ebm-papst Fans, Blowers and Technology

ebm-papst: Efficiency Starts at Home

Posted on Mon, Jan 07, 2013

aerial shotebm-papst Inc. has recently replaced all the heating and cooling units in the main production areas at the U.S. headquarters in Farmington, CT. The units that were removed were mostly installed in 1998. Originally, we had only one gas fired central heating system in the assembly area (circa 1985) and one more gas fired central heating system in the sheet metal area (circa 1994). We added 9 separate air conditioning units in 1998.

The decision was made to replace 10 of these units with combination heating and cooling units that utilize the existing roof penetrations.  We selected the highest efficiency model available in the 20 ton size. 

The project was completed during the final two weeks of October – including all the new natural gas line piping, rigging of the old units off the roof, and installation of the new high efficiency units.  We also added an Energy Management System (EMS) that allows for direct communication, regulation, and temperature adjustment of all the units.  They are all connected in a machine network that is subsequently controlled through a single PC setup on our LAN system.

Also recently added was an emergency backup system that consists of two small generators for both buildings. These generators are hard wired into the building electric supply and sense when there is a loss of main power, then start up automatically and provide backup power to certain key systems.  They also shut back down automatically when power returns.  They also self-test themselves by starting up and running some diagnostics once a week – just to be certain that they are functioning correctly. Both generators (one outside the warehouse and one outside the factory) are fueled by natural gas. The natural gas services are hard lines coming into both buildings and flow gas under all conditions – regardless of utility power status.

The services covered by this tandem generator system are the site computer systems, phone systems, building alarm systems, and electronic building door locks.  We have also added some fork truck charging and also some lighting for the warehouse. While they are not designed to run a laser cutting machine or a punch press, the thought is that they would allow us to continue to operate at the most basic levels during an extended outage period.

Tags: heating, ebm-papst, Energy Efficiency, cooling, generators

Q&A with the Director of Operations at ebm-papst

Posted on Fri, Nov 30, 2012
with Brian Ladegard, Director of Operations

Q: A recent article in Design News discusses how ergonomics and repetitive motion injuries are major issues in manufacturing. How does ebm-papst address these concerns?

A: We review ergonomics continuously on our shop floor.  We work with outside consultants on an annual basis with tours and audit reviews – but we also use both engineering controls and supervisory controls to prevent injuries.

For example, we do ergonomic stretching exercises with each and every production employee at the beginning of the shift and then once again right after the lunch break.  These stretches are a series of basic movements that were developed independently and given to us for this purpose.  The total stretching time is approximately 5 minutes and is mandatory.  Just like athletes would stretch out before a game – so do our workers!

Also, we use engineering controls like counterbalanced tool holders for any screw driver or torque tool that applies a strong “reverse torque” that would twist operators’ arms.  We use supervisory controls like job rotation.  This is where take three people in one working place and have them switch tasks – within a single job – every two hours.  One person might be crimping for 2 hours, then switch to riveting for the next two – and then finally to testing for the last two hours.  This basic rotation allows each person to change their range of motion during the day, thus preventing too much repetition.

In the sheet metal shop, we use part supports to hold heavy parts at the required tool height – along with extensive use of scissor style pallet jacks to help prevent operators from having to bend down to floor level for the first few layers of finished parts as they come off machines.

The final examples are the use of robotics for tasks that combine high levels of repetition with higher levels of production – like the new robotic welding cell and the robotic bending cell.

Factory102011 066

Tags: ebm-papst, Manufacturing, ergonomics

ebm-papst Inc: Careers in Engineering

Posted on Tue, Nov 20, 2012
by Scott Beauchemin, Vice President - Engineering

ebm-papst’s success in the market can partially be attributed to our dedication to maintaining engineering resources to support customer projects.  Our local technical expertise allows us to provide a level of support that most competitors aren’t able to provide.  We have several engineering departments within the organization that help make that possible.

The Applications Engineering department has the highest head count of the various engineering groups at ebm-papst.  Applications Engineers are responsible for providing technical support to all customers within an assigned geographic region. Technical support can range from helping the customer select the proper air mover for their equipment to answering basic technical questions about ebm-papst product.  Applications Engineers work with customers from various market segments including HVAC, medical, industrial, IT/ telecom, etc. The diversity of our customer base gives the engineering group an opportunity to learn about various types of equipment.  Applications Engineers also spend part of their time working in our engineering lab which consists of several air flow chambers and a semi-anechoic sound room.  Customers send their equipment to our lab for baseline testing and optimization.  The Applications Engineers coordinate this effort, help perform the tests and report the results back to the customer.  The knowledge of ebm-papst product and customer’s applications gives Applications Engineers an opportunity to advance within the company if they perform well.  The educational background for an Applications Engineer is typically a Bachelor’s of Science in Mechanical Engineering.  Since our product is very much electro-mechanical, an educational background in Electrical Engineering can also be attractive. 

IMG 0855 edit resized 600

A portion of ebm-papst’s business is producing value-added assemblies for customers.  A value-added assembly can come in different configurations but it generally involves packaging a fan or multiple fans within a sheet metal assembly.  The assembly can include various other components such as connectors, filters and specific control boards.  While Applications Engineers serve as the project manager for these projects, there are three additional engineering groups that have direct responsibilities for these projects. 

The Design Engineering group is responsible for developing the value added assembly in Pro-Engineer and creating Bills of Material.  They are directly involved in working with the production floor regarding their designs.  The Design Engineer will often be seen building prototypes and working with their hands. Design Engineers will also conduct air flow modeling using Computational Fluid Dynamics software.  The goal is to optimize the air flow path in simulation so we only make sheet metal one time.  Design Engineers typically have a Bachelor’s of Science in Mechanical Engineering.  

The Electrical Engineering group is tasked with developing control boards that are used in conjunction with ebm-papst fans.  Members of the Electrical Engineering group will design the circuits, lay out the PCB so it can be fabricated, write software, build and test prototypes.  The controllers developed by this group are most often installed into a value added assembly but can be sold as a separate component on occasion. Members of the Electrical Engineering group generally have a Bachelor’s of Science in Electrical Engineering.

The last link in the value added chain is the Manufacturing Engineering group.  Manufacturing Engineers are tasked with supporting the production floor with work instructions, developing processes for manufactured parts and creating new tooling.  We are constantly expanding our manufacturing capabilities so the Manufacturing Engineers keep busy introducing new technology to the floor.  The Manufacturing Engineers work side by side with the Design Engineering group to bring a new product into production.  Manufacturing Engineers typically have a Bachelor’s of Science in Mechanical or Industrial Engineering.   

 

 

Tags: Fans, application engineers, engineering, CT, Manufacturing, jobs, design

What did that fan say? A few words from our W3GZ50 Axial fan.

Posted on Thu, Nov 08, 2012
by Lou Moffa, Market Manager - Refrigeration

W3GZ50

Our definition of "Giant" is continually evolving here at ebm-papst.  Our new W3GZ50 series EC axial fan has a 1250mm (49.2 inch) blade diameter and is currently the world's largest diameter EC air mover with integrated electronics!

Just like the other products in our EC giant line up, this new axial fan was designed from the beginning to be energy efficient, simple to use and able to be installed in a variety of air moving applications.  It can easily be customized by the end user so that it is a perfect match for use with refrigeration condensers, chiller applications or large scale ventilation applications.  Its large size allows you to reduce the number of smaller fans used.

A complete fan assembly like the W3GZ50 series streamlines your purchasing and inventory requirements.  The complete fan assembly has a motor, blade, venturi and finger guard that have all been designed to work together for maximum efficiency and eliminates the need to work with multiple vendors and patch together a fan assembly from various manufacturers.  A complete assembly can simplify your production line by reducing wiring and installation time.  

This air mover has an impressive list of features to match its size. 

-Air performance- the direct drive motor and blade combination are able to produce over 38,000 CFM and can operate efficiently with backpressure levels of up to 0.8 inches of water.

-Factory balanced blade - the rotating motor and blades are balanced as a complete assembly on the production floor to insure a smooth operation.

-Accepts traditional control inputs - So that you can fully speed control this fan in your application, our integrated electronics will accept a variety of control inputs.   For a simple set up, this means that you can use either a 0-10VDC input, 0-100% PWM input, or a 4-20mA input from an outside controller to completely vary the speed of the fan. 

-RS485 Modbus RTU protocol ready - Many of the previously mute devices that are part of our daily lives are starting to become vocal whether we like it or not!  Our cars, heating systems and even our home refrigerators are now capable of telling us what condition they are in with texts and e mails.  Our lineup of EC Giants that are over 500 Watts are ready to be heard as well!  If you would like this fan to be a vocal participant in your assembly, it is simple to establish two-way communication using the on board RS485 Modbus RTU protocol.   Not only can you command it what RPM to run at, but you can obtain the run hours, the specific alarm status, internal motor temperature and many other bits of information that will keep you informed and up to date for critical applications.   Our ongoing partnerships with key worldwide controls manufacturers make incorporating  digital communication  easier than ever before. 

-Built in PID controller- for ultimate flexibility, our built in process controller allows you to program this unit to run independently without the need for a separate process controller to handle common field tasks.  For example, when programmed to operate in closed loop sensor mode with your supplied temperature, pressure or other sensor, the fan will maintain a process specific set point.  Simply set the sensor parameters and how quickly you want the fan to respond and the process controller will take it from there.  The set point can be either entered using software to prevent unauthorized changes or from an accessible potentiometer for simple adjustments by anyone in the field.  This powerful feature is a perfect way to reduce components in your overall assembly.  Even if you choose to not use this feature as the main process controller, it can easily be programmed and can remain dormant in the background as a back up to the main process controller.

These are just some of the advanced features that this exciting new product has to help simplify your larger air moving projects.  

We welcome you to come see this impressive fan and all of our equally advanced products on display at the AHR Expo in Dallas.

AHR logo resized 600

Visit us at Booth #2967 at AHR Expo at the Dallas Convention Center in Dallas, Texas on January 28-30, 2013 

 
Please contact us for additional information at Marketing@us.ebmpapst.com

Tags: Fan Technology, Fans, Efficiency, AHR, Energy Efficiency, Refrigeration, Axial, W3GZ50

How does design influence production at ebm-papst Inc.?

Posted on Thu, Nov 01, 2012
by Scott Beauchemin, Vice President - Engineering

Factory102011 051 resized 600

An important part of ebm-papst Inc.’s business is our value-added assemblies.  These assemblies are generally customer specific sheet metal enclosures that contain one or more ebm-papst air movers.  The development process for these assemblies is very much a collaborative effort between ebm-papst and our customer.  Our goal is to create a cost-effective design that meets customer requirements and can be easily manufactured on our production floor.

A critical phase in the development process is the initial design review.  At this stage, a cross-functional team of engineers is assembled to evaluate the product and offer input into the design.  We use historical knowledge from previous products to avoid design characteristics  that may have caused issues in the past.  Our philosophy is to avoid failures by designing them out.  The product is modeled in Pro-Engineer which also allows us to get an idea of how easy the product will be to assemble.  As the type of projects we work on has evolved, we have implemented Computational Fluid Dynamics simulations into the process to optimize the air flow path before making our first prototype. 

Despite all the planning in the development phase, input from the first prototype build will be used to tweak the design.  Every product we build evolves throughout the life of the product.  Our production staff that build the product day-in and day-out provide regular feedback on how to improve the design.  Nothing replaces the feedback you get from the people that build the product.   At the end of the day, there is a feeling of satisfaction you get from seeing a product being built 10 years after you worked on the project!

Tags: ebm-papst, Manufacturing, design

Making life easier for boiler OEMs and their residential customers

Posted on Thu, Oct 25, 2012
By Tom Costello, Market Manager, Appliance and Heating

Selecting, purchasing and integrating parts from many suppliers is a really cumbersome method to create gas-air-control (GARC) systems. But as far as anyone can remember, that’s exactly the way many original equipment/appliance manufacturers (OEMs) have assembled condensing boiler systems for their residential customers.

Over the years, ebm-papst’s role in this process has been to supply premix gas blowers as part of the overall GARC assemblies.

Enno Vroljik, who runs gas valve production for ebm-papst’s European and North American operations, knew there had to be a better way. Enno joined ebm-papst in 2010 and brought with him more than 20 years of gas valve development experience from Honeywell, located in the Netherlands.

enno resized 600

Enno Vroljik, Program Manager – Gas Valves, ebm-papst Landshut.

 

To make life easier for our OEM partners and speed delivery of condensing boiler systems to their residential customers, Vroljik and his engineering team have developed a pre-assembled GARC system called the NRV Series.

Developed for residential condensing boilers rated up to 150 MBTU/H (45 kW), the NRV Series includes an NRG118 premix gas blower, mutli-venturi and GB 055 E01 gas valve that can be configured, pre-adjusted and supplied to customers as a turn-key GARC assembly.

As shown below, the NRV118 GARC assembly allows for the gas valve to be mounted in three different positions and the venturi to be rotated into six positions.

 nrv118 resized 600Vroljik and his crew aren’t done yet: They’re putting the final touches on NRV Series products for appliances rated up to 500 MBTU/H (150 kW). These will be launched in January at the AHR Expo 2013 in Dallas. Stop by our booth (#2967) to check out these new NRV systems, or contact us at sales@us.ebmpapst.com.

 

 

NRV118 Series
Gas-air ratio control assembly

Tags: ebm-papst, gas valves, NRV118, OEM, GARC

Satisfaction, Guaranteed at ebm-papst Inc.

Posted on Wed, Oct 17, 2012

A Day in the Life of a Regional Sales Administrator (Customer Service)

By Liz Callaghan

The main objective of a Regional Sales Administrator (RSA) is to ensure 100% customer satisfaction for all of our current and potential customers. Each RSA works with a member of the Sales Team to cover customers in a specific geographic territory.  Their jobs change daily, depending on what our customers need. At any given time, the RSA Team could be on a conference call with a customer or out in our warehouse. The RSA and warehouse Logistics Team work together very closely to ensure their orders are going out on schedule and shipping the correct method the customer requires. The RSA works with our international purchasing team to schedule deliveries from our factories based on customer needs.  RSAs also work with the Quality Department to manage returns. When a new project comes up, RSAs work closely with our Application Engineers to make sure the customers get the product samples they need.   RSAs work with our Planning department to make sure all Value-Added orders are on schedule.

A big part of the day is discussing the customer’s activities with their appropriate Sales People.  The RSA might need to adjust orders, expedite parts, discuss new customer details, and add new customers to the system - anything that ensures customer satisfaction.

As technology changes, we provide our RSA team with training that will keep them up to date with the latest and greatest information. Developing relationships with customers are a top priority for ebm-papst. We strive to make sure customer service is giving personal attention to the needs of each of our customers. The RSA team works every day to continue growing those relationships that our business is built on.

 

100office resized 600

Tags: Customer Service, ebm-papst

Reflecting on the "In the Pocket" Video

Posted on Tue, Oct 09, 2012
by Bob Sobolewski, President & CEO of ebm-papst Inc.

In The Pita Group'sIn the Pocket” video interview, I had the chance to speak about trending topics that affect business in terms of customer needs and communication.   

So how has ebm-papst evolved to meet customers’ needs?  In one simple word, innovation.  Innovation can help discover what opportunities exist now, or are likely to emerge in the future. Our teams collaborate with the feedback given from our customers based on market trends, to redesign and develop new products that are the leading-edge technology, ahead of our competition.   Customers look to us for the newest solutions and know they can present new air moving challenges for us to solve.  Innovation is not only about designing a new product or service to sell, but can also focus on existing business processes and practices to improve efficiency.  Recently, ebm-papst published the philosophy of GreenTech.   This idea reflects a simple but clear philosophy that goes back to our company principle: "Each new product that we develop has to be better than its predecessor in terms of economy and ecology."  It is extremely important to us that with innovation, comes the responsibility of eco-friendly practices to preserve our environment.  Not only are we producing new efficient technology to benefit our customers, but we are also ensuring that every product carries along with it the assurance of sustainability in our production practices. In addition to various enhancements, 50kW of solar panels were installed on the roof of our engineering office in Farmington, CT, in June 2011. This past June, another 50kW array was installed to supplement the original installation.


Another evolution in the way business is done. Everyone wants things instantaneously.  So at the tip of our fingers, we have the ability to instantly communicate and search for information. We must adapt to the changing business practices and stay ahead of the curve!  

Bob Sobolewski filming the "In the Pocket" video.
bob interview resized 600

Tags: ebm-papst, GreenTech, Bob Sobolewski, Energy Efficiency

Alternative energy? Germany’s All Over It

Posted on Thu, Oct 04, 2012

Lessons in sun, wind and collaboration power

By Todd Cardillo, Market Manager, Alternative Energy

Did you know that in 40 minutes the sun spills enough energy on the earth’s surface to provide our entire planet with energy for one year? Or that it would take 250 million barrels of oil (10 billion gallons) to generate as much electricity as U.S. wind turbines will generate this year?

Mulfingen 2007 06 17 resized 600Why are we not utilizing our natural resources more effectively? What I saw during a recent trip to ebm-papst’s global headquarters in Mulfingen, Germany offers a vision for what the United States could achieve.

Face time with my German colleagues gave me new information on world market trends in air movement, as well as insight on new projects. I also completed the company’s 17th annual marathon and finished in 1 hour 57 minutes and 12 seconds - my personal best.

todds trip2 resized 600

However, what struck me most during this visit was how well Germany utilizes alternative energy. During the two-hour ride from Frankfurt’s airport to headquarters in Mulfingen, I saw multiple wind farms. Set back in the countryside’s rolling hills, the size and infrastructure of these huge turbines are amazing – they’re engineering marvels! It’s hard to believe that people in the United States call these an eyesore, or complain about the noise they emit. These seem like very minor issues compared to the benefits they provide.Solar power is also huge throughout Germany – the country is ranked #1 in the world for solar usage. Bloomberg reports that Germany managed to break its record for new solar installations in 2011 despite sizable reductions in subsidies for the industry.

todds trip3 resized 600

It is very hard to drive (or run) through the villagesin Germany without seeing solar panels – they are everywhere! Germany’s large solar farms, commercial businesses and residential homes are all harnessing the sun for electricity. They have spent a lot of time and money to build this infrastructure. Now they’re reaping the benefits of low-cost, clean power.

Incentives play a BIG role in how far Germany has come in alternative energy use. In the United States, where we’re ranked #4 for solar power usage, we have federal tax rebates and similar solar incentives. In contrast   Germany offers manufacturers a fixed amount for every kilowatt-hour of energy produced by a solar system.

While Germany has concerns with the possibility that their solar incentives could be reduced by putting a one gigawatt-per year cap on new installations, we in the U.S. face an uncertain future for our Production Tax Credit (PTC). While the credit is due to expire this year, I am hopeful that it will be renewed by Congress.

The U.S. has come a long way in alternative energy use. Following Germany’s lead, it’s essential we continue to grow our alternative energy production and markets. Our population and economy will be better for it.

Tags: Solar Power, Wind Power, ebm-papst, Energy Efficiency, Alternative Energy, Germany

Connecticut ASHRAE chapter visit to ebm-papst brings mutual learning

Posted on Tue, Oct 02, 2012
by Phil Hartman, Senior Director of Marketing

On September 13, 40-50 members of the Connecticut ASHRAE chapter paid ebm-papst a visit in Farmington for a technical session. These sessions are held once a month from September through May; consisting of a technical session given by a host company, social hour, dinner, and presentations by the host company. They are an  opportunity for members to learn more about other companies and their products, and for the host company to showcase their expertise.

Those who arrived early were able to visit our new showroom and view our extensive range of products, including fans, blowers, and value-added assemblies.

displayroom 013 resized 600

To start our technical session we divided into two groups for tours – one of our manufacturing area led by Brian Ladegard, Director of Operations, and the other of our test lab, including airflow and acoustic testing areas, led by Scott Beauchemin, Vice President of Engineering. 

In the manufacturing areas, participants were able to see a variety of processes, such as sheet metal punching, bending, forming, painting, assembly and end-of-line testing.

In the lab and testing areas, Scott described the testing we are capable of for air moving devices with focus on our air test and acoustic chambers.  Participants were able to see actual customer units currently being tested. 

ASHRAE acoustic resized 600

ASHRAE axial resized 600

After the tours, the group reconvened at the Farmington Marriott for a social hour, dinner, and presentations by Armin Hauer, Advanced Technology Manager and Tom Costello, Market Manager - Heating.  Armin covered the latest fan & EC motor technology for buildings, fan efficiency metrics and the latest fan energy legislation.  Tom focused on gas component and system technology used in high efficiency residential and commercial gas fired condensing boilers, with emphasis on comparing pneumatic and electronic GARC (gas-air-ratio-control) technology.

Many thanks to Armin Hauer, an active ASHRAE member himself, for being instrumental in making this possible and for providing guidance for the content.  This was our first time hosting an ASHRAE tech session, and based on the feedback we received, the group found the tours and presentations to be informative and interesting.  It was our pleasure to host and we thank ASHRAE for their assistance and participation with this event!

Tags: Fan Technology, ASHRAE, EC motors, ebm-papst, CT