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A bout Us. C ase Studies. S ervices. Exit. • We cover many facets of a job – mechanical electrical & controls programming electronics. R eturn. The true solution is normally a combination of issues…. • We know how to work with people – basic business sense timely communication
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About Us Case Studies Services Exit
• We cover many facets of a job – mechanical electrical & controls programming electronics Return The true solution is normally a combination of issues…
• We know how to work with people – basic business sense timely communication sense of urgency professionalism Return Treat others as you would be treated…
• We have almost 100 years combined experience – metals processing oil & gas industry security & evacuation scientific testing Return Wisdom from experience, but leave the ego at home…
• We know and have worked with the contacts – specialists in many industries technical answers when needed Return Only part of a solution is still a problem…
• We can provide creative answers – not afraid of new ideas the latest in technical advancements step back and study the problem challenge ideas that have been discarded Return If you try the same thing, you’ll get the same results…
• Our approach is our name – Think First, then act save cost and time most people don’t have interest in doing it over focus on the right issues Return Together, we build good reputations for all involved…
PLC Operator Terminal .Net (Visual Basic, C#, C++) Assembly & Microprocessor Scripting Return Programming
AutoCAD & Inventor -- 2D & 3D Mechanical Design HMI Design Mathematical Algorithms Technical writing & Illustration Return Design & Concept
Circuit Boards – populate & test Cable Assemblies Control panels & enclosures Product Prototypes Mechanical Equipment Return Manufacturing
Computer & PLC Install Wireless Infrastructure Control Systems Instrumentation Operator Terminals Return Installation
Product Quality Inspections Expediting Project Management Vendor Qualification Audits Return Project Management
Focus: Programming Industry: Radiator Fabricator Under a one-day deadline, we solved a tough programming issue which was the result of poor programming from another software vendor. Return The System was tested and shipped on time because we worked through the night to make it happen. The features we added completely replaced the other software, while only using a scripting tool.
Focus: Mechanical Design Industry: Cookware Manufacturer Water pressure fluctuations were causing major quality issues. The unreliable pressures were causing errors in control system predictions. Return Because the piping was mostly large diameter (over 24”), off-the-shelf devices were cost prohibitive. ThinkFirst created a vertical piping overflow system which requires very little floor space and no maintenance.
Focus: Mechanical Design Industry: Light Metals Standard roll designs were causing scratches and poor drying performance on moving metal strip. Costs were very high for standard design. Return This is an example of how we think differently. The problem centered on too much mass of the standard roll. We redesigned the roll to remove mass and over 50% of the cost. Drying performance was increased greatly and lifetime in service increased by a minimum of 4-fold.
Focus: Database Design Industry: Fabricator An industrial fabricator had files and papers everywhere. Finding related information was a major chore, if possible at all! True costs were unavailable. Return We rolled up our sleeves and got to work identifying all important documents, as well as information that was needed – but missing. Armed with this information, we created a relational database that pulled all infor- mation together. Now good data is just a click away.
Focus: Turbulent Heat Transfer Industry: Steel When rolling hot steel, it is necessary to cool it at the right rate, to the right temperature. Heat Transfer is a difficult field to model and control. Return Since we helped in the design of the mechanical cooling devices, we already had a head start – understanding the mechanics of cooling in this application. By identifying all required process parameters, and creating appropriate control algorithms, targets and cooling rates are achieved well over 99% of the time.
Focus: Mechanical / Controls Industry: Railcar A sheet bending machine was not giving the right physical positioning for a known travel measurement. This resulted in non-uniform and unacceptable sheets. Return Because we designed and programmed the controller and all instrumentation for this machine, we knew that the controls were working as expected based on sensory input. The problem? We pinpointed the mechanical drive had “slipping” issues which caused the error. When fixed, the sheets met spec!
Focus: Programming / Wireless Industry: Data Acquisition Data was to be transferred wirelessly within a noisy industrial environment. The path was not line of sight. Differences in text encoding could cause errors. Return This system we designed from the ground up – sensors, physical mounting, circuitry, and programming (microprocessor and .Net). Using standard ASCII, data was sent using a pre-written radio API for all error correction and acknow-ledgement. Operators love this system -- because it simply works.
Focus: PLC Programming / EE Industry: Oil & Gas A major natural gas drilling site needed immediate help with a poorly documented gas compressor. Controls were partially installed and no programming existed. Return Without the compressor working, all the money spent would mean nothing – because they couldn’t deliver what they produced. ThinkFirst tackled the job by identifying all operating parameters and instrumentation. Then, we wrote the program to control a Modicon PLC and OIT. And we did it under the deadline.
Focus: Mechanical Design / ME Industry: Steel A fabricator’s multi-chamber header design required long, continuous welds. The heat caused warping and alignment issues. Efforts to control this cost too much. Return We thought first, then asked a few questions. The long welds had to go. There was a potential for water leakage without the welds. Our redesign centered around the multiple header design, but accomplished the seal with one extra o-ring and a custom mixer. With each new installation, the design is validated.
Focus: Programming Industry: Light Metals To check cleanliness of a surface, one method is to wipe the surface with a cloth. Then, it is compared to an identical clean cloth. Results are too subjective to use. Return Here’s a case where it would definitely be better for a computer to “look” at the results. A clean “control” cloth was scanned and stored as a reference. Then, when a reading is required, the wiped cloth is scanned & compared within a custom program which evaluates the dirt load as a histogram. Predictable.
Focus: Engineering / Project Mgmt Industry: Steel On a galvanizing line, steel is required to be cleaned before coating. Large equipment is required – cleaning, brushing, rinsing, drying & all support systems. Return Here, we divide a large challenge into manageable subsystems, then into disciplines – mechanical, electrical, programming, systems. Of course, project management was key to keeping the total supply on track and within budget. After finishing the design, we closely monitored the fabrication and assembly.
Focus: Mechanical Design Industry: Scientific Testing In order to test hot gas for presence of key elements and impurities, it must be tested at 700C. A “quick-change” requirement needed careful seal selection! Return The seal was the problem – at that temperature. In addition, the ingredients of the gas were aggressive to most options. We designed a vertical clamping mechanism that held appropriate closure force hydraulically. The seal was custom designed by calling one of our contacts in the industry.
PO box 1495 Cranberry Township, PA 16066 Mailing Address: Return Telephone: 724 / 602 - 4354 Fax: 866 / 687 - 6003 Email: sales@TFControl.com If you need to work with a company that “gets it”, a company that will take your project seriously, and real people who understand how to work with you, give us a call. It’s time for a new way of thinking. It’s time for a serious yet creative approach to what’s challenging you. Let ThinkFirst tackle your challenges. That’s what we love to do, and you’ll love the results!
