Advanced Engineering

Engineering technologies
that excel in tough conditions

Electrical, power, and control systems engineering
for industrial and mining machines

FLANDERS engineers state-of-the-art power and control system technologies for machines used in heavy industry and mining, finding unconventional ways to eliminate wasted time, money, energy, production, and resources through innovation.

Field-smart technology development

We have decades of on-the-ground experience with the machines we optimize and a deep understanding of the practical applications.

As a result, whether you’re looking for a retrofit, a machine enhancement, or a clean-sheet design, our engineering team will develop a custom, field-smart solution that excels in real-world conditions.

We can serve as an innovation R&D partner or simply customize machines for your specific needs.

  • 16%

    Lower operating temperatures

    With our transformer and line-reactor combo

  • Up to 40%

    More horsepower

    In the same motor frame

  • 30%

    Production increase

    Proven, with our mining drill automation system

Concept-to-commissioning engineering services

Electromechanical systems, control system, and field engineering

Power conversion engineering
  • AC and DC drives, motors, and controls
  • DC to AC conversions for excavators and other machines
  • Front-end-only DC upgrades
  • Electrical system modernization
  • Re-engineering obsolete replacement parts
  • Machine customization
  • Engineering novel machines for manufacturing processes

Control system engineering
  • Hardware, firmware, and software
  • ProfiBus, ProfiNet, Ethernet, and other automation networks
  • System integration
  • Custom PLC programming and system design
  • Data collection and Level 2 Software
  • Siemens Totally Integrated Automation (TIA) capabilities
  • Winders and material handling controls

A highly consultative approach

It’s easy to miss opportunities for big performance gains if you don’t view a solution in context. That’s why we work closely with you to understand the big picture of what you want to accomplish with the machines in your operation.

Once we understand that big picture, we can design and engineer new technology approaches to turn a motor repair into a machine advancement.

We’ve engineered 300+ custom
motors for clients in heavy industry.

Attention to details that make life easy for operators

We take special pride in designing flexible configurations, exceptional HMI, and modular physical systems that are easier to operate and maintain.

No FLANDERS solution is complete until we’ve equipped your team to make the most of it. So our engineers deliver documentation and provide follow-up support. We also offer hands-on technical training for any system we put in place.

 

We can manufacture anything we engineer

With our in-house custom manufacturing capabilities, we have end-to-end process control to ensure you get a product of exceptional quality that meets or exceeds your specifications.

  • Custom DC and AC drives and motors
  • Horsepower upgrades and DC drive retrofits
  • Generators and alternators
  • Transformers
  • Industrial and portable switchgear
  • And any other component of electric rotating equipment or control systems

Engineering for intrinsically hazardous conditions

We routinely engineer motors, drives, and control systems to Underwriter Laboratory (UL) Standards for intrinsically hazardous environments such as chemical plants, refineries, mills, underground coal mines, and oil and gas fields.

The safety of your team and ours is always our top priority, and we engineer it into our systems.

FLANDERS Quality & Safety

Example projects

  • Power system engineering—and reengineering

    Developing the first DC to AC dragline retrofit in North America

    • Purpose-engineered FLANDERS AC drives and motors were the foundation of the DC to AC conversion we did on a 50-year-old Bucyrus Erie 770 dragline for a Kentucky coal company. The high-efficiency drop-in motors and drives that we used required no structural modifications, eliminated noisy DC generators, and delivered more power.

      Less than a year after commissioning, the dragline was two months ahead of dig schedule, consistently outperforming newer machines.

  • Drive system upgrades for coordinated systems

    Replacing 110 drives for a total hot mill automation upgrade

    • A large international mill builder and automation provider enlisted FLANDERS to supply 110 DC drives and all related engineering, design, installation, and commissioning for a complete aluminum hot mill automation upgrade in Texarkana, Texas.

      FLANDERS first performed a detailed engineering study to understand the mill’s performance requirements in depth, and determine the most cost-effective way to update the drive systems. Based on the study findings, our engineering team defined the optimal solution as

      • New Siemens 6RA70 DC drives, configured to communicate with the mill control system by way of PROFIBUS DP
      • Re-using the original ASEA DC drive power components for the main stand, unwind, and rewind applications, and using new 6RA70 control modules to control the power sections.
      • Completely replacing the enclosures and power components for all other drives with FLANDERS hardware and technology

      FLANDERS also provided an installation package that included around-the-clock installation supervision and assistance to ensure timely, successful completion of the project.

      Highly satisfied with our comprehensive drive system solution for their hot mill, the client has since contracted with FLANDERS for several additional projects.

FLANDERS upgrades can take a machine’s production and lifespan from good to great. We work with your maintenance and production schedules to minimize interruptions and make sure the work is performed at the optimal time for your team.

Partner with our engineering team

If you have an idea for improving your industrial equipment or a tough machine challenge you haven’t been able to solve, give us a call. We’d love to collaborate and develop a solution.
Contact us

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