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However ice machines use electricity, and, in view of soaring energy prices, it is advisable to make sure that the ice machine is energy efficient and check that it is being used in a way to maximise performance.
Manitowoc, the leading commercial ice machine manufacturer in the US, produces some of the most energy efficient models on the market.
Note for editors: British manufacturer Classeq, part of the Winterhalter group, is the UK’s leading and most popular warewasher brand for independent and smaller-scale caterers. The Publicity Works is a division of The Publicity Works (UK) Limited, registered in England no. With up to 5,000 spot welds in a typical mid-sized car, OEMs are investing in the latest energy-efficient welding technologies to cut costs. The researchers have developed a new welding technique which is said to consume 80% less energy than a common method, yet creates bonds that are 50% stronger. In resistance spot welding, manufacturers pass a high electrical current through pieces of metal, so that its natural electrical resistance generates heat which partially forms a melt pool and creates a weld. In VFA welding, a high-voltage capacitor bank creates a very short electrical pulse inside a thin piece of aluminium foil. So far, the team has created strong bonds between commercial steel and aluminium alloys, and has joined high-strength steel and aluminium with weld regions that are said to be stronger than the base metals. To overcome these issues, the DeltaSpot spot-welding system from Fronius features a continuous process tape that runs between the electrodes and the metal sheets. The flexible and totally controllable process permits continuous spot welding of a consistently high quality, says Fronius, regardless of whether the material to be welded is aluminium, different grades of steel, or galvanised or organically coated sheets. Georg Fischer is among the automotive suppliers that have worked with Fronius to develop a DeltaSpot solution, notably to help manufacture the aluminium doorframe of the latest Porsche Panamera. The latest DeltaSpot development is an evolution of its pincer gun, which is said to improve both the serviceability and the technology of the system, leading to shorter production downtime and lower operating costs. At last year’s Laser World of Photonics exhibition in Munich, Germany, Audi took to the stage to outline how a range of laser-based welding processes are having a positive effect on production. Jan-Philipp Weberpals, from Audi’s Neckarsulm plant said that the remote laser welding of aluminium hang-on parts using a 4kW direct-diode source from Laserline was able to complete nine seam welds in just 12 seconds – half the time taken by more conventional, tactile laser welding.
Among the major developers of laser welding technology is Trumpf, which as well as supplying OEMs is now rolling out its products to the supply chain, such as the recently launched TruLaser Robot 5020 Basic Edition.
These costs are cut further if the company already owns a laser-cutting machine incorporating a TruDisk solid-state laser. Among the users of Trumpf TruDisk laser technology is GKN Driveline’s Zwickau plant, Germany, which two years ago switched from CO? to a TruDisk 5302 fibre-guided laser.
Another advantage of the solid-state laser is that it operates at a wavelength that the material can absorb more efficiently, thus requiring far less laser power.
Another process gaining popularity in automotive applications is laser hybrid welding, where arc welding and laser welding are carried out simultaneously, in the same weld pool and in the same welding operation.
Compared with conventional metal inert gas (MIG) or laser processes that use a cold wire feed, laser hybrid welding is said to achieve three times the welding speed and, thanks to lower energy input, consumes far less electrical energy while simultaneously reducing thermal distortion.
In CMT, the wire movement is incorporated into the process control and heat is inserted only very briefly.
In friction stir welding (FSW), the energy required at the weld lies between laser welding (which needs less) and MIG welding (which needs more), says The Welding Institute (TWI). Using aluminium, the partnership says that the new process can deliver a car-door inner panel that is 62% lighter and 25% cheaper than that produced with today’s manufacturing methods, while maintaining the speed, scale, quality and consistency required by the automotive industry. The research team decided that improving FSW to allow companies to manufacture aluminium tailor-welded blanks (TWBs) had very good potential for expanding the use of this lightweight material in vehicles. With this new process, a single FSW machine can join more than 250,000 automotive components a year. According to the TWB Company, more than 100 aluminium blanks were independently welded, formed and analysed in close co-ordination with GM. ABB’s Statcon and Dynacomp technologies for reactive power compensation are being used by Fiat in India to address weld quality issues due to challenges in local power quality. Statcon and Dynacomp are claimed to provide fast and smooth, dynamic reactive power compensation, and to solve a variety of industrial network power quality problems associated with fast and variable loads such as low power factor, voltage sags, flicker and high harmonic levels.
Statcon is a technology based on IGBT (insulated gate bipolar transistor – a fast-switching and highly efficient power semiconductor) that ABB says provides fast and dynamic reactive power compensation with a response time of only 20 to 30 milliseconds.
The latest generation of Statcon – developed by ABB India – features control, operational, optimisation, protection diagnostics and user-interface enhancements that meet the market’s growing needs for advanced functionality. Dynacomp is a thyristor-switched capacitor technology said to provide rapid and transient-free power factor compensation for low-voltage networks.
To receive bi-weekly updates on global manufacturing and production, please subscribe to our free newsletter. American Hospital Lighting Company, LLC (AHL) provides energy conservation lighting solutions to healthcare organizations. ASSA ABLOY has introduced its Ecoflex lock technology, available from ASSA ABLOY Group brands CORBIN RUSSWIN and SARGENT. ASSA ABLOY has introduced its Ecoflex lock technology, available from ASSA ABLOY Group brands CORBIN RUSSWIN and SARGENT.In a move that signals a breakthrough in energy efficiency, ASSA ABLOY has introduced its Ecoflex lock technology, available from ASSA ABLOY Group brands CORBIN RUSSWIN and SARGENT.

The lock is ideal for electronic access control applications whether it’s used as a basic electrified lock in conjunction with a wall reader, in an integrated hardwired lock or in an integrated battery powered lock. With the lower power draw, the load on each power supply is lessened, reducing costs, simplifying deployment and improving system reliability. ABOUT RETROFITThe world as we knew it is undergoing a historical change, thanks to a grueling shift in the economy that is forcing our nation and others to navigate away from consumption and toward savings. RetrofitTVExperience a world of retrofitting without leaving your desk via our retrofitTV channel.
The measurements and tests, conducted by Pon Power in collaboration with ABB on Myklebusthaug Offshore’s platform supply vessel “Dina Star” identified reduction of specific fuel oil consumption of up to 27 percent. The tests also measured fuel consumption in dynamic positioning operations during challenging weather conditions, identifying fuel savings of 14 percent.
In addition to fuel consumption, Pon Power and ABB measured Onboard DC Grid’s effect on engine room noise levels.
Dina Star is powered by four Caterpillar 3516 engines in combination with a C32 in a variable speed application. ABB’s Onboard DC Grid represents a breakthrough for the maritime industry in optimized propulsion by distributing power through a single DC circuit providing significant power savings while also improving the safety and redundancy compared with traditional AC systems.
By distributing electricity in DC, the Onboard DC Grid system allows engines to be operated at different speeds.
Posted on June 16, 2014 with tags ABB, dina star, News, Offshore, Onboard DC Grid, Pon Power.
Maersk Drilling Norge AS was established in 1990 and employs a staff of approximately 1000 people. Do you attach great importance to quality and do you have an affinity with offshore projects? Where previously some got away with buying-in bags of ice, they now find demand has far outstripped this method of supply. Many ice machines need clearance space around the sides for proper ventilation to work efficiently.
Placing it next to heat-generating kitchen appliances will force the machine to work harder.
If the water flow becomes restricted due to built-up mineral deposits, the ice machine takes longer to run through its cycles. Harvest assist technology speeds the release of ice from machine to storage bin, shortening ice production cycle time and reducing energy consumption. The importance of reducing energy consumption has seen this topic come under increasing scrutiny at academic institutions worldwide, with engineers at Ohio State University, US, among those claiming a breakthrough. It could have a significant impact on the automotive industry, which is trending on cars that combine traditional steel parts with lighter, alternative metals to reduce vehicle weight. However, the high currents consume a lot of energy, and the melted portions of metal are never as strong afterwards as they were before. Within a few millionths of a second, the foil vaporises, and a burst of hot gas pushes two pieces of metal together at speeds approaching thousands of miles per hour. The technique can also be used to shape metal parts at the same time it welds them together.
However, conventional spot welding, especially of aluminium components, is characterised by high electrical consumption and electrode wear. This protects the electrodes, brings clean, fresh material to the contact points before each weld, and reduces total energy consumption. According to the company, the demonstrable increase in product quality and system productivity, along with reduced energy consumption and material, all come together to provide a more efficient and stable production process. The transformer and the rectifiers have also been moved closer to the electrodes so as to reduce transmission losses. As well as increasing the weld speed, the remote laser is said to be 25% more energy efficient.
Said to pave the way toward automated laser welding, the compact robotic system has six axes and welds mild steel, stainless steel and aluminium at sheet thicknesses up to 4mm.
This is because the laser can be used to power an extra unit integrated into its network, for instance the TruLaser Robot 5020 Basic Edition.
Furthermore, arc welding consumables (and gas mixtures) can be used, giving a degree of control over the weld quality and properties greater than is possible with autogenous laser welding. However, robots equipped with conventional MIG or metal active gas (MAG) welding systems must stop frequently to clean welding spatter from the nozzles. However, a partnership between General Motors, TWB Company, Alcoa and Pacific Northwest National Laboratory (PNNL), has seen the development of an FSW process that is claimed to reduce production time and costs while delivering strong, lightweight parts. Since then, TWB Company says it has become the first in the world to install and operate equipment for aluminium TWBs with high-volume manufacturing capability. In addition, the solutions have helped to improve energy efficiency with regard to power factor, which has been boosted to 99.5%.

It delivers smooth, step-less compensation by generating inductive or capacitive power and is suitable for improving power quality in weak networks. A total of 23 Dynacomp panels of various power ratings were installed at substations that feed the powertrain, body-in-white, paint and assembly shops, as well as the R&D facility and utility systems.
Furthermore, the solution’s power-save mode restarts automatically when loads are sensed, thereby saving on auxiliary power and eliminating manual starts.
The energy efficiency lighting solutions provided by AHL are designed to help reduce energy consumption and to promote the overall wellness of patients and healthcare staff. Ecoflex electrified mortise locks offer a remarkable 97 percent reduction in energy usage compared to standard electrified locks. Ecoflex’s innovative actuator design further improves system reliability by eliminating the risk of voltage drops and inductive kickback, enabling longer cable runs and eliminating the need to add kickback diodes to an installation, for reduced cost and complexity.
One lock body can be used for 12V – 24V applications and can be easily field-configured for fail-safe or fail-secure operation. The design and construction industries have experienced huge losses in revenue, opportunities and employees. These are the first documented results from a vessel outfitted with ABB’s Onboard DC Grid, which allows engines to run at variable speeds for top fuel efficiency at each load level.
Dynamic positioning operations, where computers automatically maintain a vessel’s position and heading, account for a considerable portion of a typical offshore vessel’s operational profile. Tests showed 30 percent noise reduction, contributing to improved working conditions aboard the vessel. The ability now to document this level of fuel efficiency alongside the noise reduction is a very important new step for us as a power solution provider, especially for our customers operating in challenging conditions,” says Ole Knarberg, Commercial Director for the Marine segment in Pon Power Scandinavia.
The results from Dina Star, the first vessel to feature ABB’s advanced Onboard DC Grid technology, are promising and enhance our competitive edge,” says Tore Myklebusthaug, General Manager at Myklebusthaug Management. Platform support vessel “Dina Star” delivered to Myklebusthaug Management by Kleven Yard in 2013, is the first vessel powered by the Onboard DC Grid. As a result, the fuel consumption and emissions are reduced significantly in comparison with traditional propulsion systems. The solution is to install an in-house ice machine to ensure a constant supply of freshly made ice.
In line with current worries about climate change and energy consumption Manitowoc suggests the following guidelines when selecting ice machines. To help keep machines cleaner, look for ice machines that have built-in antimicrobial materials that inhibit the growth of bacteria and reduce the frequency of cleaning.
However, despite recent advances in materials design, alternative metals still pose a practical challenge to OEMs.
In recent years, Daehn and his team have been trying to find ways around these problems, amassing more than half a dozen patents on a system called vaporised foil actuator (VFA) welding. Importantly, the system’s TruDiode direct-diode laser, with its 40% efficiency, means that users also benefit from low operating costs. Careful assessment of a welding line’s needs and power usage is always the first step in generating savings. Selected re-use of editorial content from this site is permitted conditional on attribution and a link. In particular, Ecoflex can offer significant savings in fail-safe applications such as stairwell towers, where locks on every floor draw constant power. ABB’s Onboard DC Grid power distribution system was granted “Approval in Principle by American Bureau of Shipping” in January 2014. Annual savings on energy is about 2640 tons of standard coal, 6.6 million kilowatts hours of electricity. As a result, a number of automotive manufacturers, notably Hyundai Motor, have switched to the cold metal transfer (CMT) process.
From that point forward, facilities can decide to upgrade, streamline and monitor welding equipment in the way that best suits the plant’s needs and overall savings goals. The Onboard DC Grid also facilitates use of batteries and other energy storage devices which further improve the energy efficiency and reduction of emissions. Critically, energy use is reduced because the electrical pulse is short, and the energy required to vaporise the foil is less than what would be needed to melt the metal parts.
CMT is said to result not only in far less welding spatter, but also considerably more stable metal transfer and a significant reduction in the tilt angle of the electrode.
This alone is said to reduce the stoppage time of robot welding cells by more than 60% as well as increasing energy efficiency.

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