16.11.2014 Views

English - Rice Lake Weighing Systems

English - Rice Lake Weighing Systems

English - Rice Lake Weighing Systems

SHOW MORE
SHOW LESS

Create successful ePaper yourself

Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.

A magazine and REFERENCE TOOL FOR THE WEIGHING INDUSTRY / Summer 2011 • issue 1 • vol. 8


This issue<br />

Editorial Staff<br />

Carol Ailes, Technical Writer<br />

Mobile technology is sweeping the world.<br />

Handheld devices like smartphones are playing a wider,<br />

and very soon indispensable, role in everyday life.<br />

<strong>Rice</strong> <strong>Lake</strong> is ahead of the curve. Now our catalogs, technical manuals, literature,<br />

and part numbers are available on phones, tablets, laptops, and desktops.<br />

We’re looking for the next innovation to make <strong>Rice</strong> <strong>Lake</strong> information even handier.<br />

For example, see the cube at the right? It’s called a<br />

Quick Response, or QR code—a unique matrix barcode<br />

readable by QR barcode readers and camera phones.<br />

To try it, scan the QR with your smartphone—you’ll<br />

go straight to m.ricelake.com—the mobile version of<br />

our website.<br />

There, you can even access this <strong>Rice</strong> <strong>Lake</strong> magazine. It is<br />

packed cover-to-cover with interesting scale applications<br />

in weighing and process control. You’ll find information<br />

SCAN IT<br />

about wireless technology including the differences<br />

between Bluetooth®, ZigBee® and Wi-Fi. We also visit <strong>Rice</strong> <strong>Lake</strong> equipment applications<br />

at a commercial bakery, a manufacturer of car racks for sports equipment, a busy stone<br />

quarry, and a facility that performs force testing on airplane wings.<br />

Whether online or printed we hope you enjoy this issue. Then, feel free to take a moment<br />

to use any of today’s innovative forms of technology to tell us what you think. Call,<br />

email, or post a note on our Facebook page at<br />

facebook.com/ricelakeweighingsystems.<br />

We enjoy hearing from you.<br />

Melanie Al Faraj, Technical Writer<br />

Tamala Anderson, Designer<br />

Cheryl Aune, Literature Manager<br />

Bob Chatten, Translator<br />

Matt Davis, Marketing Specialist<br />

Jessica de la Cruz, Writer<br />

Melissa Hjelle, Marketing Specialist<br />

Katy Madden, Senior Editor<br />

Kelly Musil, Catalog Manager<br />

Caleb Olson, Technical Writer, Reporter<br />

Pat Ranfranz, Marketing Director<br />

Hannah Rechsteiner, Designer<br />

Adam Sharpe, Web Master<br />

Tina Slayton, Marketing Specialist<br />

Kevin Theese, Marketing Support<br />

Stacy White, Marketing Specialist<br />

Kristina Zengaffinen, Senior Designer<br />

Pat Ranfranz<br />

Director of Marketing<br />

Pat is a private pilot . He has spent years<br />

searching the Pacific for missing WWII<br />

American air crews—one including his uncle.<br />

2 RICE LAKE MAGAZINE | www.ricelake.com


this issue<br />

RICE LAKE MAGAZINE • Summer 2011 • Issue 1 • Vol. 8<br />

Inside<br />

page 4 What’s New 920i ® FlexWeigh <strong>Systems</strong>, 720i Advanced Truck Mode, Lift truck test<br />

weight, RailBoss rail scale, and RS-232 to USB Smart Cable. page 6 Raising the Dough<br />

How a single inventor fabricated a batching system for bakeries and burglars burgled the prototype.<br />

page 9 Give Your Balance a Brain Using the 920i as a serial scale control adds<br />

intelligence to precision weighing. page 10 Search for the Missing Part<br />

6<br />

Thule makes sure all the parts are in the box of auto racks for sporting equipment.<br />

page 13 Smoothing the Road Chrysler uses four pit-style RoughDecks ®<br />

to checkweigh automobile center of gravity. page 14 Wing Walking the 920i<br />

Stress-testing airplane wings with analog load cells disguised as digital load cells.<br />

page 18 Time Flies at Tilcon Automated Ticketing <strong>Systems</strong> cut the chit-chat and<br />

increase rock quarry throughput. page 22 Blowin’ in the Wind A comparison of<br />

Bluetooth ® , ZigBee ® and Wi-Fi wireless technology.<br />

10<br />

RICE LAKE MAGAZINE<br />

Online<br />

Going green? Access the <strong>Rice</strong> <strong>Lake</strong> magazine online.<br />

You will enjoy the same great stories plus links to more<br />

information. Also, with electronic access, you can easily<br />

share articles with employees and customers.<br />

To Subscribe<br />

Go to www.ricelake.com/ricelakemagazine<br />

and complete the online form. It’s that easy.<br />

If you have any questions, please email us at<br />

rlmagazine@ricelake.com.<br />

Find us on Facebook:<br />

www.facebook.com/<br />

ricelakeweighingsystems<br />

14<br />

www.ricelake.com | RICE LAKE MAGAZINE 3


WHAT’S NEW<br />

From Off-the-shelf<br />

to ready-to-weigh<br />

920i ® FlexWeigh <strong>Systems</strong><br />

Process Control<br />

Pre-engineered and programmed, 920i<br />

FlexWeigh <strong>Systems</strong> are <strong>Rice</strong> <strong>Lake</strong>’s turnkey<br />

solution to manufacturers’ most commonly<br />

used weighing processes. No need<br />

for lengthy quoting and design. Each 920i<br />

FlexWeigh <strong>Systems</strong> model is a standard<br />

design, factory tested and programmed for<br />

your specific task—yet customizable to allow<br />

you to do it your way. For more information<br />

visit ricelake.com/920iflexweigh. ▪<br />

The 720i you need for truck<br />

scale enterprises<br />

720i Programmable Indicator with<br />

Advanced Truck Mode (ATM)<br />

Advanced Truck Mode offers more data storage<br />

and reporting capabilities. Ramped-up memory<br />

capacity stores up to 99 unique customers,<br />

material, or source files and 1400+ transaction<br />

files. With ATM, the 720i programmable indicator<br />

can provide a wide range of useful reports—by shift, customer, material and a summary<br />

of the day or entire data range. See a demonstration at ricelake.com/webinars.<br />

▪<br />

Check lift truck<br />

scale accuracy without<br />

dismounting the<br />

lift truck<br />

Lift Truck Test Weight<br />

Operators stay safely in the lift truck<br />

cab. No hooks, chains or spreader bars<br />

to adjust, and accuracy verification is<br />

fast and easy. Drive in, lift, set down,<br />

and back to work.<br />

Designed for pancake cargo scales<br />

and fork truck scales. Mild steel<br />

painted weight. ASTM Class 6 tolerance.<br />

1000- and 2000-lb weight. For<br />

more information visit ricelake.com/<br />

ltweight. ▪<br />

4 RICE LAKE MAGAZINE | www.ricelake.com


WHAT’S NEW<br />

plug in this cable<br />

and connect serial devices<br />

to your PC or Mac<br />

RS-232 to USB Smart Cable<br />

Scales, balances, RFID or barcode readers<br />

can be connected, allowing the operator<br />

to instantly see output on screen.<br />

No software or driver installation required.<br />

The Smart Cable draws power from the<br />

USB port, requiring no external power<br />

supply. Windows® 7 no longer has a free<br />

HyperTerminal. With the Smart Cable, you<br />

can test RS-232 and be sure data<br />

is outputting. For more information visit<br />

ricelake.com/smartcable. ▪<br />

Wish you could weigh railcars<br />

before they leave your yard?<br />

RailBoss Rail Scale fits in your yard and your budget<br />

Many scrap yards, agricultural operations and plants that could never afford the<br />

installation downtime and cost of a conventional rail scale can afford to install<br />

RailBoss. It usually takes less than eight hours to install and is one-third the cost<br />

of conventional rail scales.<br />

The system is a series of 5'10" rail sections fitted with strain gauges. Each rail<br />

section is a weighbridge for a single wheel. The system provides total car weight<br />

plus individual truck weight. (Not Legal-for-Trade) For more information visit<br />

ricelake.com/railboss. ▪<br />

Unplug<br />

Are you hardwired to RS-232?<br />

“The scale industry is hardwired to RS-232,” Ann<br />

Crowley, <strong>Rice</strong> <strong>Lake</strong> product manager, holds up<br />

one of many cables snaking off her desk. They<br />

often overlook using Ethernet® to send data from<br />

the production line to their office.<br />

“We recently had a request from a MotoWeigh®<br />

customer. They wanted a printer to carry around<br />

occasionally to print data from the production<br />

line.” Ann suggested they use a printer with<br />

Ethernet capabilities. “They can print out their<br />

reports to the printer in the office as needed and<br />

they don’t have to carry around a printer.”<br />

The customer needed a small footprint and wide<br />

printout. The TSP800 Star printer with Ethernet<br />

option filled the bill. ▪<br />

www.ricelake.com | RICE LAKE MAGAZINE 5


on location<br />

John Imparato, the proud and colorful owner of Giannella<br />

Modern Baking Company in Paterson, New Jersey, has one of those<br />

“bigger-than-life” personalities that makes meeting him an unforgettable experience.<br />

His bakery is famous for authentic Old World breads baked from recipes handed<br />

down through his family—recipes John wants kept secret.<br />

Marcelo Tise, engineer, inventor, and owner of Advanced Automation, Riverdale, N.J., had experience working with bakery equipment and<br />

knew what needed improving at Giannella. The result is a minor-ingredient batching system geared toward the baking industry and named<br />

6 RICE LAKE MAGAZINE | www.ricelake.com


on location<br />

the Batch Process Analysis (BPA) system,<br />

all designed, fabricated and installed<br />

by Advanced Automation in Riverdale.<br />

With BPA’s modular design, Marcelo and<br />

his team can design and build systems with<br />

as many ingredient hoppers as needed, and<br />

write all the software needed as well.<br />

The BPA also allows bakeries to tweak<br />

recipes for maximum cost savings. For<br />

instance, if a recipe calls for five pounds of<br />

sugar, a bakery could leave out one ounce<br />

of sugar from each batch. The end product<br />

will be consistent from batch to batch,<br />

and the BPA allows a bakery’s recipes to<br />

remain secret under password protection.<br />

The BPA has a very small footprint,<br />

taking no more room than the work<br />

benches used today. The system also<br />

allows bakeries to track all minor ingredients<br />

without having to put pen to<br />

paper. Giannella uses eight IQ plus® 355<br />

weight indicators and one 820i® weight<br />

indicator. The IQ plus 355 indicators<br />

have analog outputs that the PC reads.<br />

It is used to monitor the weight in any<br />

one of eight feed hoppers that are filled<br />

with micro ingredients for commercial<br />

baking. The PC stores the many familysecret<br />

formulas. The operator can select<br />

the formula he or she wants. The 820i<br />

indexes a moving bench scale under the<br />

feed hoppers. As the hoppers get low<br />

on product, a signal is sent to the batch<br />

master who manually re-loads. Software<br />

automatically tracks and records daily<br />

production runs, allowing bakeries to<br />

adhere to strict standards demanded by<br />

quality regulation associations.<br />

Through the BPA’s touchscreen system,<br />

workers can select the recipe and the total<br />

batch count and hit “run.” The BPA will<br />

measure the ingredients into a tray, with<br />

accuracy down to the ounce, eliminating<br />

waste of expensive minor ingredients.<br />

It took Marcelo about a year and a half<br />

to develop the BPA, from conception<br />

to programming to manufacturing. The<br />

machine and software system conforms<br />

to, and in some instances surpasses, all<br />

mandatory ingredient traceability and<br />

handling standards.<br />

Continued on page 8<br />

“I can’t control the prices of my ingredients, but I can control how much I use.<br />

BPA was the answer. Since installing BPA we increased our yield, tracked our use,<br />

and traced raw products via lot numbers down to the batch number.<br />

No more writing down lot numbers or errors in my batch. Our operators just<br />

select the recipe, select the mixer to use, and start the batch.”<br />

John Imparato, president of Giannella Modern Baking Company, Paterson, N.J.<br />

John demonstrates the old way—when bakers measured<br />

ingredients by eye and instinct, with a pinch of<br />

this and a scoop of that. He scoops and pinches ever<br />

more expensive ingredients like sugar and flour out<br />

of a barrel before weighing them on a baker’s scale.<br />

This inevitably results in waste and spillage.<br />

With BPA’s modular design, Marcelo and his team can design and build systems with as many<br />

ingredient hoppers as needed. The eight-silo BPA, 10 feet tall and 8 feet wide, stands in the back corner<br />

of Giannella’s, turning out perfect batches every time.<br />

www.ricelake.com | RICE LAKE MAGAZINE 7


on location<br />

Angela recalls,<br />

“We were floating<br />

on air— until we went<br />

outside to the parking<br />

lot; the trailer with the<br />

prototype inside<br />

was gone!”<br />

Center: Marcelo Tise, and left: Angela Falzarano<br />

Raising the Dough continued from page 7<br />

What trailer?<br />

the Advanced Automation team showed<br />

their first BPA prototype at the International<br />

Baking Industry Exposition in Las<br />

Vegas last September. Companies of all<br />

sizes showed great interest in Marcelo’s<br />

innovative solution.<br />

Angela Falzarano, director of New<br />

Business Development, said, “After the<br />

show, we were floating on air—until<br />

we went outside to the parking lot. The<br />

trailer with the prototype inside was<br />

gone!” Angela recalls a comment Marcelo<br />

made at the time, ‘This is not going to<br />

bring us down!’ ”<br />

Indeed, it did not. Marcelo’s team rebuilt<br />

the BPA and made it even better.<br />

Today, the eight-silo BPA,<br />

10 feet tall and 8 feet wide,<br />

stands in the back corner<br />

of Giannella’s, turning out<br />

perfect batches every time.<br />

8 RICE LAKE MAGAZINE | www.ricelake.com<br />

During initial installation and setup,<br />

Marcelo ran into some glitches with one<br />

of the scales and called Joe Geisser, director<br />

of <strong>Rice</strong> <strong>Lake</strong>’s Northeastern region.<br />

Joe told Marcelo not to worry. He would<br />

be there the next day, and he would stay<br />

there until the system was up and running<br />

perfectly.<br />

Angela said, “It was this level of commitment<br />

that solidified the reason for<br />

Marcelo to depend on <strong>Rice</strong> <strong>Lake</strong> for all<br />

his needs when it comes to all scales and<br />

accessories.” Angela added, “Whether it<br />

is a Saturday at 2 p.m. or a regular work<br />

day, Joe Geisser and the <strong>Rice</strong> <strong>Lake</strong> team<br />

have been there to support us with ALL<br />

of our needs. We appreciate that. We believe<br />

in that same level of commitment.”<br />

Angela confides, “We love Joe...we love<br />

<strong>Rice</strong> <strong>Lake</strong>.”<br />

What became of the missing trailer?<br />

It was found ditched along the roadside.<br />

Security video caught the thieves cutting<br />

the lock and hitching up the trailer.<br />

It turns out that the theft wasn’t to steal<br />

Marcelo’s invention. There was also a<br />

Harley-Davidson show going on, and<br />

the perps thought there were a couple<br />

of nice “hogs” in the trailer. The thieves<br />

went to prison for grand theft. The<br />

prototype was returned to Marcelo—<br />

disassembled. Had the thieves actually<br />

stolen a bro’s bike, they might have been<br />

disassembled and ditched themselves. ▪<br />

Just-in-time technology<br />

The introduction of the BPA to the<br />

market falls directly in line time-wise<br />

with President Barack Obama’s signing<br />

of the Food Safety Modernization Act<br />

(FSMA) into law on January 4. The bill<br />

brings the first major updates to U.S.<br />

food safety legislation in more than 70<br />

years. It requires food processors and<br />

manufacturers to be able to verify that<br />

any imported ingredients or products<br />

are produced in compliance with U.S.<br />

laws and regulations. The food safety<br />

bill also calls for increasing government<br />

inspections at food processing facilities<br />

and, for the first time, gives the Food<br />

and Drug Administration (FDA) the<br />

power to recall unsafe foods.<br />

The Food Safety Modernization<br />

Act requires the FDA to establish a<br />

product tracing system, which, in turn,<br />

could force food companies to better<br />

track the supply-chain movement of<br />

each ingredient used in every batch.<br />

Bakers in New Jersey, for example,<br />

will need to document which sack of<br />

salt they used to make the last round<br />

of semolina bread, and more importantly,<br />

which stores and restaurants<br />

received those loaves. ▪


Tech talk<br />

Give your<br />

balance a brain<br />

Add 920i® intelligence<br />

to precision weighing<br />

By Ann Crowley, <strong>Rice</strong> <strong>Lake</strong> product manager<br />

Balances typically have some built-in functions<br />

for weighing, counting or percentage calculations,<br />

but do not have configurable controls or<br />

outputs to each application. <strong>Rice</strong> <strong>Lake</strong> can create<br />

custom software linking the control power<br />

of the 920i indicator/controller to any precision<br />

balance application. Using the 920i as a serial scale<br />

controller (without an A/D scale) gives precision weighing<br />

the same flexibility and programmability demanded in<br />

industrial weighing.<br />

Example 1: This custom program was designed for a pharmaceutical company.<br />

The custom 920i program allows the user to directly interface a scanner to the 920i.<br />

The operator can either scan or input data through the 920i keypad. The scanner has<br />

the ability to scan code 39 or 128. The 920i interfaces to the Datamax® M-4206 label<br />

printer and produces a label bearing a Datamatrix barcode. These labels are manually<br />

applied to boxes. This system can also be connected to two serial scales.<br />

Feature Descriptions<br />

Storage for 5000 Products.<br />

Data prompted for entry:<br />

• Raw material grade<br />

• STD weight number<br />

• Lot number<br />

• Expiration date<br />

Example 2: This solution was created for an application where micro ingredients<br />

as little as one milligram are precision-weighed before adding to batches weighing<br />

1,000 lbs or more.<br />

The recipe consists of several ingredients (up to 10) and each ingredient may have<br />

multiple lots (maximum lots per ingredient is three).<br />

If the target for the the ingredient is 550 grams:<br />

1. The operator places an empty pan on the balance and zeroes the scale.<br />

2. The operator adds product to the pan.<br />

3. The 920i prompts “Enter/Scan Lot.” The operator scans the 39 barcode with the lot<br />

number or keys it on the 920i front panel. If it is a valid lot for that ingredient in<br />

the recipe database, it will continue,<br />

otherwise it will jump to the “Supervisor<br />

Needed” section.<br />

4. The gross weight from the scale is<br />

stored and subtracted from the target.<br />

Example 3: The end user needs to measure<br />

the density of pork skin. Pieces are<br />

measured and cut a determined length<br />

and width. The operator is prompted to<br />

enter this length and width in millimeters.<br />

The operator then pushes the print button<br />

on the balance and the 920i computes<br />

the value and displays in grams per<br />

cubic centimeter.<br />

The 920i is programmed for a serial scale<br />

input using the TS-6200 balance. The TS-<br />

6200 balance was chosen for the platform<br />

size and IP65 rating for washdown.<br />

Just three examples from many options,<br />

adding precision to the intelligence<br />

used in industrial weighing and giving<br />

your balance a brain—it’s the smart<br />

thing to do! ▪<br />

www.ricelake.com | RICE LAKE MAGAZINE 9


on location<br />

Imagine being responsible for quality control—<br />

with newly hired packers packing thousands of car rack kits<br />

containing dozens of parts during your busiest season.<br />

Imagine being a customer service rep taking “missing part”<br />

calls from people assembling their Thule car rack<br />

for a weekend trip leaving tomorrow.


on location<br />

John Bova, Thule quality coordinator,<br />

acknowledges, “Last year was a phenomenal<br />

year for us. We were so busy;<br />

we set all kinds of records. The size of<br />

our workforce tripled. The ratio of new<br />

people to experienced people was four<br />

to one. That brought in a whole new<br />

array of challenges for training and<br />

quality control.<br />

“We received complaints from customers<br />

about missing parts and hardware. At<br />

that time we were doing what we called<br />

‘dock audits.’ We would go out to our<br />

shipping area a couple of times a day,<br />

open random boxes, see what was inside<br />

to make sure everything was there. If<br />

something was missing, packers would<br />

have to take apart the whole skid of<br />

boxes. It meant shutting down the line so<br />

they could go through every box, count<br />

the parts, re-pack and re-tape. If it was a<br />

big issue, we might ask them to go to the<br />

warehouse and check everything they<br />

had packed that day. We pack thousands<br />

of boxes a week. So the likelihood of<br />

us finding something just by random<br />

checking was slim.”<br />

Thule was determined to give their<br />

customers a product that presented the<br />

best buying experience. The Thule quality<br />

control group determined the cost of<br />

labor alone in one year to investigate<br />

customer complaints, find the missing<br />

part, write the order, and send to shipping<br />

was about $30,000. Thule created<br />

Continued on page 12


on location<br />

Who is Thule?<br />

The next time you see a sleek car rack for sports gear,<br />

look for the distinctive THULE logo, pronounced<br />

“Too-lee.” In 1942, Thule was founded in Sweden by<br />

the Thulin family, when Erik Thulin put his name on<br />

a Pike Trap he designed and sold in Scandinavia. By<br />

the 1960s, the company concentrated on car-related<br />

products, and the first roof rack was born. New<br />

product categories were added in the 70s, and new<br />

markets all over the world were opened.<br />

Thule North America is headquartered in Seymour, CT.–<br />

a perfect setting. Thule employees share a common bond<br />

of passion for their chosen sport. Seymour is surrounded by<br />

hilly roads along the Naugatuck River Watershed. The parking<br />

lot is filled with small, smart cars bristling with racks and carriers.<br />

Search for the Missing Part continued from page 11<br />

some unique package-identifying<br />

procedures to reduce costs but were<br />

still not satisfied.<br />

John Bova’s team decided to look into a<br />

checkweighing system that would also<br />

record product ID for traceability. John<br />

Russo, Jr., integration specialist with<br />

Progressive Scale & Software Solutions,<br />

Bethel, CT., designed the first system<br />

using four scales running off the 920i®.<br />

John Bova says, “We tried that for about<br />

six or eight months to work the bugs<br />

out. During the six months prior to installing<br />

the system, we found 120 boxes<br />

with missing parts. Once the system was<br />

installed, the drop in missing part complaints<br />

was immediate. After we tested<br />

it, my plan was to spread the application<br />

through the entire plant, and I had a<br />

year to put together the plan, get capital<br />

funding, and marshal equipment.”<br />

Thule corporate folks interviewed the<br />

distributors and end users at trade shows.<br />

When asked about product concerns,<br />

the most outstanding complaint involved<br />

missing parts in packages. Several distributors<br />

objected to the cost for them<br />

to replace the part and meet customer<br />

deadlines. The package checkweighing<br />

“Fifteen or more people will go out for<br />

a noon ride. Most of our rides are ten to<br />

fifteen miles. Some people take an hour;<br />

some can do it in thirty minutes. And we<br />

have lots of people who do marathons<br />

and triathlons.”<br />

“I think the gas crunch gave our business<br />

a boost. People are buying smaller cars so<br />

they need racks and rooftop carriers. People<br />

are taking shorter trips by car and longer<br />

trips by bike, canoe, and kayak.”<br />

John Bova<br />

We are an international group of passionate people who help active families, outdoor<br />

enthusiasts, and professionals find safe, easy, and stylish ways to transport their gear.<br />

Working for Thule is more than just a job. Our employees live an active lifestyle and bike,<br />

ski, run, hike, sail, and camp—on their own or with colleagues at Thule supported events.<br />

Connecticut is biking beautiful<br />

The state extends 90 miles (145 km) from east to west and 55 miles (90 km) from north<br />

to south. The state is divided into two sections, the eastern highland and the western<br />

highland, which are separated by the Connecticut Valley lowland. In the south, low rolling<br />

coastal plain leads to the Connecticut shore and the famous bike trails along<br />

Long Island Sound.<br />

John Russo, Jr., improved on the first 920i-based<br />

system. “To reduce cost, I used 720i’s. Now the user<br />

can checkweigh and see the actual results.“ Operators<br />

can now enter a comment recording what was<br />

wrong or missing.<br />

12 RICE LAKE MAGAZINE | www.ricelake.com


solution became an obvious answer to<br />

the problem. Checkweighing 100% of the<br />

packages makes the best buying experience<br />

for Thule customers.<br />

“Corporate had been thinking of systems<br />

to ID product for traceability, and we<br />

were already on it from the checkweighing<br />

for missing parts.” Representatives<br />

from the corporate office in Sweden came<br />

out, looked at the solution, and wanted it<br />

duplicated. “They’re talking about all the<br />

products and plants. In October we’ll do<br />

Chicago, then Florida, then Massachusetts,<br />

then Europe.”<br />

John Russo, Jr., improved on the first<br />

920i-based system in the second build.<br />

“To reduce cost, I used 720i s instead of<br />

the 920i. Now the user can checkweigh<br />

and see the actual results whereas we were<br />

just running a light box with a remote<br />

920i. When there is an error, the operator<br />

can enter a comment to record what was<br />

wrong and which part was missing.” The<br />

first system John designed was hard-wired.<br />

But because of the way Thule constantly<br />

“All the cell leaders<br />

can change jobs; these<br />

720i systems can be<br />

rolled to where they’re<br />

needed. It’s a great<br />

benefit to have<br />

the display right in<br />

front of them.”<br />

John Bova,<br />

Thule quality coordinator<br />

changes their packing areas, this second<br />

system has evolved into 16 wireless 720i<br />

units networked back to a computer running<br />

MS SQL Server 2005 Express Editor.<br />

The units can be rolled to any work cell as<br />

needed. John is working on an even more<br />

sophisticated system which will include<br />

negative weighing—checking to see if the<br />

operator took a part from a bin.<br />

John Bova is pleased. “All the cell leaders<br />

can change jobs; these 720i systems can<br />

be rolled to where they are needed. It’s a<br />

great benefit to have the display right in<br />

front of them. I can monitor the whole<br />

system at my desk and pull up all the<br />

scales or any one scale and monitor to<br />

read the comments in real time. If I see<br />

a lot of errors, I can go and investigate<br />

what may be going wrong; maybe they’re<br />

putting in the wrong hardware bag or<br />

maybe they changed cartons.”<br />

When you assemble your car rack from<br />

Thule, they want you to be completely<br />

satisfied. It’s part of the Thule experience<br />

from start to the finish line. ▪<br />

Smoothing the Road:<br />

RoughDecks ® checkweigh<br />

Chryslers<br />

In 1920, Walter P. Chrysler teamed up<br />

with three ex-Studebaker engineers<br />

to design a revolutionary new car.<br />

They defined the Chrysler brand as<br />

affordable “luxury” vehicles known<br />

for innovative, top-flight engineering.<br />

Within a decade of its founding, Chrysler<br />

Corporation had earned the title of<br />

Detroit’s “engineering company.” Their<br />

automotive firsts included Floating<br />

Power (a new method of mounting<br />

engines to isolate vibration), replaceable<br />

oil filters, downdraft carburetors<br />

and one-piece curved windshields.<br />

For years, Chrysler enjoyed a premium<br />

luxury position competing with<br />

Cadillac and Lincoln.<br />

Following Fiat’s acquisition of a 20%<br />

stake in Chrysler LLC, Fiat declared their<br />

plan to return the brand to an upmarket<br />

marque and launched their marketing<br />

slogan—Imported from Detroit. One<br />

example of that return to top-flight<br />

engineering and luxury is a smooth,<br />

quiet ride. Toward that end, Ron Little,<br />

Kanawha Scales, Michigan, has devised<br />

an unusual application of RoughDecks.<br />

The system consists of four pit-style<br />

RoughDecks® and a 920i dual channel<br />

indicator that is set up in Chrysler’s<br />

“customer satisfaction audit area” at<br />

the auto manufacturing plant in East<br />

Detroit. Ron explains that during each<br />

shift, twenty cars are “audited” by being<br />

driven over the four scales. The driver<br />

gets out and scans the VIN number<br />

sticker into the 920i. The system weighs<br />

each wheel, records the individual<br />

wheel weight, combined weight, time<br />

and date. The information is then<br />

passed on to each local plant and then<br />

on to corporate over Chrysler’s dedicated<br />

server. The whole process takes<br />

about 30 seconds. Kanawha installed<br />

the first test system in 2008. After several<br />

months of testing, Ron has installed<br />

several more systems in Chrysler plants<br />

in the U.S. and Canada. ▪


ON LOCATION<br />

An estimated one out of three people is afraid to fly. Their constant thoughts of what might go<br />

wrong can be overwhelming. After all, when soaring 30,000 feet in the air, one cannot pull over for<br />

a pit stop in the rare case of an emergency. Fortunately, innovations in the industry are helping to improve systems and<br />

equipment—and thus easing the fears of the bug-eyed flier.<br />

Before assembly of an aircraft can even begin, one of a plane’s most essential elements—the wings—must undergo strenuous<br />

force testing. Sophisticated system diagnostics are integrated, and rigorous maintenance schedules must be followed.<br />

One Quebec wing manufacturer has been performing these tests for over 25 years. Because of the wide range of plane sizes, wing<br />

specifications are diverse and so are their test requirements. A Cessna wing’s force threshold is obviously less than a passenger<br />

jet’s threshold. Sturdy wings can be guaranteed by using an indicator to interpret these force tests into a weight value.<br />

However, when Balances Industrielles Montréal (BIM) started working with the wing manufacturer<br />

in 2006, they observed that inefficient data capturing and collection were<br />

elements that could be corrected and streamlined with <strong>Rice</strong> <strong>Lake</strong>’s<br />

durable load cells and 920i® programmable indicator.<br />

Simon Grenier, programmer analyst for BIM,<br />

had an idea. Simon thought it would<br />

be ideal to use a variety of load<br />

Continued on page 16<br />

A Cessna wing’s force threshold is obviously less than a<br />

passenger jet’s threshold. By using a 920i programmable<br />

indicator to interpret these forces as weight values,<br />

sturdy and balanced wings can be designed; providing<br />

smooth flights to soothe the bug-eyed flier.<br />

14 RICE LAKE MAGAZINE | www.ricelake.com


ON LOCATION<br />

by Caleb Olsen, reporter<br />

www.ricelake.com | RICE LAKE MAGAZINE 15


ON LOCATION<br />

Wing Walking the 920i continued from page 14<br />

cells for different wings tests to accommodate<br />

the different load requirements.<br />

With only two indicators on site, it would<br />

require the creation of a custom plugand-play<br />

load cell system.<br />

Simon contemplated the possibility of<br />

starting with a six-wire cable, but using<br />

only the standard four-wire connection<br />

and repurposing the additional two wires.<br />

Could he disguise an analog load cell as a<br />

digital load cell that could be recognized<br />

by the controller?<br />

Simon began work on the plug-and-play<br />

load cell system. He applied resistance<br />

to the two supplementary wires—which<br />

are only on the connector and are not<br />

going to the load cell. “When we connect,<br />

it is linking the analog input that is<br />

sending a signal to it,” Simon explains.<br />

“The signal travels through the resistance<br />

and returns with a value we use to assign<br />

an ID for that load cell. Because each<br />

load cell undergoes a 25,000-pound<br />

bench test for calibration and we use the<br />

same simulator for each load cell in the<br />

system, we are able to calculate an accurate<br />

resistance factor for each load cell.<br />

“In the database, we have a correction<br />

factor to the calibration that we have<br />

done with the simulator. So when we<br />

perform the 25,000-pound bench test,<br />

we determine the difference between<br />

Simon says “plug in your load cell.”<br />

With Simon Grenier’s one-of-a-kind system, any load cell<br />

can be connected and display an accurate weight on the fly.<br />

Referencing a database of predetermined correction factors<br />

paired with load cell IDs, the system applies the appropriate<br />

factor before displaying the weight value.<br />

what it’s supposed to show, with what we<br />

get. The multiplier required to bring it<br />

back to the correct value is added to the<br />

920i database. If a portable bench test for<br />

25,000 pounds would be easy to bring to<br />

the customer, we could have used something<br />

much simpler, but they are sending<br />

the load cell here without an indicator.”<br />

Simon explained when they plug in<br />

the load cell, it uses the calibration and<br />

applies the correction factor before displaying<br />

the weight. “No linearity point is<br />

required, but it gives the correct calibration<br />

for wherever the load cell is plugged<br />

in on any indicator. We mirror the same<br />

database in all their indicators, and it’s<br />

adjusting the weight automatically to<br />

give them the correct value.”<br />

Each indicator reads two load cells<br />

simultaneously and captures one<br />

weight per second for 45 minutes at a<br />

time, recording immense amounts of<br />

information. This data is stored in the<br />

920i’s internal memory for<br />

up to 12 hours before it is<br />

downloaded to a PC via a<br />

920i WLAN option card.<br />

Prior to BIM’s system,<br />

only raw data could be<br />

recorded. Now, with the<br />

comprehensive 920i database,<br />

more meaningful<br />

data can be collected.<br />

“When weights are captured,<br />

we link all information<br />

through the database,<br />

including employee number,<br />

time, date, and type<br />

of wing. We create a graph<br />

showing the high and low<br />

values and the estimated<br />

breaking point assigned<br />

to that wing. The client<br />

imports the database<br />

access file and can immediately<br />

see the test results by<br />

looking at the graph. They<br />

used to spend significant<br />

time analyzing the data.<br />

It would take a full day for<br />

only a few tests. Now, they<br />

just click a button and the<br />

job is done.”<br />

BIM also incorporated another visual<br />

aid into the system—a warning light<br />

that indicates when the test is approaching<br />

the estimated breaking point. This<br />

decreases the possibility of too much<br />

weight being accidentally applied to a<br />

wing. Since each wing’s test specifications<br />

are in the 920i database, adding<br />

the light was a breeze.<br />

BIM is not done with the system yet,<br />

however. The client has been working on<br />

external battery power, and BIM is programming<br />

a low-battery alert. Using the<br />

16 RICE LAKE MAGAZINE | www.ricelake.com


ON LOCATION<br />

same analog input, BIM is programming<br />

the 920i to get a battery voltage reading<br />

at specified time intervals (every five<br />

minutes). When the voltage drops below<br />

a certain level, an alert will be displayed.<br />

“It is another step to make them more<br />

efficient,” Simon says. “After they saw<br />

the improvements with our first system,<br />

they are all about efficiency.”<br />

Simon explains before the new system<br />

was in place, the old setup was constantly<br />

breaking. “The load cell was like<br />

a plastic box. It was a nightmare. The<br />

solution we had at first was a simple<br />

system with a competitor’s indicator.<br />

The project really evolved after we had<br />

training with <strong>Rice</strong> <strong>Lake</strong>.” The competitor’s<br />

indicator used a programming<br />

language that was too difficult. “With<br />

a book, I could read the code if it was<br />

very small, but it seemed like gibberish.<br />

These days, a lot of people are familiar<br />

with the basics of programming, and<br />

when you look at the <strong>Rice</strong> <strong>Lake</strong> code, it<br />

is structured like any PC programming<br />

language. You just need to learn the specific<br />

commands for the application.”<br />

Simon recalls that a lot of programming<br />

was involved, but when it was up and<br />

working, he was pleased, though not<br />

surprised. “I was confident in the <strong>Rice</strong><br />

<strong>Lake</strong> equipment. Recording everything<br />

was no problem.”<br />

Capturing a stable resistance value<br />

through the repurposed load cell wires<br />

was more of a challenge. When the load<br />

cell is connected, the wire is moving and<br />

the resistance gives different values. Simon<br />

decided to put a timer on capturing the<br />

resistance—when a change in voltage is<br />

detected, a three-second timer begins<br />

before the value is captured, allowing<br />

for stability. When a load cell is connected<br />

to the calibration system at BIM,<br />

an automated message, “Recondition in<br />

Progress,” is displayed and a confirmation<br />

message appears when the load<br />

cell is complete. “It’s perfect!” Simon<br />

explains. “We have never had a load cell<br />

that didn’t detect, and we are very happy<br />

with them. The client is rough on their<br />

connectors, which is why the old ones<br />

were always breaking. We have a good<br />

load cell with a good connector now.”<br />

Adding new load cells to the system is<br />

easy; the client simply sends it to BIM<br />

for calibration. Once finished, BIM<br />

sends the load cell back with an updated<br />

data file containing the new load cell ID.<br />

Current data is updated with the new<br />

calibration factor.<br />

The client is currently manufacturing<br />

the lower portion of the wings, but they<br />

are in the process of adding the upper<br />

part, so the system will need to be<br />

modified to accommodate a different<br />

test. BIM is also working on automating<br />

the system with hydraulic jacks controlled<br />

by the 920i.<br />

A once simple application has evolved<br />

into a sophisticated data collection<br />

behemoth with plug-and-play, automatically<br />

calibrated load cells. With the<br />

help of <strong>Rice</strong> <strong>Lake</strong> as co-pilot, Balances<br />

Industrielles Montréal has been able to<br />

soar to safe new heights. ▪<br />

Grad School<br />

for Scale Techs<br />

New scale techs learn a lot on the job, and they learn<br />

even more in our classroom. Even experienced scale techs benefit<br />

from ongoing training to keep up with the latest weighing equipment,<br />

software and techniques.<br />

<strong>Rice</strong> <strong>Lake</strong> Technical Training Seminars are the quickest, surest<br />

and most economical means to bring all your scale techs<br />

up to speed. Newcomers learn the basics—<br />

old hands learn new skills.<br />

Go to ricelake.com/training for class dates and details,<br />

or call Paul Cernick: 715-434-5128<br />

800-472-6703 • www.ricelake.com<br />

mobile: m.ricelake.com


ON LOCATION<br />

Time<br />

Automated<br />

18 RICE LAKE MAGAZINE | www.ricelake.com


ON LOCATION<br />

Flies at Tilcon<br />

go<br />

Ticketing <strong>Systems</strong> increase plant throughput<br />

Tilcon owns and operates dozens of quarries, asphalt and<br />

recycling plants, water terminals, and highway construction divisions,<br />

in New York and New Jersey. At the Mount Hope Quarry alone they<br />

weigh hundreds of trucks on a busy day. Advance Scale Company, Inc., Rockaway, N.J.,<br />

has installed Automated Ticketing <strong>Systems</strong> (ATS) on the truck scales to handle that<br />

volume of traffic and the enormous amount of data they generate.<br />

“Safety–Productivity–Data Security–Lower Overhead”<br />

There are four major reasons for using the <strong>Rice</strong> <strong>Lake</strong> Automated Ticketing <strong>Systems</strong>. You<br />

might even be able to justify the purchase of an ATS if you had only two of these important<br />

reasons, but when you can hit all four, you will have made a big contribution to<br />

your company’s bottom line. The management at Tilcon. recognized this important tool<br />

several years ago as a means of gaining more throughput from their truck scale transactions,<br />

and have instituted a program to install an ATS at all of their truck scales.<br />

Efficiency<br />

In the past it took an average of three minutes (and sometimes up to eight minutes) for<br />

a truck to drive on a truck scale, capture a weight, drive off the scale, have the driver<br />

into the scale house to get his ticket,<br />

get back in his truck and drive off. These<br />

trips were sometimes drawn out by conversation<br />

and coffee.<br />

<strong>Rice</strong> <strong>Lake</strong> <strong>Weighing</strong> <strong>Systems</strong>’ ATS has<br />

reduced this three-minute process to 45<br />

seconds. The driver now drives on the<br />

scale, takes the ticket from the kiosk without<br />

leaving the cab, converses through an<br />

intercom with three of the most efficient<br />

(and friendly) weigh masters in the industry,<br />

and moves on.<br />

Inside the scale house, Ellen Hays, Ronnie<br />

Mattia and Chrissy Bishop, weigh masters,<br />

say “saving time” is the first advantage<br />

of the ATS. Weigh masters like to keep<br />

the line moving fast; it makes time fly.<br />

When truckers came into the scale house,<br />

they were likely to visit a few minutes.<br />

According to Ellen, “We would talk about<br />

traffic or weather or family. We are still<br />

able to offer a friendly greeting over the<br />

intercom and keep the traffic moving<br />

without ignoring the personal contact”.<br />

Cell phones can be a problem when the<br />

Continued on page 20<br />

Ronnie Mattia, Tilcon weigh master, has seen incredible improvements in efficiency. “It wasn’t so long ago,<br />

everything—driver ID, weight, product—was recorded manually.”<br />

Ellen Hays, Tilcon weigh master, has a large sign taped<br />

on her window: “GET OFF YOUR PHONE, please.”<br />

www.ricelake.com | RICE LAKE MAGAZINE 19


ON LOCATION<br />

Time Flies at Tilcon continued from page 19<br />

driver is chatting instead of processing<br />

the ticket. Ellen has a large sign taped<br />

on her window, “GET OFF YOUR<br />

PHONE, please.”<br />

Safety<br />

Dan Batelli, supervisor of Tilcon’s scale<br />

operations, is enthusiastic about auto<br />

ticketing. And, surprisingly, not primarily<br />

because they are operating far more<br />

efficiently. “Safety” was the first benefit<br />

he mentioned—keeping truckers in<br />

their vehicles. “Tilcon is committed to<br />

a full-bore safety program.”<br />

It was obvious that this statement is true.<br />

When we got out of our vehicle, Paul<br />

Gerard instructed us to turn our wheels<br />

into the curb so that the vehicle would<br />

not go straight down the incline where<br />

we had parked. Hard hats and safety vests<br />

were the order of the day while out of the<br />

vehicle. We knew going in that safety was<br />

not just a slogan on the wall at Tilcon.<br />

When the driver gets out of the truck, there<br />

is an increased opportunity for injury. With<br />

hundreds of trucks passing through the<br />

yard daily—in snow, ice, and rain—keeping<br />

drivers in their trucks keeps them safer and<br />

lowers liability risk for Tilcon.<br />

Reduced Costs<br />

Before the ATSs were installed, each of<br />

the scales needed a weigh master standing<br />

at a booth taking care of drivers,<br />

one at a time. Now three weigh masters<br />

handle all the scales with the streamlined<br />

process created by the ATS.<br />

Right: Paul Gerard, Advance Scale<br />

vice president of operations, and Kyle<br />

Vough, Advance Scale senior technician,<br />

installed and maintain ATSs on the<br />

Tilcon truck scales to efficiently handle<br />

hundreds of trucks a day.<br />

Secure Data<br />

Weights are captured electronically and<br />

information is streamed to their Enterprise<br />

Software that keeps track of all costs,<br />

inventory, and billing. No keying errors.<br />

Keying errors cost most companies 1%<br />

to 2% in annual revenue. No paper to<br />

lose or misplace. They have captured the<br />

information, which is only going into<br />

their system.<br />

Dealing with the environmental issues<br />

on the high-activity truck scales at Tilcon<br />

represented a challenge that Paul and<br />

Kyle Vough, Advance Scale senior technician,<br />

had long prepared. The kiosks are<br />

located out in the weather. Hot in summer,<br />

and way below freezing in winter.<br />

High volume meant frequent changes<br />

of ticketing stock.<br />

Everyone interviewed explained how the<br />

ATS improved their workday. Efficiency,<br />

safety, reduced cost and secure data—<br />

those are the four big reasons Tilcon lists.<br />

How would Automated Ticketing <strong>Systems</strong><br />

improve your workdays? ▪<br />

The Dirt on<br />

Gravel<br />

Gravel is any loose rock that is of<br />

particular particle size. Geologic classes<br />

place gravel between sand and cobble.<br />

Gravel can also be classified by size—granule<br />

and pebble. One cubic yard of gravel<br />

typically weighs about 3,000 pounds; or a<br />

cubic meter is about 1,800 kilograms.<br />

Gravel can also be distinguished by type.<br />

• Bank gravel is gravel intermixed with<br />

sand or clay.<br />

• Bench gravel is a bed of gravel located<br />

along the side of a valley, usually the<br />

former location of a stream bed when<br />

it was higher.<br />

• Creek rock is rounded, semi-polished<br />

stones, potentially of a wide range of<br />

types, dredged or scooped from river<br />

and creek beds.<br />

• Crushed rock is rock that is mechanically<br />

broken into small pieces then sorted by<br />

filtering through various size screens.<br />

• Crushed stone is crushed limestone or<br />

dolomite, screened to size classes, widely<br />

used in concrete and to surface roads<br />

and driveways, often topped with tar.<br />

• Limestone crushed stone is dense grade<br />

aggregate (DGA), or crusher run, a<br />

mixed grade of mostly small crushed<br />

stone in a matrix of crushed limestone<br />

or dolomite powder.<br />

• Fine gravel consists of particles<br />

with a diameter of 2 to 4 mm.<br />

• Lag gravel is a surface accumulation,<br />

or topping, of coarse gravel<br />

produced by removing finer particles.<br />

• Pay gravel is also known as “pay dirt”; a<br />

nickname for gravel with a high concentration<br />

of gold and other precious<br />

metals, which are famously recovered<br />

by panning.<br />

• Pea gravel consists of small, rounded<br />

stones used in concrete-surfaced sidewalks<br />

and driveways, and in home aquariums.<br />

• Piedmont gravel is coarse gravel washed<br />

down from high ground by mountain<br />

streams and deposited on relatively flat<br />

ground, where the stream runs slower.<br />

• Plateau gravel is a layer of gravel on<br />

a plateau or other region above the<br />

height where stream-terrace gravel<br />

is usually found.<br />

• River run gravel is naturally deposited<br />

gravel found in and next to rivers<br />

and streams.<br />

Source: Wikipedia.org<br />

20 RICE LAKE MAGAZINE | www.ricelake.com


Order an Epson ® printer and you could<br />

win a Kindle ® loaded with <strong>Rice</strong> <strong>Lake</strong><br />

and Epson manuals!<br />

Your name goes into the drawing when you order<br />

one of these printers during our Epson Printer<br />

Promotion between April 1 and May 31, 2011.<br />

The Epson TM-U295 is the smallest ticket<br />

printer in the world with the most user-friendly<br />

features. It is ultra-light and ultra-compact, but<br />

loaded with features, like an easy-to-use<br />

touch panel and automatic paper ejection.<br />

The Epson TM-U590 Ticket Printer prints<br />

one to four copies on a variety of tickets.<br />

This highly versatile printer handles<br />

slips, checks, and ticket applications<br />

up to 42 columns.<br />

Learn more at<br />

ricelake.com/epsonkindle.<br />

TM-U590<br />

800-472-6703<br />

www.ricelake.com<br />

mobile: m.ricelake.com<br />

TM-U295


Tech talk<br />

Blowin΄ in the Wind<br />

Wireless<br />

technology<br />

made simple<br />

by Jim Daggon, <strong>Rice</strong> <strong>Lake</strong> senior engineer,<br />

Emerging Technologies<br />

22 RICE LAKE MAGAZINE | www.ricelake.com


Tech talk<br />

The first wireless message sent over<br />

the open sea was “Are you ready?”<br />

Guglielmo Marconi sent that message<br />

across the Bristol Channel over a distance<br />

of a little under four miles, a record for<br />

wireless broadcast distances and the<br />

first to prove that wireless communication<br />

over long distances including ships<br />

at sea was possible.<br />

Ready or not, ever since that day—May<br />

13, 1897—the use of wireless communication<br />

has continued to increase in both<br />

distance and capability. Wireless communication<br />

has been all around us, invisible<br />

to all but those who are actively using it.<br />

Today, turning on a radio, TV, or GPS,<br />

using a Bluetooth® headset for our<br />

phone, or even a laptop in a coffee shop,<br />

transforms us into users of wireless<br />

technology. There are many different<br />

uses, implementations, applications,<br />

and frequencies in use today. They all<br />

co-exist in the same air space that we<br />

live in, blissfully unencumbered by its<br />

presence until we request it.<br />

In this article, we look at three specific<br />

implementations, their uses, and advantages<br />

and disadvantages for certain applications:<br />

Bluetooth, ZigBee, and Wi-Fi.<br />

Bluetooth<br />

Bluetooth was initially just a code name<br />

for the technology and was taken from<br />

the nickname of Harald Blåtand who<br />

was the King of Denmark between AD<br />

940 and AD 985. The rumor was that<br />

the Danish king was given the nickname<br />

“Bluetooth” because he was so fond of<br />

blueberries that his teeth were stained<br />

blue. The founders of the Bluetooth<br />

SIG (Special Interest Group) felt that<br />

the name was appropriate because<br />

Harald Bluetooth and the technology<br />

are both of Scandinavian origin. Just<br />

as King Harald Bluetooth united the<br />

warring factions in parts of what are<br />

now Norway, Sweden, and Denmark,<br />

Bluetooth technology unites multiple<br />

forms of wireless communication such<br />

as the computing, mobile phone, and<br />

automotive markets into a single, secure,<br />

low-power, low-cost, globally available<br />

radio frequency.<br />

Bluetooth wireless technology is geared<br />

toward voice and data applications in<br />

what is referred to as a Personal Area<br />

Network. Bluetooth wireless technology<br />

operates in the unlicensed 2.4 GHz spectrum,<br />

and is therefore able to penetrate<br />

solid objects.<br />

The range of Bluetooth wireless technology<br />

is application specific. The Bluetooth<br />

Specification mandates operation over<br />

a minimum distance of 10 meters or<br />

100 meters depending on the Bluetooth<br />

device class, but there is not a range limit<br />

for the technology. Manufacturers may<br />

tune their implementations to support<br />

the distance required by the use case<br />

they are enabling. Bluetooth technology<br />

sets up a Personal Area Network and is<br />

primarily used for connecting devices in<br />

a small physical perimeter.<br />

A maximum of seven devices can be<br />

paired with a master device. The master<br />

Continued on page 25<br />

www.ricelake.com | RICE LAKE MAGAZINE 23


Tech talk<br />

Honey Bee Dance<br />

Scout bees look for nectar. Once they find a source they return to the hive and<br />

perform a dance which tells the forager bees where the source is located.<br />

The forager bees dance behind the scout bees until they learn the location.<br />

Once they know they fly out to collect the nectar.<br />

Why Bluetooth?<br />

If you are in your car, it is convenient to<br />

set up your cell phone, your car’s GPS,<br />

and your hands-free headset to “talk” to<br />

each other. That way, if you have your<br />

headset with you, as you get in the car,<br />

your headset can talk to the phone. If<br />

you forgot your headset, the GPS can be<br />

paired with the phone to allow you to talk<br />

on the phone via the microphone in the<br />

GPS. Since they are close to each other and<br />

need to be paired up differently each time<br />

you use them, it is convenient to pair them<br />

once, and when they are in range, have<br />

them connect automatically.<br />

In a scale application, you could use<br />

Bluetooth for a master device that occasionally<br />

has to travel around to different<br />

scales and get the readings from them<br />

when the operator is close by.<br />

Why ZigBee®?<br />

The main advantage to ZigBee is its ability<br />

to self-form a “mesh” network to get the<br />

message through. A good example of this<br />

would be in a building where you wanted<br />

to collect the temperature in every office<br />

on multiple floors, to balance the heat or<br />

air conditioning. If someone rearranged<br />

his or her office and unknowingly placed<br />

a big steel file cabinet in front of a node,<br />

it might be cut off from the rest of the<br />

network. However, only the messages<br />

from that node would be lost. The rest of<br />

the messages that used that node as a<br />

routing device would simply form a new<br />

route around it by using another path. It<br />

would also make it very obvious where the<br />

problem was, rather than a whole section<br />

of the network going down and having<br />

the old “Christmas tree light” problem of<br />

locating the fault or faults.<br />

A load cell (and its associated A/D circuitry)<br />

could be connected to a ZigBee end device<br />

and transmit weight on a regular basis<br />

to an indicator that was within range of<br />

either the load cell or a coordinator node<br />

to extend the distance.<br />

Why Wi-Fi?<br />

Wi-Fi is rapidly growing in use. The<br />

advantages are the ability to handle large<br />

amounts of data with a long range (see<br />

chart on page 27) between devices. PCs<br />

use this regularly to communicate on the<br />

Internet, at home, or in coffee houses and<br />

other establishments that offer free Wi-Fi.<br />

Hotels use this since it is much easier to<br />

equip an existing hotel with Wi-Fi than it<br />

is to hard wire Ethernet® to every room.<br />

A scale indicator can be equipped with<br />

Wi-Fi to communicate wirelessly to either an<br />

existing Ethernet network or the Internet.<br />

24 RICE LAKE MAGAZINE | www.ricelake.com


Tech talk<br />

Blowin’ in the Wind continued from page 23<br />

device is placed in a discovery mode,<br />

and the slave device is also placed in a<br />

pairing mode. When the master detects<br />

the slave device, a confirmation is usually<br />

required. Once this is acknowledged, the<br />

master can be placed in a mode that will<br />

always acknowledge the slave with or<br />

without a manual confirmation. Manual<br />

confirmation is slower but more secure.<br />

Also, master units can be set to nondiscoverable<br />

mode to prevent them from<br />

sending out discovery packets.<br />

Technical Specs<br />

Bluetooth uses adaptive frequencyhopping<br />

spread spectrum modulation<br />

(AFHSS), which uses 79 channels or<br />

frequencies at 1 MHz intervals between<br />

2.4 and 2.485 GHz. It is unlicensed in<br />

most countries. Because of this, it can<br />

easily co-exist with other technologies<br />

and modulation schemes even in the<br />

same frequency.<br />

The peak data rate of Bluetooth technology<br />

depends on the version and power,<br />

which ranges from 2.5 microwatts (low<br />

energy) and 1-3 Mbps to 2.5 milliwatts<br />

with a data rate of up to 24 Mbps.<br />

Bluetooth technology is omnidirectional<br />

and does not require line-of-sight positioning<br />

of connected devices.<br />

Security has always been and continues<br />

to be a priority in the development of the<br />

Bluetooth specification, which allows for<br />

three modes of security.<br />

The cost of Bluetooth chips is under $3.<br />

ZigBee®<br />

The ZigBee technology was initially<br />

designed to make a mesh network of<br />

sensors for use in building automation<br />

for lighting and temperature control. The<br />

name of the brand is a reference to the<br />

behavior of worker honey bees after they<br />

return to the beehive.<br />

When food is discovered by scout workers,<br />

they return to the hive. Shortly after<br />

their return, many foragers leave the hive<br />

and fly directly to the food. The remarkable<br />

thing about this is that the foragers<br />

do not follow the scouts back (the scouts<br />

may remain in the hive for hours). So the<br />

scout bees have communicated to the<br />

foragers the necessary information for<br />

them to find the food on their own by a<br />

dance. The scouts zig and zag back and<br />

forth in a certain manner and number of<br />

repetitions to convey to the foragers information<br />

about the odor of the food, its<br />

direction from the hive, and its distance<br />

from the hive.<br />

In the same manner, ZigBee wireless<br />

devices have the ability to create ad hoc<br />

networks dynamically, so that messages<br />

can get through even if the environment<br />

or the different nodes in the network<br />

are changing or adversely affected<br />

in some way.<br />

There are three different types of ZigBee<br />

devices:<br />

ZigBee coordinator (ZC): The most<br />

capable device, the coordinator forms<br />

the root of the network tree and might<br />

bridge to other networks. There is exactly<br />

one ZigBee coordinator in each network<br />

since it is the device that started the<br />

network originally. It is able to store information<br />

about the network, including<br />

Continued on page 26<br />

Top<br />

Access<br />

SURVIVORS’ ® bolt-free covers<br />

permit easy access to load cells<br />

and electronic components<br />

through the scale deck. Side<br />

access can be difficult depending<br />

on the scale location to buildings.<br />

Harsh weather and age also cause<br />

bolts to seize up or break off.<br />

Owner benefits: fast throughput, low maintena


Tech talk<br />

Blowin’ in the Wind continued from page 25<br />

acting as the trust center and repository<br />

for security keys.<br />

ZigBee Router (ZR): As well as running<br />

an application function, a router can act<br />

as an intermediate router, passing on data<br />

from other devices.<br />

ZigBee End Device (ZED): Contains just<br />

enough functionality to talk to the parent<br />

node (either the coordinator or a router);<br />

it cannot relay data from other devices.<br />

This relationship allows the node to be<br />

asleep a significant amount of the time,<br />

thereby extending battery life. A ZED<br />

requires the least amount of memory,<br />

and therefore can be less expensive to<br />

manufacture than a ZR or ZC.<br />

Technical Specs<br />

ZigBee is also referred to as the IEEE<br />

802.15.4.<br />

Low Power—Individual devices must<br />

have a two-year battery life to pass<br />

ZigBee certification.<br />

ZigBee operates in the 2.4 GHz region<br />

also, in most of the world, with an ad-<br />

ditional spectrum at 915 MHz and 868<br />

MHz in Europe. It uses direct-sequence<br />

spread spectrum (DSSS) modulation and<br />

a very powerful 128-bit AES encryption<br />

scheme. The ZigBee network can have<br />

as many as 65,000 nodes, all of which<br />

can be with routers, or end users, but<br />

only one coordinator! With all the traffic<br />

going along its network, collisions are<br />

avoided and corrected when they do<br />

occur using CSMA/CA—Carrier Sense<br />

Multiple Access/Collision Avoidance.<br />

This means that whenever a device has<br />

a need to transmit, it listens for a free<br />

carrier, and then transmits. This method<br />

avoids collisions, rather than trying to<br />

sort them out later.<br />

One advantage of the low power<br />

(multiyear) specification is that it includes<br />

a very fast “wake-up time” for end devices.<br />

Wi-Fi<br />

The term Wi-Fi is almost always associated<br />

with the IEEE 802.11x standard.<br />

The term Wi-Fi was originally coined<br />

as a twist on Hi-Fi, and references to<br />

Wireless Fidelity appear in some early<br />

documents from the Wi-Fi alliance. The<br />

Wi-Fi alliance serves a purpose similar<br />

Potential Wireless LAN Uses<br />

802.11<br />

A B G N<br />

Data Rate 6-54 mBPS 1-11 Mbps 1-54 Mbps 7.2-72.2<br />

MIMO 1 1 1 4<br />

Modulation ODFM DSSS OFDM,DSSS OFDM<br />

Indoor Range 115 125 125 230<br />

Outdoor Range 390 460 460 820<br />

Patented Mounts<br />

SURVIVORS’ exclusive G-Force mount system also eliminates<br />

excess movement and troublesome check rods and bumper bolts.<br />

Bumper bolts often cause binding and end up loose if they are not<br />

properly tightened when set.<br />

Open Bottom<br />

SURVIVORS’ open-bottom design eliminates enclosed areas where<br />

moisture builds up and causes rust. <strong>Rice</strong> <strong>Lake</strong>’s unique asphalt<br />

emulsion coating is applied to non-visible steel surfaces and undersides<br />

before pouring concrete decks.<br />

ce, long service, and bragging rights―you own th


Tech talk<br />

Comparison Chart<br />

Mode Power Data Rate<br />

(Max Bps)<br />

Cost<br />

Minimum<br />

Range<br />

Nodes<br />

Determinism<br />

Ease<br />

of Setup<br />

Security<br />

Bluetooth Pairing 1mW-100mW 24M Low 10 Meters 7 High Very easy Fair<br />

ZigBee ZigBee 1mW and lower 250K Low 75 Meters 65,000 Little or none Simple Good<br />

Wi-Fi TCP/IP 100mW 54M Med 95 Meters 4 million + Little or none Moderate Very good<br />

to both the Bluetooth SIG and the<br />

ZigBee alliance—to provide testing and<br />

assurance of conformity to the standard.<br />

It is almost synonymous with computer<br />

wireless communications.<br />

Wi-Fi is used for a Local Area Network<br />

of PCs. These can be connected in an<br />

ad hoc network or as a more static<br />

method using either MAC addresses<br />

or fixed IP addresses.<br />

Technical Specs<br />

There are 14 channels designated in<br />

the 2.4 GHz range spaced 5 MHz apart<br />

(with the exception of a 12 MHz spacing<br />

before Channel 14). Because the protocol<br />

requires 25 MHz of channel separation,<br />

adjacent channels overlap and will interfere<br />

with each other. Consequently, using<br />

only channels 1, 6, 11, and 14 is recommended<br />

to avoid interference.<br />

Potential Wireless LAN uses of this range<br />

are documented by IEEE 802.11a, b, g<br />

and n. Countries apply their own regulations<br />

to the allowable channels, allowed<br />

users, and maximum power levels within<br />

the frequency range. (See Potential Wireless<br />

LAN Uses chart.)<br />

So, which is best? It depends on the application.<br />

(See Comparison Chart).<br />

Need an easy-to-set-up, on-the-fly network<br />

with a limited number of nodes that<br />

you can simply pair up? Use Bluetooth.<br />

Need a very low-power network to reliably<br />

send small amounts of data over a<br />

wide range regardless of network conditions?<br />

Use ZigBee.<br />

Need a fast network that can be expanded,<br />

can send large amounts of data<br />

quickly, can be scaled quickly, and is<br />

future-proof? Use Wi-Fi. ▪<br />

Rodent<br />

Barrier<br />

SURVIVORS’ flexible steel<br />

conduit at the connection point<br />

to the load cell and steel conduit<br />

throughout are the ultimate<br />

protection against rodents<br />

chewing through to wires. They<br />

can chew through braided or<br />

sheathed cable causing scales<br />

to malfunction or fail.<br />

Stone Crusher<br />

SURVIVORS’ exclusive rock guard crushes<br />

stones before they find a spot to bind the scale.<br />

e toughest truck scale on earth<br />

Watch the video, send for the book, and register for a free<br />

SURVIVOR safety vest at ricelake.com/survivor<br />

800-472-6703<br />

www.ricelake.com<br />

mobile: m.ricelake.com


230 W. Coleman Street<br />

<strong>Rice</strong> <strong>Lake</strong> WI 54868<br />

Change Service Requested<br />

Presort Standard<br />

U.S. Postage<br />

Paid<br />

<strong>Rice</strong> <strong>Lake</strong><br />

<strong>Weighing</strong> <strong>Systems</strong><br />

Who knew weighing equipment could be so<br />

interesting—or so critical to an enterprise?<br />

But it is. Scales touch our lives every day.<br />

So let’s stay in touch.<br />

Catch up with old friends, make new ones,<br />

collaborate on solutions, share weighty stories,<br />

and keep up with what’s new.<br />

Just go to www.facebook.com/ricelakeweighingsystems, click the Like button,<br />

and join the conversation. Share a snippet or story involving <strong>Rice</strong> <strong>Lake</strong> equipment<br />

and we will enter your name in a drawing to win this iPad. That’s something else you’re bound to Like!<br />

*Do it before July 1, 2011, and you’ll be in the drawing to win this iPad.

Hooray! Your file is uploaded and ready to be published.

Saved successfully!

Ooh no, something went wrong!