one, it’s a 10 mm valve with extra long wire leads.

Here is a 15 mm latching valve with a custom 4.3 volt coil on it. They needed the 4.3 volt coil for a lithium ion battery pack in a mobile application.

Here we have two custom 15 mm 2-way valves with EPDM seals on a manifold with custom fittings for use with refrigerant.

Here we have a 15 mm 3-way valve with custom low temperature seals and a DIN connector which allowed our customer to go from DIN to a Deutsch connector for IP protection.

And finally, we have a bank of 15 mm 3-way valves with custom orifice and spring configuration to achieve 250 psig working pressure.

I hope this helps you understand what’s possible with �ǳ�web custom valves. For more information, please visit us at clippard.com. Thanks, and have a great day.

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10 mm Valves	15 mm Valves

Laboratory Automation for Pesticide Residue Analysis

Rachel Desenberg — Sun, 28 Feb 2016 15:00:06 +0000

Category:

Applications

To help keep consumers safe, laboratories test fruits, vegetables, and other foods for pesticide residues. Cutting edge laboratories are now able to test more of these samples than ever before—with improved precision and greater accuracy—through automation made possible with �ǳ�web miniature pneumatic valves.

An October 2014 report by the U.S. General Accountability Office (GAO) suggests the Federal Drug Administration (FDA) and the U.S. Department of Agriculture's (USDA) Pesticide Data Program "have room for improvement in the way they collect and share data on pesticide residues on fruits and vegetables and other food." The GAO claims that the FDA's "approach to monitoring for violations has limitations," pointing to the fact that while the FDA shows that "pesticide residue violation rates in 10 selected fruits and vegetables were low" from 2008 to 2012, "less than one-tenth of 1% of imported shipments in 2012" were tested for the pesticides. However, cutting edge laboratories now have the potential to test more samples thanks to an innovative new machine designed to increase efficiencies in the pesticide residue analysis process.

The most common method for examining pesticide residues in fruit, vegetables and other foods is known as the QuEChERS Method. QuEChERS (pronounced "catchers") stands for Quick, Easy, Cheap, Effective, Rugged and Safe. Originally published in 2003, this method has since been accepted around the world and is possibly the most used preparation method for multi-residue analysis today. Using the QuEChERS Method, the analyst homogenizes a sample (fruits, vegetables, etc.) in a blender and puts it in a centrifuge tube with a reagent, then agitates it for one minute. The reagents used depend on the type of sample to be analyzed. Following this, the sample is put through a cleanup column prior to analysis by gas-liquid chromatography.

The AutoMate-Q40, designed by Teledyne Tekmar, Mason, Ohio, is the first product specifically designed to optimize and automate the QuEChERS extraction process. It enables laboratories to achieve improved precision and accuracy for QuEChERS sample preparation while increasing sample capacity and improving workplace safety. Prepared sample trays are loaded into the machine and a method and/or schedule is selected through the TekTouch™ software control. The chemist can now step away and perform other tasks, such as important data analysis, while the AutoMate-Q40 methodically executes a litany of manual tasks to complete the sample extraction. It decaps the sample vial, adds solvent and standard, recaps and vortexes the sample, decaps and adds salt to the sample, recaps and shakes the sample, centrifuges the sample and validates the sample's extract volume. If clean-up is desired, the AutoMate-Q40 will then pipette the sample extract into dSPE clean-up, shake the clean-up vial, centrifuge the clean-up vial, validate the clean-up extract volume, and pipette the clean-up volume into a final extract volume. Finally, the extract vial is returned to the sample tray for analysis.

This automation is powered by pneumatics, a decision that was ultimately based on cost and ease of programming. For Michael Maroon, Mechanical Engineer at Teledyne Tekmar, the choice was clear. "The air valve actuates, then the cylinder moves. As opposed to using a motor to drive a lead screw or a pulley or a belt until it hits an end stop—all while utilizing encoder feedback to verify how many steps were required to make the motion. It was simpler," says Michael. "For example, on our capping wheel where we're capping different diameter vials, we just want to push the wheel over apply a force on the vial, then spin it to remove the vial cap. Electronically, that would difficult to implement because a feedback device would be needed to signal how much force the unit is applying against the vial. That would be very time-consuming and costly to implement." Additionally, according to Tom Hartlein, Tekmar's Product Line Manager, "We know historically from using pneumatic solutions for our other product lines for 30+ years, our warranty values are typically less than 1%. That translates into a high probability of success using pneumatics."

When the time came to specify components, Tekmar consulted with Isaacs Fluid Power who recommended �ǳ�web's line of 10 and 15 mm valves. Offered in both Normally-Open or Normally-Closed models, these valves are perfect for small areas where compact electronically-controlled pneumatics are needed. According to Michael Maroon, an added benefit was the flexibility of having the same valve throughout the machine, thereby simplifying the need for inventory. In addition to the pneumatic valves, other �ǳ�web products integral to the machine include fittings, pressure regulators, and tubing. Working in concert, Teledyne Tekmar, �ǳ�web Instrument Laboratory and Isaacs Fluid Power engineer, manufacture and build the components and subassemblies that make up the machine's pneumatic controls.

Teledyne Tekmar's AutoMate Q-40 is an impressive example of laboratory automation made possible with �ǳ�web pneumatics. In addition to pesticide multi-residue analysis, other possible applications include analysis of polycyclic aromatic hydrocarbons (PAH) in seafood, analysis of veterinary drug residues in livestock, analysis of nutraceuticals and dietary supplements and more. Hartlein says, "the possibilities are basically unlimited. Generally, anything that goes through an extraction that requires a solid, addition of a solvent, shaking, centrifuging and pipette vetting is a candidate for the AutoMate-Q40."

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10 mm Valves	15 mm Valves	Pressure Regulators	Hose & Tubing

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Optimizing Pneumatic Control Systems with Injection-Molded Manifolds

Rachel Desenberg — Mon, 31 Jul 2000 18:57:54 +0000

Category:

Applications

Injection-molded manifolds can help solve some of the challenges industrial OEMs struggle with, including maintenance issues and energy inefficiencies that contribute to unnecessary downtime and high operational costs.

Problem:

Maintenance issues, downtime, energy inefficiencies, and increasing operational costs.

Industrial OEMs often face challenges when it comes to optimizing their pneumatic control systems. These systems are critical for maintaining precision and efficiency in a wide range of industrial applications, from material handling to assembly operations. Frequent maintenance issues, energy inefficiencies, and inconsistent performance can contribute to higher operational costs and unplanned downtime, disrupting production schedules and reducing overall productivity.

OEMs require solutions that are not only reliable and efficient but also scalable and cost-effective. The pneumatic control systems must integrate seamlessly into existing machinery, often within space and weight constraints imposed by the specific industrial environment. Additionally, there is a growing need to reduce energy consumption and enhance sustainability across operations, adding complexity to the challenge.

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Solution:

Special �ǳ�web valve banks with injection-molded manifolds

One way �ǳ�web is able to address these challenges is by upgrading the pneumatic control systems with compact, lightweight banks of valves on injection-molded manifolds. These three-way, two-position valves are selected for their versatility, reliability, and efficient air flow control, making them suitable for a wide range of industrial applications. They offer precise control over pneumatic actuators, minimizing air leakage and reducing energy consumption throughout the system. This not only results in significant energy savings but also improves the overall performance and reliability of the machinery, reducing the need for frequent maintenance and increasing uptime.

Injection-molded manifolds feature a lightweight and compact design that fits easily within the space constraints typical of many industrial environments. Its modular construction allows for easy scalability, enabling OEMs to implement the solution across a variety of machines and production lines with minimal modifications.

Furthermore, the cost-effectiveness of the injection-molded manifold and valves ensures that the solution meets budgetary requirements, making it ideal for large-scale deployment across multiple facilities. The outcome is a highly efficient, reliable, and scalable pneumatic control system that addresses the immediate needs of industrial OEMs while supporting long-term energy savings and sustainability goals.

�ǳ�web's solution offers industrial OEMs a tailored approach to overcoming common pneumatic control challenges, delivering enhanced performance, reduced energy consumption, and improved operational efficiency across diverse production environments.

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Special Valve Bank with Injection-Molded Manifold	Special Valve Bank with Injection-Molded Manifold	10 mm Electronic Valves	15 mm Electronic Valves

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