METTLER TOLEDO Railroad Weighing Technology. Agenda About METTLER TOLEDO Making the right Rail...
-
Upload
gervais-carroll -
Category
Documents
-
view
241 -
download
3
Transcript of METTLER TOLEDO Railroad Weighing Technology. Agenda About METTLER TOLEDO Making the right Rail...
METTLER TOLEDORailroad Weighing Technology
Agenda
About METTLER TOLEDO
Making the right Rail scale investment for your business
Building the system
POWERCELL PDX® innovations in: - Accuracy- System reliability
Operational savings from railroad scale performance & accuracy
3
Our Company
METTLER TOLEDO is a global manufacturer and marketer of precision instruments for use in the laboratories, manufacturing,
and food retailing.
Worldwide presence
12,000 employees
Sales $2.3 billion in 2011
Company History
5
Sales per Region
in mUSD
1595
1482
936 10
96 1148 12
14 1304 14
04
1
998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
1065
1794 19
73
1729
Americas 34%
Europe 37%
Asia / RoW29%
2309
1968
Global Manufacturing
USAGermany
United Kingdom
China
Switzerland
Internal usage only
Complete Truck and Rail Scale Solutions
Software
Life Cycle
PRODUCTS
SERVICES
Global Technology Leadership
Load Cells
PDX
Truck Scales Rail Scales
Installation Construction Service Calibration
Terminals
Internal usage only
MT – Global Leader in Vehicle / Rail Scales
MT Vehicle Units Market Leadership
From 2009 – 2011: Over 16,000 vehicle and rail scale systems installed using either POWERCELL PDX or POWERCELL MTX
MT has direct operations & local partners in 44 countries supporting our vehicle business
There are over 1M POWERCELL's installed across the globe
POWERCELL® PDX® is the most successful vehicle load cell system on earth!
Internal usage only
Railroad Scale Solutions
• Above Ground & Pit
• Filling
• Concrete & Steel Deck Combos • Custom Solutions
• Liquid Weighing • Grain Dumps • Coupled in Motion
Internal usage only
Delivery Services / Installation / Project Management
Internal usage only
Delivery Services / Installation / Project Management
Internal usage only
Global Rail Scale Customers
12
Internal usage only
Agenda
About METTLER TOLEDO
Making the right railroad scale investment for your business
Building the system
POWERCELL PDX® innovations in: - Accuracy- System reliability
Operational savings from truck scale performance & accuracy
Customers expect the investment to last 20-30 years +
Selecting the right technology is vital
Reliability is business critical – Unplanned downtime can cost an operation in lost business & profit margin
Scale inaccuracy is a hidden profit drain – How much product are you giving away with each weighment?
Your cash register is expected to reliably operate in the elements for years –
How to defend against temperature, lightning, moisture & flooding
You can't afford to be out of compliance with legal weight limits
Making the right Railroad Scale investment
The Railroad Scale is the cash register or compliance system of
your operation.
15
Railroad Scale Applications
Single Draft Weighing Un-Coupling & Weighing Individual cars
High Accuracy
On Board Loading and Unloading
Legal for Trade
High Initial Investment
Dual Draft WeighingIndividual Carriage Weighments
Less Accurate
Not Legal for trade
Lower initial investment
16
Railroad Scale Applications
Coupled In Motion
New PSD CIM for Liquid Weighing
Single & Dual Draft CIM
High Accuracy
High Efficiency
Legal for Trade
High Initial Investment
Good for weighing solids
Pseudo Single Draft (PSD) CIM
More accurate than traditional CIM
High Efficiency
Can be Legal for Trade
High Initial Investment
Good for weighing liquids
MT Patented Technology
Internal usage only
The typical rail scale system costs…
34%
20%
Internal usage only
Load Cell System
5%
76%
Accessories
4%Terminal
3%
Software
10%
Weighbridge
Maintenance & repair costs over the life of the rail scale*
Most Common Service IssuesLoad Cell / Sensor failure (lightning, moisture, fatigue)Junction box / totalizer failure Load Cell line / cables (moisture, cut, wear)Terminal failureWeighbridge issues (bumpers, checking, cleaning)
* Based on actual service records
Typical Service Expenses
$ 2,500: Annual PM, re-calibration
$ 2,500: Replacement of single LC
$12,000: Repair from lightning strike
Internal usage only
Agenda
About METTLER TOLEDO
Making the right truck scale investment for your business
Building the system
POWERCELL PDX® innovations in: - Accuracy- System reliability
Operational savings from truck scale performance & accuracy
Internal usage only20
The Weighbridge
Internal usage only21
VRS241
The New VRS241
25' Double
12.5' Single
Internal usage only22
VRS241
The VRS241 is an improved design replacing the 7260
Several improvements have been made to provide additional benefits to the customer including- POWERCELL® PDX ® load cells included standard
- Installation improvements make installation faster and easier.
- Rail has improved adjustability
- Available in Concrete or Steel
- Available with standard rail clips or Pandrol fasteners
- Faster Load Cell Update Rate 17 Hz 36 Hz
Internal usage only
Liquid Weighing Applications
Installation
23
Improvements from 7260 to VRS241
Serviceability
Load Cell Network
POWERCELL ® PDX ®
Predictive Diagnostics
Simplified Network
Accuracy & Reliability
Update Rate 2X
PSD Patented Technology
Checking easier to access
Rail Adjustment
Removed difficult to set embed plates
Lock in place shimming
Internal usage only24
Design compared to Competition
METTLER TOLEDO VRS241
Low Profile Competitive Units
Direct loading from rail into the load cell is the most accurate method.
Low profile designs can cause high stress in the welds and inaccuracy.
Indirect loads translate loads in different directions
METTLER TOLEDO has learned from previous designs that cantilevered designs can cause long term accuracy and maintenance issues.
Internal usage only25
Design compared to Competition
METTLER TOLEDO VRS241
Gauged Rail
Gauged rail solutions are typically not Legal for Trade
Life expectancy of a gauged rail solution is 2-3 times less than a traditional railroad scale
Gauged rail solutions are susceptible to lightning, junction box and grounding issues.
Internal usage only
Designed for Cooper E80 Loading
26
The scale is designed to handle massive Cooper E80 Locomotive loading forces and produce no more than 10,000 psi stress in any structural member in the weighbridge.
40,0
00 l
bs.
80,0
00 l
bs.
80,0
00 l
bs.
80,0
00 l
bs.
80,0
00 l
bs.
80,0
00 l
bs.
80,0
00 l
bs.
80,0
00 l
bs.
40,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
52,0
00 l
bs.
80,0
00 l
bs.
Loading of a Cooper E80 Locomotive
Agenda
About METTLER TOLEDO
Making the right truck scale investment for your business
Building the system
POWERCELL PDX® innovations in: - Accuracy- System reliability
Operational savings from truck scale performance & accuracy
Internal usage only
Digital Technology Delivers Better Performance
ANALOG CONVERTERS DIGITAL
LOA
D C
ELL
ST
ELE
VIS
ION
ANALOG Load Cells Smart Sectional Controllers
+
+
+
+
+ OR
OR
Mettler Toledo Digital POWERCELL PDX
INTALOGIX®
Internal usage only
POWERCELL PDX
POWERCELL 760 POWERCELL PDX
The Legacy continues with POWERCELL PDX
POWERCELL MTX
POWERCELL PDX
Highest Accuracy
Unequaled Reliability- No Junction Boxes
- Environmental Protection & Predictive Diagnostics
Leveraged 20+ years of field experience and an install base of 1 million load cells
Internal usage only
The impact on your business
The value of 100lb of your product?
How many cars per day leaving your operation?
What is the revenue lost from one day of an unplanned shutdown?
How much time to you currently spend weighing cars?
Internal usage only31
Accuracy Data – As Found in the Field
We collected "As Found" performance on hundreds of scales to see how much error was found on each scale
The results are incredible
MT test trucks drop weights on scales to see if they are in tolerance
Typically using around 25,000 lb. for truck, 40,000 lb. for rail scales
Internal usage only32
Field Accuracy Data
POWERCELL = More certainty in each measurement
There is a remarkable difference, and it is not accidental!
POWERCELL compensation technology corrects for factors that other load cells ignore: temperature changes, creep, linearity, hysterisis
It is easy to meet legal limits, but not easy to do what we do
Internal usage only33
Field Accuracy Data
Selling by Weight?
These scales are cheating customers;damaging reputations and relationships
Selling by Weight?
These scales are giving away free product andhurting profits
Purchasing by Weight?
These scales are causing overpayment and inventory leakage leading to lost profits
Purchasing by Weight?
These scales are cheating suppliers; damaging reputations and partnerships
Comparison of Metrology Specs
34
At Capacity:
OIML R60 C3 tolerance is 60% tighter than HB44 10K III L-M.
All MT truck/rail scale load cells exceed the requirements of both!
In general, OIML R60 (Europe) specifications are much tighter than the NTEP HB44 10K III L-M (USA).
Vehicle Scale Accuracy
35
200 lbs. of Error on a 100,000 lb. car, 400 lbs. on 200,000 lb. car!
Car Weight Allowable Error (NTEP)
Allowable Error (OIML)
20,000 lb. 40 lb. 44 lb.(20 kg)
60,000 lb. 120 lb. 88 lb.(40 kg)
80,000 lb. 160 lb. 88 lb.(40 kg)
100,000 lb. 200 lb. 132 lb.(60 kg)
200,000 lb. 400 lb. 132 lb. (60 kg)
What is Legal for Trade for static rail scales?
These US tolerances have been the same for over 50 years! They were established for lever systems.
For our new ROI calculators:- Just show the customer that we can improve accuracy by 20 or 40 lb.
- This is conservative!
Based on typical scale capacities
Internal usage only36
Video: POWERCELL PDX Accuracy
Accuracy is designed-in, field tested, and provides strong ROI
Internal usage only37
An Accuracy Example: Did you know?
Can anyone afford to give away full truckloads?
Here is some amazing math:
In a hypothetical example, a customer weighs 100 trucks per day of grain
Gross truck weights are around 50,000 kg and net loads are 32,000 kg
Their scale is weighing 40 kg light on every truckload they sell
- Not unusual; legal for trade
- Accuracy test is -10 kg a with test load
They are giving away a free truckload worth of grain every 8 days!
Internal usage only
POWERCELL PDX Unequaled ReliabilityEnvironmental Protection
Cheating
Flood, punctures & abuse
Rust and corrosion
Lightning
Rodents
High temperature
Radio and Electromagnetic
Cold, ice
v
Protects against the key causes of inaccuracy, downtime, and vehicle scale failure
Internal usage only
Unmatched Lightning Protection
Can withstand multiple lightning strikes up to 80,000 Amperes- An average strike is 30,000
Amperes
The only cell with REAL Proof of System Performance - In the lab & in the field
METTLER TOLEDO provides total system protection for Load Cell, Cables, and Industrial Terminals
Third party certified
POWERCELL PDX Unequaled Reliability
Internal usage only40
Video: Lightning Protection
Full system protection from lightning strikes
Internal usage only41
Video: No Junction Boxes
Eliminate the primary source of vehicle scale system failures
Internal usage only
Competitive Systems use Junction Boxes Hard to seal against moisture Complicated installation, troubleshooting Expensive to maintain and failure prone
POWERCELL PDX Has NO Junction Box Easy to install and troubleshoot Fast, reliable, and accurate
operation
Eliminates the primary source of vehicle system failures - the Junction Box
Manual wiring of Junction Box
POWERCELL PDX Unequaled Reliability
Internal usage only
Sectional Controller
43
Internal usage only
POWERCELL: Unequaled Reliability
Model 7560 Tulare, CA (near Death Valley)
Locations Recorded temperature # 1 Al'Az-is-iyah, Libya 136.4° F (58.0° C)# 2 Death Valley, USA 134.0° F (56.7° C)
Hottest Places on Earth
Locations Recorded temperature #1 Vostok, Siberia -67° F (-55.0° C)#2 McMurdo, Antarctic -59° F (-50.0° C)
Coldest Places on Earth
Operates in Extreme Places
Model 7560 McMurdo Station, (only scale in Antarctic)
This scale in Antarctica has been used for nearly 20 years without
replacing a single load cell
Internal usage only45
Video: Environmental Protection
Proactive information to prevent unplanned downtime
Internal usage only
Potential water entry points
Protection from Corrosion & Failure
POWERCELL PDX Unequaled Reliability
POWERCELL PDX
Stainless steel components
Passed IP68¹ and IP69K tests
Integrated breach detection
You will always know if a cell has been broken open - before failure!
Competitive Analog Solutions
Often made of painted/plated carbon steel
Integrated cable connection secure
Weld seams not leak tested
You will never know that a load cell has failed!
¹ 7 days with cables attached
Internal usage only
All critical errors immediately displayed to your operator - Overloads, weighing or cell failures
- Water ingress detected by breach detector in the cell
Allows a technician to troubleshoot remotely
Problem causes are accurately pinpointed
Email alerts for fast communication of key conditions
Weighing terminals store historical data for analysis
At cell voltages Network condition
Predictive Diagnostics for Network Health
POWERCELL eliminates analog load cell weaknesses
POWERCELL PDX Unequaled Reliability
Internal usage only
Items Monitored With POWERCELL PDX
48
Accurate Weight
Node Address
Serial Number
Cell Counts
COM Errors
Min Supply Voltage
Supply Voltage
CAN-H Voltage
CAN-L Voltage
Major over-voltage/current
Major under-voltage
Minor over-voltage/current
Minor under-voltage
Total Transactions
Temperature Deviation
Current Temperature
Max Temperature
Min Temperature
Gas Concentration
Displacement deviation
Current Displacement
Energy Deviation
Current Energy
Zero Drift Errors
Zero Drift Value
Cell Overloads
Average Overload Weight
Symmetry Errors
Symmetry Difference
Internal usage only49
POWERCELL PDX TechnologyHow It's Made: POWERCELL PDX Load Cells In Japanese: http://www.youtube.com/watch?v=VtrxW32_qgo
Built and tested like no other load cell on Earth
Agenda
About METTLER TOLEDO
Making the right truck scale investment for your business
Building the system
POWERCELL PDX® innovations in: - Accuracy- System reliability
Operational savings from rail scale performance & accuracy
51
Estimate the Return on the Rail Scale Investment
Page 3 is the interactive form - most important
Different between the two versions, with similar elements
Business Input
Performance Input
Price Input
Output
Page 3 Page 3
52
ROI Tools – Business Input
Input from client to reflect their operation
Use conservative estimates if the client is unsure
Business days per year: 240 reflects an average Monday-Friday schedule, change if facility operates beyond this
Price of goods / Profit margin: if client has numerous goods or the price/margin varies, use conservative average
53
Calculator Output
This gives you the “Price Difference Payback”- Based on the price premium of POWERCELL PDX – NOT on the entire system price
When comparing to a competitor, remind client that these figures reflect annual savings that they will experience every year
Or, these are the figures that they will be losing each year with a less accurate and reliable system from a competitor
This is simply how POWERCELL PDX stacks up to the competition – if they currently have a scale, their savings over a current system will be even larger
Partnership Value
METTLER TOLEDO offers
Technology Leadership- Accuracy
- Reliability
- Diagnostics & Control
- Integration
Global Presence - Sales & Service
- Support
Experienced and Committed Partner- Proven partner who is the leader in its field
- Knowledge of local regulations
- Committed to innovation
- Flexible and comprehensive application offering supported by an agile team