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Watts Current - Volume 36

SERIES PD Controllers Now Include EtherNet/IP
Case History - Watlow's E-SAFE® Relay
Sensor Selection 101: Optimal Temperature Sensor Selection
Watlow Black Belts Chop Customers' Costs
Watlow Aggressively Addressing RoHS and WEEE Requirements
Watlow Unveils New i-Catalog, an Interactive Product Catalog

Watlow Black Belts Chop Customers' Costs

Black Belts Last year, Watlow was experiencing a major yield problem with one of its key customers, a major supplier of vacuum pump equipment primarily used in the semiconductor industry in cryogenic environments. Watlow was incurring tens of thousands of dollars in scrap that was not meeting the stringent test criteria needed to meet the customer's expectations. The pump is critical to the process, so if a heater problem arises, the pump will not work. Therefore, it is critical that the customer have 100 percent product quality.

The customer, like most customers, expects that a supplier will work to investigate the true cause of a quality issue and implement the appropriate containment and corrective action. When the issue of product waste came up in conversation, Watlow Six Sigma experts, dubbed "Black Belts," kicked into high gear.

Black Belt is the designation given to engineers who complete the Six Sigma-based training course, which focuses on a series of tools, techniques and business metrics that result in quality and process improvement through structured analysis and reporting. Globally, Watlow has 10 Black Belts on staff, which is proving to be a competitive advantage for Watlow -- and a tremendous asset for customers.

Watlow Six Sigma Black Belt Ben Johnson headed up the effort on this customer challenge. By applying the Six Sigma principles, he and his team were able to identify a problem surrounding the hot insulation resistance, or "hot IR." The insulation resistance testing measures leaks to the heater sheath. That testing process identified that excess moisture in the heater was causing the "hot IR" failure to occur.

By identifying moisture as the culprit, Watlow was able to correct the issue through making changes to the manufacturing process. Today, Watlow boasts an impressive 100 percent yield on the product, which has eliminated the product waste costs to Watlow, increased line productivity and gives an important customer the confidence in the performance of the product.

This customer is but one example of the endless possibilities for manufacturing process improvement. In fact, Watlow Design Engineer Chris Govero, who just completed Black Belt training, is excited to think about the possibilities of improving processes that can help all customers.

"Sometimes there are obvious challenges that customers will bring to the table, but in many cases, customers may not even be aware of an opportunity for improvement or may have come to accept certain manufacturing issues as something to be expected," Govero says. "Our team relishes the chance to help Watlow's customers and improve our processes because of the tremendous benefits of doing so."

Those benefits are indeed significant -- and, importantly, measurable. They include:

  • Improvements in manufacturing processes
  • Improvements in efficiency
  • Reduced manufacturing costs and increased profitability
  • Shortened cycle times

    In a recent benchmark study, a survey found that the median value of "hard" financial savings per Six Sigma Black Belt project is $187,500 annually. Additionally, the median "soft cost" savings is $107,500 per year. "The ability to see real improvements and bottom-line savings has made the Six Sigma approach very popular," Johnson says. "Our number of Black Belt certifications continues to go up, and so does our customers' interest in learning more about how we can help them with process improvements."

    To become certified as a Black Belt, participants must attend full-time training one week a month for five months. Participants are assigned a specific product challenge which they follow throughout the course of the training. Participants must apply what they have learned to that product challenge, and report on their progress, how they used Six Sigma tools, and employ measurement metrics to chart the project's success. A demonstration of actual savings is required for Black Belt certification.

    A green belt designation is also granted to participants who go through three shorter training sessions once per month. The training is similar to -- but not as deep as -- Black Belt training. Watlow also employs a number of Green Belts. Johnson adds that Watlow's Black and Green Belts are tasked with taking the knowledge that they learn out to their engineering teams in Watlow's various locations, so the principles of Six Sigma become a part of the global company culture.

    All of this training has come in quite handy for another Watlow customer, a leading manufacturer of systems that apply adhesives, sealants and coatings to various packaging applications.

    Through its Black Belt staff, Watlow engineers helped to address a specific need for longer heater life in these types of applications. The customer had been requesting design enhancements from Watlow for sometime but until the Six Sigma approach was used, they were unable to provide significant improvement.

    Using the Six Sigma tools enabled Watlow to improve the manufacturing process which in turn created tighter tolerance capability and ultimately provided longer heater life. This was specific to the diameter requirements of the heater. Watlow was able to achieve this at no additional cost to the customer and also reduced their own internal total cost of quality by eliminating future returns for premature failure.


  • Volume Thirty-seven, Special Issue - 2006
    Volume Thirty-five, Third Quarter, 2005
    Volume Thirty-four, First Quarter, 2005
    E-SAFE® meets future government regulations that will potentially eliminate the use of mercury relays in the foodservice industry.

    Volume Thirty-seven, Special Issue - 2006
    Volume Thirty-five, Third Quarter, 2005
    Volume Thirty-four, First Quarter, 2005
    SERIES PD Controllers Now Include EtherNet/IP Watlow's SERIES PD now includes EtherNet/IP communications.

    Volume Thirty-seven, Special Issue - 2006
    Volume Thirty-five, Third Quarter, 2005
    Volume Thirty-four, First Quarter, 2005

    Sensor Selection 101: Optimal Temperature Sensor Selection

    Sensor Selection There's no simple solution to achieving accurate temperature measurement. It's a combination of knowing the inherent accuracy of particular sensor types, but also how environmental factors can create further measurement uncertainty and the sensor calibration techniques available to reduce this uncertainty.

    Thermocouples
    Thermocouples are the smallest, fastest and most durable temperature measurement solution. They can withstand high temperatures, harsh mechanical punishment and are simple to operate. Their size allows for rapid temperature response times and the sensing junction can often be placed very close to the desired point of measurement. The durability and simplicity of this sensor type makes them ideal for embedding into other devices.

    However, the thermocouple is most at risk from accuracy, noise and precision error. When extreme accuracy and precision is required, many of these shortcomings can be compensated for -- simply by using short runs of insulated and shielded thermocouple wires with balanced, low-pass filtered differential amplifiers (to avoid common-mode voltage offsets), as well as through relatively complex calibration procedures.

    Thermistors
    Thermistors are ideal for measuring applications that require high accuracy sensitivity over a relatively narrow range of temperatures (typically less than 300°C (572°F)). However, they cannot endure high temperatures or mechanical stresses like thermocouples, which makes them difficult to use in applications and assembly operations where these influences are not well controlled. To compensate for this limitation, the sensor can be encased in a protective metal enclosure - but this will be at the cost of thermal responsiveness. Some special version thermistors are capable of working to temperatures of 1000°C (1831°F).

    RTDs
    RTDs are suitable when extremely stable and precise measurements are required, or when accuracy over a prolonged time is the most important factor (the accuracy and precision of an RTD often exceeds that of both a thermistor and thermocouple). RTDs follow Deutsche Industrie Normen (DIN) and/or Joint Information Systems Committee (JISC) national standards and with good tolerance specifications, off-the-shelf RTDs are very consistent regardless of their batch number.

    RTDs are very delicate, and while the melting temperature of an RTD element is sufficiently high enough to survive many high-temperature manufacturing operations, they do not tend to survive aggressive mechanical operations (such as compaction), which results in them being difficult to embed into custom mechanical devices.

    Sensor Considerations
    When building your knowledge base on sensor types, be sure to consider inherent accuracy in terms of durability, range of operation, and susceptibility to external noise influences. Also examine how the sensor will be used in terms of temperature range, the required level of accuracy and repeatability, handling/ installation endurance, whether it will be calibrated/grounded, and the type of environment it will be used in.

    Location and Transient Errors
    It is nearly impossible to sense temperature exactly where you need it. At the very least, the sensor itself has a finite size that displaces the sensing element from its attachment - resulting in the sensor being at a different location than the desired measurement location. Thermistors and RTD's are at greater risk for location error than an equivalently placed thermocouple - simply because of their size.

    Heat Transfer Error
    Sensors receive conductive, convective and/or radiative inputs that contribute to measurement inaccuracy. In Figure 1, these types of errors can be represented by ambient conditions that heat up or cool down the sensor -- often along specific pathways such as along the thermally conductive electrical wires used in thermistors, RTDs and some thermocouples, from a nearby heating element. In this instance, heat from a local source travels up the copper wire to the sensing element and distorts the measurement. E and J thermocouples use alloys that are less conductive, which makes them ideal for mitigating this kind of error.

    Self-Heating Error
    The third form of measurement error applies to thermistors and RTDs, and results from heat dissipating inside the sensing element itself. This causes the temperature inside the sensor to rise, which makes the measured temperature less indicative of the environment. Strategies for minimizing this include keeping the current low or pulsing the sensor with a low duty cycle to keep the average power dissipated in the sensor low.

    Atmosphere and Environmental Influences: Moisture, Oxidation and Reduction
    For all three sensor types, operating or cycling them near their temperature limits can cause deterioration, which then results in a drift from the initial profile. Thermistors and RTDs are usually well sealed from the environment, which makes them less susceptible to internal corrosion. However, these sensors are usually connected to copper wires, which increase the risk of lead wire deterioration.

    Mechanics, Acoustics, Vibration and Triboelectric Effects
    Small wire gauges and fragile sensors should be avoided in applications that subject them to extreme mechanical motion, vibration or high intensity acoustics. The most common wire failures occur near connection points, where there is the greatest amount of flexure. However, mechanical motion or vibration can also stimulate internal resonances inside the sensor - leading to early failure.

    Magnetic, Capacitive, RF and Grounding Effects
    Thermocouples and RTDs generally have the lowest noise immunity of the three sensor types. By shielding and properly grounding these sensors, their immunity from potential noise offsets can be further improved. This is true for offsets caused by capacitive, radio frequency (RF), and offset currents, but immunity from magnetic sources is not so easily achieved.

    The environment in which sensors operate can often contain large motors and solenoids, or high current devices that can cause transient currents or magnetic surges. For sensor types that require stimulating electronics (thermistors and RTDs), these power droops could potentially affect the power supplies and sensing circuits inside the sensor electronics, which subsequently affects temperature readings.

    Sensor Calibration Techniques to Reduce Measurement Uncertainty
    A common way to correct for inherent accuracy errors is to calibrate the sensor in a controlled isothermal liquid bath and compare temperature readings against a standard reference. Alternatively, point calibration -- immersing sensors in an ice bath (0.01°C is standard) or other standardized freeze point (such as a gallium freeze bath at 29.7646°C) - is an alternative way to characterize accuracy, providing assumptions can be made as to how the accuracy at the calibration points can be extrapolated to predict the accuracy at other temperatures.

    To view the entire article, check out www.watlow.com/news/productreleases/notallaboutsensor.pdf and www.watlow.com/news/productreleases/sensorselection.pdf.

    Sensor Selection 101: Optimal Temperature Sensor Selection

    Volume Thirty-seven, Special Issue - 2006
    Volume Thirty-five, Third Quarter, 2005
    Volume Thirty-four, First Quarter, 2005

     
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