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New facility: Six net zero benefits, seven smart manufacturing methods 

The ABB New Berlin, Wisconsin, facility geothermal heat-pump installation has 225 tons of capacity using 78 vertical wells, 500-feet deep, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

 

Learning Objectives

  • Understand six benefits to automated, advanced manufacturing and warehousing facility, seven smart factory attributes.
  • Learn about new automated manufacturing, educational labs, sustainability methods.
  • Explore a $100 million automated, advanced manufacturing and motor, VFD and electrical training facility.

Automated smart manufacturing, net zero facility and motor-VFD training insights 

  • Six benefits to a new automated, advanced manufacturing and warehousing facility are explained, along with seven smart factory attributes. 
  • A new ABB automated manufacturing site in New Berlin, Wisconsin has motor and variable frequency drive (VFD) educational labs; learn about demonstrated sustainability methods. 
  • Tour a $100 million ABB automated, advanced manufacturing and educational facility with text, photos and videos. 

Customers can see how ABB technologies are saving energy in a new $100 million advanced manufacturing facility, customer experience center and innovation lab that combines and expands two other Wisconsin sites and adds adjacent warehousing space. At the ribbon-cutting event Oct. 29, company executives explained how ABB motors, drives, and other products can show customers how to effectively and efficiently apply advanced technologies to meet 2030 sustainability and decarbonization goals. The facility (see videos, photos) will employ more than 700 workers with an additional 100 jobs within three years in a phased opening and expansion.  

ABB Drives USA HQ (Lincoln Facility) held an open house, ribbon-cutting ceremony and facility tour for staff, customers, local educators, government representatives and media Oct. 29. The New Berlin, Wisconsin, facility, over 500,000 square feet, showcases the future of sustainable manufacturing and job growth in Wisconsin, officials said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
ABB Drives USA HQ (Lincoln Facility) held an open house, ribbon-cutting ceremony and facility tour for staff, customers, local educators, government representatives and media Oct. 29. The New Berlin, Wisconsin, facility, over 500,000 square feet, showcases the future of sustainable manufacturing and job growth in Wisconsin, officials said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

Six benefits to automated, advanced manufacturing and warehousing facility 

At the event, ABB explained six key benefits to employees, elected officials, education leaders and media that the site: 

  • Supports future growth in ABB’s largest market with production of electric drive technologies used in a variety of industries. The highly automated, advanced manufacturing facility is expected to attract engineering and other skilled workforce talent. 

  • Creates a new manufacturing and customer experience facility with digital technologies that help ABB meeting sustainability goals for 2030 and beyond. 

  • Applies geothermal heating and modern HVAC system designed to recycle waste heat, eliminate natural gas use and reduce energy use more than 45%. 

  • Saves transportation costs and associated emissions by locating a warehouse distribution center on the campus.  

  • Meets requirements of the Build America Buy America Act (BABAA). 

  • Is important for industrial, power, transportation and building sectors. 

Kelly Kling, drives site leader and head of finance for U.S. ABB motion business, said, “It is important for business, government and educational institutions to work together to prepare the workforce for modern manufacturing,” then detailed how the new ABB New Berlin, Wisconsin, facility does that. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Kelly Kling, drives site leader and head of finance for U.S. ABB motion business, said, “It is important for business, government and educational institutions to work together to prepare the workforce for modern manufacturing,” then detailed how the new ABB New Berlin, Wisconsin, facility does that. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

Automated manufacturing, educational labs, sustainability benefits explained  

ABB executives and government representatives discussed the importance of the new facility investments. (ABB has about 20,000 U.S. employees.)  

Kelly Kling, drives site leader and head of finance for U.S. ABB motion business: “It is important for business, government and educational institutions to work together to prepare the workforce for modern manufacturing. STEM education will better prepare the nation for the high demand of electrical and mechanical engineers, contractors and automation technicians. It is important for ABB, our customers and will build a stronger America.” 

In separate comments to Control Engineering and other WTWH Media publications, Kling said skilled labor is available in the area along with partners and educational resources, including access to trade programs. The facility includes failure analysis and application testing, a showcase for ABB products, in-person and remote learning and, eventually, a customer experience center.  

Brandon Spencer, president of ABB’s motion business area sustainable manufacturing (new head of motion, globally) said ABB has invested $14 billion in 10 years in infrastructure and people to support U.S. manufacturing, including the New Berlin, Wisconsin site, enabling people to buy from and build in America. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Brandon Spencer, president of ABB’s motion business area sustainable manufacturing (new head of motion, globally) said ABB has invested $14 billion in 10 years in infrastructure and people to support U.S. manufacturing, including the New Berlin, Wisconsin site, enabling people to buy from and build in America. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

While the facility geothermal system is pricier up front, and the ROI is longer, “We practice what preach. We’re protecting the environment, using automation, smart manufacturing lines, insulation, building management system (BMS) intelligence and a state-of-the-art mechanical room,” she said. 

On the solar power roof-top installation, Kling said, it’s a three-to-five-year ROI; geothermal ROI we haven’t worked through, yet, but that’s more like 15-20 years. 

Because government contracts require a certain percentage of U.S. sourced and purchased, this project helps ABB U.S. sales and customers. 

Tuomo Hoysniemi, president of ABB’s U.S. motion business area and global drive products division, said ABB technology is being used to run a cleaner factory and integrate with building design features at the New Berlin, Wisconsin, site, such as solar power, geothermal heat pump and modern HVAC systems and ABB advanced building controls, to help ABB meet its 2030 sustainability goals. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Tuomo Hoysniemi, president of ABB’s U.S. motion business area and global drive products division, said ABB technology is being used to run a cleaner factory and integrate with building design features at the New Berlin, Wisconsin, site, such as solar power, geothermal heat pump and modern HVAC systems and ABB advanced building controls, to help ABB meet its 2030 sustainability goals. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

For staffing, Kling said, “We’re building to the 700 number.” About 300 people work in the office at present, she said, and production is moving over from two one facilities facility in the area. Manufacturing areas include low- and medium-voltage drives and cabinet drives, along with a repair shop. The numbers also increase during summer with contractor workforce in the line and functional areas. Adjacent to the ABB building is a logistics facility operated by a third party. 

Brandon Spencer, president of ABB’s motion business area sustainable manufacturing (new head of motion, globally): “ABB is a technology leader in electrification and automation and the U.S. market is an important growth engine for our business. Investment in this modern manufacturing facility gives ABB access to a highly qualified workforces, strengthens localized supply chains and keeps us close to our customers.” 

ABB product showcase planned on-site: At the ABB New Berlin, Wisconsin, facility the large open area beyond the main entrance will become a showcase for ABB products, according to comments to Control Engineering from Kelly Kling, drives site leader and head of finance for U.S. ABB motion business. Upper right are stairs to the mechanical room. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
ABB product showcase planned on-site: At the ABB New Berlin, Wisconsin, facility the large open area beyond the main entrance will become a showcase for ABB products, according to comments to Control Engineering from Kelly Kling, drives site leader and head of finance for U.S. ABB motion business. Upper right are stairs to the mechanical room. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

During the event, Spencer said ABB has invested $14 billion in 10 years in infrastructure and people to support U.S. manufacturing, enabling people to buy from and build in America. He reemphasized the advantages to of a highly qualified workforce, supply chain and markets. The facility provides lean and clean infrastructure sustainability: “We’re walking the walk. Doing it ourselves for own facilities, serving customers with higher availability. This is part of the energy transition across the U.S. We’re proud to have the team here. Motors and drives play key roles across all the megatrends, and we’re proud to manufacture here in New Berlin. We provide energy with a lower carbon footprint. We’re proud of Kelly and the team here to put together this facility in a sustainable way.”  

More ways to design a building for net zero carbon emissions 

Tuomo Hoysniemi, president of ABB’s U.S. motion business area and global drive products division: “ABB is strengthening America’s infrastructure and introducing new, cleaner technologies to help customers boost competitiveness while lowering their carbon footprints. We are also using technology to run our own factory cleaner with building design features such as solar power, geothermal heat pump and modern HVAC systems and advanced building controls. The innovations will help ABB meet its own 2030 sustainability goals.” 

ABB training, classroom and in labs, expands with the ABB advanced manufacturing facility, customer experience center and innovation lab in New Berlin, Wisconsin. Workstations in the middle, electrical panels on the back wall and cart of variable frequency drives (VFDs), right, can help training, along with classes in progress, not shown, said Jeff Fell, application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
ABB training, classroom and in labs, expands with the ABB advanced manufacturing facility, customer experience center and innovation lab in New Berlin, Wisconsin. Workstations in the middle, electrical panels on the back wall and cart of variable frequency drives (VFDs), right, can help training, along with classes in progress, not shown, said Jeff Fell, application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

Hoysniemi presentation noted site details helping New Berlin get to net zero. 

  • Eight electric vehicle charging stations 

  • Working with the state for a power purchase agreement to offset remaining energy usage, long-term investment plan to expand roof solar panels.  

  • More robust insulation on the roof and insulated panels for better climate controls and insulated panels. 

  • Office furniture was 100% reused and refurbished. 

  • Solar panel installation on the roof assists with energy supply to the building 

  • Generator backup for the facility is a biodiesel generator used for critical emergency backup.  

  • Geothermal heating and cooling, with ABB’s BMS to control the heating and cooling of the facility.

During the presentation, Hoysniemi added that sustainability is part of ABB’s daily work, part of the company’s DNA and the value ABB provides. “It’s often said that achieving sustainability goals requires compromises and higher costs. That’s not so. There’s no increase in cost,” Hoysniemi said. “We’re demonstrating and enabling a low-carbon society, helping customers to decarbonize. This is made to showcase to customers how it can be done.” 

The new ABB drives and services manufacturing and logistics center, New Berlin, Wisconsin, includes a fieldbus connectivity area, said Jeff Fell, application engineering manager, including areas for building automation controller communication, industrial programmable logic controller (PLC) network protocols and industrial PLC network safety protocols. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
The new ABB drives and services manufacturing and logistics center, New Berlin, Wisconsin, includes a fieldbus connectivity area, said Jeff Fell, application engineering manager, including areas for building automation controller communication, industrial programmable logic controller (PLC) network protocols and industrial PLC network safety protocols. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

Rep. Scott Fitzgerald, U.S. Congressman, Wisconsin – 5th District, said many corporations that hit the pause button during the pandemic have changed to investments. ABB has been in Southeast Wisconsin for decades, he said. Wisconsin is known for manufacturing, tourism and agriculture, and has tool and die manufacturers for light manufacturing support, including the technical colleges needed to continue to feed manufacturers in the state, he said. 

HVACR tour details: High efficiency technologies help facility sustainability, decarbonization 

Decarbonization and sustainability details were provided by Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Skell said older facility mechanical rooms are dark, dingy and hidden away. This one was designed to showcase advanced energy efficient sustainability technologies.

Electrical panel safety integrated into the ABB New Berlin, Wisconsin, training area has arc flash protection. LED indicators show what receptacle is hot and if a fuse inside the panel has blown, said Jeff Fell, ABB application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Electrical panel safety integrated into the ABB New Berlin, Wisconsin, training area has arc flash protection. LED indicators show what receptacle is hot and if a fuse inside the panel has blown, said Jeff Fell, ABB application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

Geothermal and mechanical room facts include the following. 

  • Geothermal installation has 225 tons of capacity using 78 vertical wells, 500-feet deep.  

  • Condenser water pumps to geothermal provide move up to 465 GPM at 30 HP.  

  • Hot water pumps move up to 250 GPM at 15 HP. 

  • Chilled water pumps move up to 305 GPM at 7.5 HP. 

  • Air handler moves 60,000 CFM in a 12-fan array, using 10 HP motors, 120 HP total. Each motor has its own ABB ACH580 drive to control it. 

The ABB New Berlin, Wisconsin, facility geothermal heat-pump installation has 225 tons of capacity using 78 vertical wells, 500-feet deep, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
The ABB New Berlin, Wisconsin, facility geothermal heat-pump installation has 225 tons of capacity using 78 vertical wells, 500-feet deep, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

  • Motors technology: Ferrite-assisted synchronous reluctance (FASR) motors are extremely efficient, Skell explained. While they essentially mean the same thing as a permanent magnet synchronous reluctance motor from a motor theory standpoint, Skell said, the “permanent magnet” phrase also can imply “rare earth” magnets with some interpretations. For sustainability reasons, the motor design intentionally avoids using rare earth style magnets, instead using typical ferrite magnets, so the official term for the motor is ferrite-assisted synchronous reluctance or FASR. The site uses the version with a separate variable frequency drive (VFD), rather than integrated motor and drive. ABB explains more about the Baldor-Reliance EC Titanium motors and integrated drives.

  • Heat pump (6-pipe heat recovery chiller) is rated at 150 tons (six 25-ton stages). 

  • The VFDs mixed ABB ACH580 packaged solutions, with and without bypass (Bypass allows motor function without the drive, should a drive fail) and a redundant drive. 

  • Enclosures: Type 1, Type 12, Type 3R and Type NEMA 4X enclosures.

  • Drive technologies: 6-pulse (ACS320 drive, the only one that wasn’t an ACH580 family), 6-pulse with 5% equivalent impedance, and ultra-low harmonic active front end (AFE) drives to ensure high power quality in connected systems. (Harmonic disturbances, or electrical noise, can harm some devices and processes, and some utilities charge industrial companies extra fees if harmonic disturbances are introduced locally.) 

  • The controls use ABB Smart Building Solutions. All the controls, thermostats and future AI implementation will all be ABB products. A big six-screen operator workstation is expected to be installed within the next month or two, with graphics, trending and sub-metering to identify power usage. 

ABB VFD manufacturing design innovations, 7 smart factory attributes 

The ABB New Berlin, Wisconsin, facility air handler moves 60,000 CFM in a 12-fan array, using 10 HP motors, 120 HP total. Each motor has its own ABB ACH580 drive to control it, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). The air handler uses extremely efficient ferrite-assisted synchronous reluctance (FASR) motors, he said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
The ABB New Berlin, Wisconsin, facility air handler moves 60,000 CFM in a 12-fan array, using 10 HP motors, 120 HP total. Each motor has its own ABB ACH580 drive to control it, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). The air handler uses extremely efficient ferrite-assisted synchronous reluctance (FASR) motors, he said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

About ABB’s New Berlin drive manufacturing (no photos were allowed) Daniel Beaudet, director quality – advanced manufacturing, continuous improvement, U.S. motion business, said ABB worked with Porche Consulting on seven attributes of this smart factory of the future: 

  1. Adaptable and scalable to handle demand variability and meet customer lead times.

  2. Attractive, creating operator engagement and demonstrating net zero carbon emission sustainability goals.

  3. Lean material and information flow, improving connections to suppliers and customers.

  4. External customer focus with on-time delivery and improved communication and feedback with greater information transparency.

  5. Lean and robust processes to mitigate issues earlier and lessen impact to assembly lines with quality, standards, early abnormality detection and error proofing.

  6. Smart and data driven systems with interoperable systems, modeling, simulation, intelligent automation, strong cybersecurity and networked sensors.

  7. Top quality enabled by integrated systems throughout the value system.

In the ABB New Berlin, Wisconsin, mechanical room, condenser water pumps to the geothermal system move up to 465 GPM at 30 HP, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
In the ABB New Berlin, Wisconsin, mechanical room, condenser water pumps to the geothermal system move up to 465 GPM at 30 HP, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

Adjustable workstations, multiple VFD models on same line, ABB products throughout 

In planning since 2021, the factory has standardized touchscreens for every work area, Beaudet said, so workers can learn one area and be able to work in all areas. Built-in ergonometric design adjusts the workstation to fit the worker when securely “carding into” each station. 

ABB New Berlin factory layout is displayed on a large screen monitor with a Lego representation below, appealing to all ages of those touring the manufacturing area.  

At the time of the tour, pilot manufacturing running in the plant were validating manufacturing workflow, production and testing of five ABB VFDs, Beaudet said, with capabilities to run multiple design and customer variations on each line.  

Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration), explains how ABB variable frequency drives (VFDs) are configured with redundancy or bypass for various design risk scenarios to fit different applications and facilities, part of the ABB New Berlin, Wisconsin, mechanical room tour. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration), explains how ABB variable frequency drives (VFDs) are configured with redundancy or bypass for various design risk scenarios to fit different applications and facilities, part of the ABB New Berlin, Wisconsin, mechanical room tour. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

He explained how an ABB robot performs laser marking, providing a “birth certificate” for each drive.  

Automated guided vehicles (AGVs) are planned for efficient material flow in the plant.  

ABB equipment is used throughout to help make more ABB products. In a few cases, Beaudet said, ABB worked with original equipment manufacturers to ensure ABB products were used in machines used in New Berlin manufacturing processes. 

In the ABB New Berlin, Wisconsin, mechanical room, a pair of chilled water pumps provide N+1 redundancy, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration).
In the ABB New Berlin, Wisconsin, mechanical room, a pair of chilled water pumps provide N+1 redundancy, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration).

Classroom and hands-on electrical, safety, mechatronics education 

Jeff Fell, application engineering manager, highlighted multiple classroom and lab training areas, showing 14 workstations, up from six in the prior facility. Drive harmonics, among areas of instruction, include an advanced demonstration area with third-generation AFE VFD technology for better electrical noise mitigation to improve power quality. 

Pumps for hot water return (orange pipes) move up to 250 GPM at 15 HP, part of the ABB New Berlin, Wisconsin, geothermal design, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media
Pumps for hot water return (orange pipes) move up to 250 GPM at 15 HP, part of the ABB New Berlin, Wisconsin, geothermal design, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media

In another demonstration, Fell showed how a drive adjusts flow to avoid creating air (cavitation) inside liquid flow, which can prevent product spoilage and decrease maintenance (see video). 

A dynameter lab provides advanced motor and drive design and application testing, including simulation of loads that water would make in pumping applications, without using water (video). 

CONSIDER THIS 

How are motors and drives contributing to sustainability, efficiency, quality and cost-saving goals? 

ONLINE 

Online version of this article expands the November/December Control Engineering in-print summary with 16 images, five video clips and more text with site details. 

Three ABB executives wrote recent Control Engineering sustainability articles about motors, drives and electrification. 

Benjamin Hinds, vice president of product management and marketing at the NEMA Motors: “How to meet sustainability goals, part 1: High-efficiency motors.” 

Michael Basler, local division manager for the System Drives Division at ABB in the United States: “How to meet sustainability goals, part 2: The drive for industrial decarbonization.” 

Rob Snyder, local division manager, ABB U.S. Motion Services Division: “How to meet sustainability goals, part 3: Examining roles of motion services.” 

An extended video interview with Hinds, Basler and Snyder explains more about motor, drive and electrification technologies and sustainability: “Expert video interview: Three ways motors and drives help industrial sustainability.” 

ABB provides training information for the New Berlin site.