Fluid Power Journal April 2021 by Innovative Designs & Publishing, Inc.

APRIL 2021

www.fluidpowerjournal.com

Off-Highway

Directory Listing P.20

TOP

MULTISTAGE TELESCOPIC CYLINDERS Breaking with Valve Position Tradition

Innovative Designs & Publishing • 3245 Freemansburg Avenue • Palmer, PA 18045-7118

SYSTEM MISTAKES

SGH TECHNOLOGY IN CYLINDERS P.34

Nonprofit Organization US Postage PAID Bolingbrook, IL Permit #323

MAKING A DIFFERENCE

FOR YOUR BUSINESS Our cutting-edge line of hydraulic hose and fittings is not just a product division. It’s a promise of superior service, quality, technical support and availability. We’ve built our company on impeccable customer service. Let us know how we can make a difference for your business. call 800.231.7116 or email sales@texcelrubber.com

IN THIS ISSUE

APRIL 2021

VOLUME 28 • ISSUE 4

Features 6

Fluid Power Faux Pas: Our Top Five Hydraulic System Mistakes Tips on avoiding costly hose, coupling, and tubing missteps.

Going Electric? SHA Is the Dynamic Choice A powerful actuation solution harnesses the best features of hydraulics and EMAs.

18 Test Your Skills Understand the Application of Hydrostatic Systems 31 Who, What, Where, How Much? Let Us Know From the C-suite to the shop floor, be counted in our 2021 Salary Survey.

32 It’s Over: Breaking with Valve Position Tradition Oil and gas tank farms are relying more and more on noncontact inductive sensors. 34 Measuring Up: SGH Technology in Hydraulic and Telescopic Cylinders A cable-based concept integrates sensors, electronics, and mechanics into a cylinder. 36 Cover Story Two Walls Are Better than One: Multistage Telescopic Cylinders Their benefits provide tangible value to the OEM and end user.

34 Publisher’s Note: The information provided in this publication is for informational purposes only. While all efforts have been taken to ensure the technical accuracy of the material enclosed, Fluid Power Journal is not responsible for the availability, accuracy, currency, or reliability of any information, statement, opinion, or advice contained in a third party’s material. Fluid Power Journal will not be liable for any loss or damage caused by reliance on information obtained in this publication.

CELEBRATING 60 YEARS

Departments 4 5 9 10 20 39

Notable Words Air Teaser NFPA Update IFPS Update Off-Highway Directory Company Listing Classifieds

HYDRAULIC HOSE & FITTINGS

QUICK DISCONNECTS

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N OTA B L E WO R D S

Challenge Your Competitors with Top Customer Service By Brandon Gustafson, Engineering Manager, Lubrication Equipment Division, Graco Inc.

I HAVE BEEN in the fluid power industry since my first job as a mechanical engineer designing hydraulic systems for aerial lifts at Altec Industries in 2005. After that I designed piston pumps for Eaton Hydraulics, and now I am the engineering manager for Graco’s lubrication equipment division. We specialize in grease and oil delivery, and management and control for lubrication applications. In all of these businesses one thing has been consistent: the high level of competition from large global companies and increasingly from local and regional competitors that are closing the product-quality and performance gap. Customers have many options to supply their fluid power and lubrication needs, and simply having the best product is not enough to secure the sale in most parts of the world. Graco has started to focus on how to make customers more profitable when they use our equipment versus any other product. We think products should be easy to use, reliable, and last a long time, and when they don’t work, help should be easy to find. That has led Graco to implement what we call A+ Customer Service. In fact, we renamed the Graco lubrication equipment division engineering team the A+ Customer Service Engineering Team. Engineers are good problem solvers, and our number one goal is to solve problems for our customers. That’s different from solving problems for Graco. We could ask ourselves, “Is this issue Graco’s fault?” and then solve the issue when it is our fault. But that’s not A+ Customer Service. We engage every customer’s issue like it was our own and find a resolution. This has led to some interesting situations. We once had a customer use excessively high pressure at close range to wash down and clean equipment. That led to water ingression and failure of a circuit board. We sent them a new pump to keep them running while we investigated. We determined the failure mode and, since our product already had the highest water-ingression rating, we didn’t make any design changes. But we did stay in contact with the end user, which changed its practices. Other times we will make design changes. For example, we once learned that a customer would occasionally drop one of our pumps during install and damage the intake grill. We changed the intake grill to withstand being dropped. It is a daily challenge to continue to provide A+ Customer Service. It has a cost that we sometimes question during times of slower sales growth. At the same time, our commitment to A+ Customer Service starts from top with our CEO. We speak about it daily when evaluating warranty claims or troubleshooting customer calls. Our motto, “A+ Service – Every Customer, Every Time,” summarizes what we think is the one thing that sets us apart from our competition. The customer’s experience is the biggest driver of their next purchase decision. If you’re in the fluid power business, you likely face strong competition in your markets. You’ve also probably heard various companies promote their “world-class service,” and you’re wondering if what I’m talking about is any different. But what I’m talking about is postsale, nonrevenue-generating support resources that provide an excellent experience to every user of our equipment. That includes an administrative team that conducts surveys and tracks service-level metrics, from phone-call length to the percentage of items in stock. A+ Customer Service is a competitive edge for Graco and is difficult to copy. However, it may just be something you want to mimic to keep customers coming back.  4

APRIL 2021

PUBLISHER Innovative Designs & Publishing, Inc. 3245 Freemansburg Avenue, Palmer, PA 18045-7118 Tel: 800-730-5904 or 610-923-0380 Fax: 610-923-0390 • Email: Art@FluidPowerJournal.com www.FluidPowerJournal.com Founders: Paul and Lisa Prass Associate Publisher: Bob McKinney Editor: Michael Degan Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Art Director: Quynh Fisher Eastern Region Acct Executive: Norma Abrunzo Director of Creative Services: Erica Montes Accounting: Donna Bachman, Sarah Varano Circulation Manager: Andrea Karges INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org 2021 BOARD OF DIRECTORS President: Rocky Phoenix, CFPMMH - Open Loop Energy, Inc. Immediate Past President: Jeff Kenney, CFPMHM, CFPIHM, CFPMHT - Dover Hydraulics South First Vice President: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC - Eaton Corporation Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. Vice President Certification: James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM - The Boeing Company Vice President Marketing: Scott Sardina, PE, CFPAI, CFPHS Waterclock Engineering Vice President Education: Randy Bobbitt, CFPAI, CFPHS Danfoss Power Solutions Vice President Membership: John Bibaeff, PE, CFPAI, CFPE, CFPS DIRECTORS-AT-LARGE Chauntelle Baughman, CFPHS - OneHydraulics, Inc. Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT Altec Industries, Inc. Randy Bobbitt, CFPAI, CFPHS - Danfoss Power Solutions Steve Bogush, CFPAI/AJPP, CFPHS, CFPIHM - Poclain Hydraulics Cary Boozer, PE, CFPE - Motion Industries, Inc. Lisa DeBenedetto, CFPS - GS Global Resources Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM Open Loop Energy Brian Kenoyer, CFPHS - Five Landis Corp. Jon Rhodes, CFPAI, CFPS, CFPECS - CFC Industrial Training Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPHS - Northrop Grumman Corp. EXECUTIVE DIRECTOR (EX-OFFICIO) Donna Pollander, ACA HONORARY DIRECTORS (EX-OFFICIO) Paul Prass, Fluid Power Journal Liz Rehfus, CFPE, CFPS Robert Sheaf, CFPAI/AJPP, CFC Industrial Training

IFPS STAFF Executive Director: Donna Pollander, ACA Communications Director: Adele Kayser Technical Director: Thomas Blansett, CFPS, CFPAI Assistant Director: Stephanie Coleman Certification Coordinator: Kyle Pollander Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk

Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published monthly with four supplemental issues, including a Systems Integrator Directory, Off-Highway Suppliers Directory, Tech Directory, and Manufacturers Directory, by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs, or manuscripts.

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AIR TEASER

Solution to the February 2021 problem: Blocked Ports and Failing Piston Seals Solving of a 2-in. x 8-in. x 1-in. cylinder that is holding a load of 314 at 4 inches of extension with air, and both ports are plugged when the piston seal develops a leak. What will the piston do, and what is the final pressure? Find standard cubic inches (sci) of free air in the cylinder: Piston dia. 50 mm Cap end area is A = D² x .7854 or 3.14 in². Rod dia. 25 mm Volume is 3.14 x 4 = 12.566 in³ (196,350 mm³) Load = 1374 N Pressure = 314 / 3.14 = 100 psi Pressure 2.80 MPa Compression Ratio is CR = (100 + 14.7) 14.7 = 7.8 C.R. sci = 12.566 x 7.8 = 98 sci (bottom half of cylinder) (1,551,656.1 smm³)

New problem

Calculating with Car Specs By Ernie Parker, CFPAI, CFPSD, CFPS, CFPMM, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPE

CALCULATE THE SCFM and nlpm needed from the turbo charger for a car with the following specifications: • 4-inch diameter pistons (101.6 mm) • 3.46-inch stroke (87.88 mm) • 8-cylinder engine • 6,000 rpm • 10 psi (0.069 bar) of boast for the turbo charger

Rod end area is 3.14 - 0.7854 (rod area) 2.35 in². Rod end volume is 2.35 in² x 4” = 9.42 in³ (5,890.5 mm³) C. R. = 1 with no initial pressure SCI = 9.42 x 1 = 9.42 sci (5,890.5 (smm³) Total volume is 98 + 9.42 = 107.4 sci

(1,557,546.6 smm³)

Before load moves, calculate the pressure in the cylinder with the leak. P1 x V1 = P2 x V2 P1 = initial atmospheric pressure in absolute form: psia =14.7 (.101 MPa) V1 = 107.4 in³ (1,557,546.6 smm³) P2= ? V2 = Volume is with the rod totally retracted: 9.42 in² x 8” = 75.36 in³ P2 = 14.7 x 107.4 / (12.566 + 9.42) = 71.8 psia Theoretical psig before load drops: 71.8 – 14.7 = 57 psig Find pressure after load drops: P1V1 = P2V2 P1 = 71.8 psia V1 = 87.9 (9.42 x 4 + 12.566 x 4) = 87.9 P2 = ? V2 = 75.36 P2 = 71.8 x 87.9 / 75.36 = 83.7 psia (0.54 MPa)

NOTE: Instead of the pressure increasing as it would with hydraulics, in this application the pressure drops even though the load falls because of no initial pressure in the rod end. Visit fluidpowerjournal.com/air-teaser to view previous problems.

PSIG = 83.7 – 14.7 = 69 psi and the load will drop (0.44 MPa)

POSITION SENSORS FOR HYDRAULIC CYLINDERS  Absolute detection of the cylinder stroke  No piston drilling necessary  Can also be used in telescopic cylinders  High shock and vibration resistance, IP69K

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APRIL 2021

FLUID POWER

TOP 5 HYDRAULIC SYSTEM MISTAKES By Cindy Cookson, Vice President of Hydraulics Global Product Line Management, Gates Corporation

With decades of experience in hydraulics, my Gates colleagues and I, especially our application engineers, have seen a lot when it comes to hose, coupling, and tubing solutions. At one end of the spectrum, we’ve been impressed, even inspired, by the ingenuity and creative problem-solving applied by end users. But at the other end of the spectrum, we’ve witnessed errors that make us cringe when we see them repeated in the field. To help everyone in our industry avoid these costly missteps, our friends at Fluid Power Journal asked us to share our top five hydraulic-system mistakes and some thoughts how to avoid them. 6

APRIL 2021

Forgetting about safety

When working with hydraulic systems day in and day out, some users become complacent about safety. Or even worse, technicians new to hydraulics may see a hose and mistakenly consider it to be the equivalent of a garden hose. In high-pressure hydraulics, mistakes can lead to critical injuries or even death, so it’s important to never take a hydraulic system for granted. Here are some critical safety reminders about hydraulic systems and hose assemblies:

• Never touch a pressurized hydraulic hose. Rubbing your hand along a hose as a leakdetection technique, for instance, is just asking for trouble. • Similar to electrical systems, hydraulic systems can be energized even when the system appears to be “off.” Therefore, always depressurize a hydraulic system prior to handling or replacing any system components. • When replacing a hydraulic assembly, always ensure the replacement assembly can meet the system performance requirements, including working pressure, temperature, and fluid being conveyed. • For hydraulic hand tools, never carry the hand tool by the hose. This can lead to pinching and pinholes. • For line-of-sight hydraulic lines in which an operator is working near the pressurized hydraulic assembly, use lineof-sight sleeving to protect the operator in the case of hose or assembly failures.

Relying on ‘what we’ve always used’

Hose and coupling standards for hydraulic systems have evolved over time. System pressures have increased, and the loads on hydraulic systems are increasingly dynamic. Meanwhile,

materials science and process technologies have improved the capabilities of hydraulic hose and coupling assemblies. Relying on “what we’ve always used” misses out on innovation and improvements in hydraulic hoses and couplings. But it could also mean compromising the safety of a hydraulic system. Hose and coupling selections should be made based on system requirements and not just on a hose construction. We often hear, “I need a two-wire braid hose,” or “my system needs a four-spiral hose.” But as OEMs have transitioned to isobaric hose ratings and hose manufacturers have innovated to deliver flexibility and weight savings in hydraulic hoses, referring to a hose by its construction is a risky move. Instead, when selecting hoses and couplings, follow system requirements for working pressure, temperature, and fluid compatibility. The STAMPED method reminds users of the considerations for selecting a hose for a specific application. Here’s a brief explanation of the STAMPED acronym: • Size – Determine what ID hose is required for fluid flow. A hose that is too large reduces system performance due to increased pressure loss and excessive system heat from excessive fluid turbulence. • Temperature – The hose must be capable of withstanding

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the system’s minimum and maximum fluid and ambient temperatures. • Application – How and where the hose assembly will be used. • Material/Media – The hose tube, cover, and couplings must be compatible with the fluid being conveyed. • Pressure – Published hose working pressure must equal or exceed the normal system pressure, including pressure spikes. • Ends – Identify the termination and threads needed for the system to define the proper couplings and adapters. • Delivery – Determine the hose size needed to deliver the required fluid volume without losing pressure or adding unnecessary weight or bulk. Also consider requirements for how the hose and assembly are physically provided to the end application, including the date required, special packaging, labeling, or certifications.

RIGHT

WRONG

Figure 1: Avoid bends near the coupling.

WRONG

RIGHT

WRONG

RIGHT

Poor system routings

Hose assembly routings are a critical component of hydraulic system performance, both in an OE application and when replacing hoses. Poor routings can lead to, at best, an under-performing hydraulic system with less system pressure than expected; or at worse, faulty routing leading to costly downtime, with the worst-case scenario being unsafe working conditions. Application engineering experts can diagnose a hydraulic system and recommend routings or system changes to improve performance, and these consultations usually reduce hydraulic system costs (figure 1). Because hoses are flexible, they are often chosen instead of rigid tubes. But that doesn’t mean hoses have unlimited flexibility. Common issues arise when hoses must bend – particularly bends near the coupling.

Figure 2: Use angled adapters or alternative couplings.

Figure 3: Cover cracks caused by ozone.

Optimized hose routings will avoid hose bends near the coupling by using angled adapters or alternative coupling options to alleviate hose flex requirements. If a bend radius is below the recommendation for that particular hose, get creative with angled adapters. Revisit your coupling selection to avoid sharp bends (figure 2). Proper routings also mitigate hose abrasion, whether against other hoses or against machine components. Return lines are another component that can be problematic. Although the lines are typically low pressure and a necessary component to return fluid to a reservoir, they are often the last component considered

when designing a system. To mitigate the risks of challenging routings, Gates makes Multi Master GMV MegaFlex, a flexible, corrugated hose design that has a tighter minimum-bend radius. Finally, hose routings can minimize the likelihood of leaks in a hydraulic system with proper termination selection. Avoid stacking adapters to minimize system cost and the risk of system leaks.

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Ignoring signs of wear

Hydraulic assembly inspection should be included in any preventive maintenance schedule. These inspections

should monitor for signs of wear, including cover damage like cracking and abrasion. Ideally, the system design reduces the likelihood of damage, but when damage reaches the hose reinforcement, replace the assembly. Cover cracks can be caused by several issues. Exposure to extreme heat, particularly in engine compartments, can cause the exterior cover of the hose to become brittle and crack (figure 3). Exposure to ozone, either from the sun or from high electrical charges, such as in welding equipment applications, can cause microcracks to appear on the surface of the hose. This is similar to the weathering seen in tire sidewalls. Ozone damage typically appears first on the exterior of hose bends, where the rubber compounds see their highest stresses. Once these cracks reach the hose reinforcement, the reinforcement is compromised because of potential damage from moisture and debris. This damage can be mitigated by protecting hoses from high electrical exposure and by choosing hoses with materials resistant to ozone. Cover abrasion is a constant challenge, particularly in congested hydraulic systems where it is difficult to isolate one hose from others or the machine frame in dynamic applications. The most obvious way to mitigate abrasion damage is to choose hose covers that are specially formulated with abrasion resistance. Specialized nitrile rubber compounds offer a midgrade level of abrasion resistance, and extreme resistance to abrasion can be realized with a hose cover made of ultrahigh molecular-weight polyethylene film. It is also possible to assemble the hose in an abrasion-resistant sleeve or hose guard, but this option considerably increases assembly costs and can complicate hose installation in the application. (Continued on page 8) APRIL 2021

(Continued from page 7) In addition to selecting abrasion-resistant hose covers or accessories, the hose routing can also have an impact on hose abrasion. Use clamps to support long hose runs or to keep hoses away from moving parts, taking special care to allow for volumetric expansion. Hoses that bend around a portion of the machine frame should be assembled with enough length to avoid rubbing over a machine corner. And it’s worth noting that hoses should never be clamped to the machine frame, which could restrict expansion in the curves when the hose is pressurized (figures 4 and 5).

Proper assembly

A user can procure the most premium and highest-performing hoses and couplings in the world, but if they’re not assembled correctly, they’ll never realize the value. Proper assembly has several criteria: a qualified hose-coupling interface, assembly by a trained technician, and a verified crimp diameter. A qualified hose-coupling interface results from verifying that the hose and coupling work together. The verification is more than just crimping to a certain crimp diameter; it should be verified by burst and impulse testing across a range of crimp diameters to account for hose and coupling manufacturing variation as well as crimper and die tolerances. The testing should mimic the intended application, particularly the temperature. A hose-coupling interface may work well at standard 100°C (212°F) operations and then not perform at elevated temperatures above 120°C (248°F). Further, all hoses are not the same. Even though hoses from different manufacturers may meet the same performance criteria, the properties of the compound affect the robustness of the hose-coupling interface. Also, the thickness of the rubber materials and the placement of the reinforcement 8

APRIL 2021

qualified crimp diameter range (figure 7). Some systems also use a go/no-go gauge to verify the crimp by reviewing either the crimp diameter or the stem collapse. Smart crimpers are gaining popularity in the market. They make operator training and quality assembly easier by mistake-proofing various steps in the assembly process. Smart crimpers, such as Gates’ GC20 Cortex crimper, typically include the crimp settings in an onboard computer to eliminate the need to reference the crimp setting and program the crimper. New technology and materials are advancing the capabilities of hydraulic hoses and couplings, as well as hydraulic systems overall. As hydraulic systems become more complex, proper hose routing keeps the system running efficiently, both in OE and replacement applications. Baseline training in hydraulics can support safe operations and provide reminders on system inspections. Finally, hose and coupling manufacturers often provide recommendations and training on proper hose assembly. Staying up to date on these innovations and recommendations is well worth the effort, as it can promote a fluid power system’s safe operation, improve its performance, and reduce downtime. 

XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX WRONG RIGHT Figure 6: Cross-section of the XXXX XXXX hose-coupling interface. XXXX Figure 4: Use clamps to prevent XXXX XXXX abrasion damage. XXXX XXXX XXXX XXXX WRONG XXXX XXXX XXXX XXXX XXXX RIGHT XXXX XXXX XXXX XXXX XXXX NO XXXX PRESSURE XXXX XXXX XXXX XXXX HIGH XXXX XXXX PRESSURE XXXX XXXX XXXX XXXX Figure 5: Allow for volumetric XXXX Figure 7: Crimp diameter expansion in hydraulic hoses. XXXX measurements with standard calipers XXXX XXXX (top) and notched calipers (bottom). XXXX XXXX material can change the crimp XXXX XXXX dimensions. Likewise, couplings trained to select the proper hose XXXX XXXX from different manufacturers are and couplings, cut the hose to the XXXX XXXX not necessarily equivalent. They correct length, remove debris XXXX XXXX may be made from different grades and contaminants from inside XXXX XXXX of steel, different material hardness, the hose, ensure full coupling XXXX XXXX and include features such as serinsertion onto the hose, select XXXX XXXX rations that are dimensionally the appropriate crimper setting, XXXX XXXX and place the assembly properly different and may significantly XXXX XXXX impact the quality of the hose-couin the crimper dies. And the techXXXX XXXX pling interface. Even the radius nician must do it all safely! XXXX XXXX Finally, after the assembly has or heights of these features can XXXX XXXX been made, the crimp diameter on significantly impact assembly XXXX XXXX performance (figure 6). each end of the assembly must be XXXX XXXX A trained assembly technician verified for proper crimping. This XXXX XXXX is also critical to the assemmeasurement is often performed XXXX XXXX bly process. She or he must be with calipers and compared to a XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXX Two case studies by Gates product application engineers demonstrate the value of optimized system-hose routings. In theX first XXXX case, a customer was having difficulty routing hoses through a channel in the rear drive. Upon further inspection, Gates engineers XXXX XXXX found a few opportunities: XXXX XXXX XXXX What Engineers Observed Optimized Solution XXXX XXXX Tee grouping created Replace tees with a manifold. XXXX XXXX challenges routing hoses Manifold design provided fixed points XXXX through the channel. of reference for routing and improved XXXX XXXX aesthetics on the machine. It also Bundled tees created XXXX eliminated abrasion concerns from XXXX abrasion concerns. XXXX bundled tees. XXXX XXXX Connections at the same Gates QuickLok connections minimized XXXX point were difficult to install. leaks and enabled fast and easy XXXX XXXX assembly. XXXX XXXX XXXX The before-and-after photos show a cleaner system with improved perXXXX XXXX formance and fewer leak points. XXXX In a second case, a customer had issues with hydraulic fluid leaks at a XXXX XXXX hose-tube connection point. The Gates engineer located the root cause of XXXX XXXX the leakage issue: a bundle of hose-tube connections that were difficult XXXX

CASE STUDY: OPTIMIZING HOSE ROUTINGS

to get wrenches on caused installation challenges and system leaks. The solution was crimp-on hose-tube connections that eliminated the leaks and reduced the number of SKUs.

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N F PA U P D AT E

robust compact reliable Pandemic Blamed for Drop in Fluid Power Exports Last Year Fluid Power Journal staff report

U.S. FLUID POWER product exports totaled $5.6 billion in 2020, a double-digit drop from 2019, the National Fluid Power Association reported. U.S. fluid power exports declined nearly $1 billion, more than 14%, as a result of numerous challenges, including a recessionary economy brought on by the COVID-19 pandemic, a Feb. 25 NFPA report said. An uncertain foreign trade environment due to unstable trade policies, including unpredictable sanctions and wavering tariffs, was another factor in the export decline, according to the report. The top 10 trading partners for U.S. fluid power exports remained consistent even through the pandemic, the report said. Those 10 trading partners accounted for 72% of fluid power exports, while 180 other countries traded for the remaining 28% of exports, according to the report. More than half of fluid power exports, 55%, were traded with the industry’s top five partners: Mexico, Canada, China, Germany, and the U.K., the report noted. Fluid power product rankings saw little change throughout the pandemic. The top five products, totaling 61% of U.S. exports, were hydraulic valves, hydraulic actuators, rotary hydraulic pumps, pneumatic valves, and reciprocating hydraulic pumps, the report said.

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APRIL 2021

I F P S U P D AT E

Update on the Mobile Hydraulic Mechanic Certification

CELEBRATING 60 YEARS

THE INTERNATIONAL Fluid Power Society expects to release an updated mobile hydraulic mechanic certification by the end of the year. The certification is designed for individuals who fabricate, assemble, test, maintain, and repair systems and components. The mechanic should understand hydraulic symbols, read system schematics, and be skilled in using hand tools, TM power tools, micrometers, and testing equipment. The upgraded MHM Study Manual compiles all the information necessary to pass both the written (knowledge) and job performance (practical ability) certification tests. Improvements and updates in the new MHM Study Manual include: Part number Part description Applicable machines Number of parts Weight (kg) • Principles of operation, explained for commonly found components within a SWINGFLGLCK2062 Swing hose FlangeLock kit IS EX3600, EX5600, EX8000 16 x 2062U - red FlangeLock IFPS ACCEPTING nominations for the 2021 6.7 Fluid mobile hydraulic system – pumps, valves, actuators, and accessories. aid in under- Swing circuit capPower Hall ofEX5600, Fame awards. The16Hall Fame acknowledges • Color-coded cutaway illustrations of hydraulic components toSWINGCAP2062 kit EX3600, EX8000 x 2062of - cap 4.5 standing operation. individuals who have made significant contributions to fluid EX3600, EX5600, EX8000 16 x 2462U - purple FlangeLock 7.7 TRAVELFLGLCK2462 Travel hose FlangeLock kit • Updated symbology is ISO 1219 standard compliant. power technology and dedicated their careers to the industry. • Expanded content on troubleshooting includes decision-tree aids. can nominate one deceased6.4indiTRAVELCAP2462 Travel circuitAnyone cap kit EX3600, EX5600, EX8000 one living 16 xand 2462 - cap • Detailed content on pressure, flow, and directional control valves. vidual. The nominee must have 25 -or more years of service 14 x 3262U black FlangeLock Front attachment EX3600, EX5600, EX8000 8.9 FRONTATTFLGLCK326162 3261U - black & silver FlangeLock FlangeLock kit • Improved graphics throughout and real-life photos assist visualization. in the fluid power industry.4 xLiving nominees will be asked 14 x 3262 - cap FRONTATTCAP326162 Front attachment cap kit EX3600, EX8000 9.5 to complete anEX5600, application. A panel • Basic hydraulic calculations useful in troubleshooting. 4 x 3261 of - capjudges will select Boom arch hose the inductees, who will be announced on Fluid Power9.9Pro• Safety tips. EX3600, EX5600, EX8000 20 x 3262U - black FlangeLock BOOMARCHFLGLCK3262 FlangeLock kit fessionals' Day, June 19. • Basic principles of electrohydraulic control – open loop and closed loop. BOOMARCHCAP3262 Boom arch hose cap kit EX3600, EX5600, EX8000 20 x 3262 - cap 11.3 Nominations are being accepted until April 15 and can be • Electrohydraulic valves. made at www.fluidpowerhalloffame.org. • Sensors used in electrohydraulic systems.

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CONTAMINATION CONTROL

Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is sometimes overlooked when performing maintenance due to incorrect practices being used.

CO U T CO NTA LTIM HE NT M A RO INA TE L T TI OO ON L

Stop the Mess

THE FLANGELOCK™ TOOL AND CIRCUIT BLANKING CAPS

The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection. Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps stop the mess.

The FlangeLock™ Tool is the ultimate contamination control tool for protecting HITACHI MAKING systems. CONTAMINATION CONTROL EASY sealing of open SAE code 61, 62 your hydraulic It allows for the simple Hitachi have packaged FlangeLock™ tool and caps specifically for Hitachi mining excavators. The Hitachi customised & make CAT-Style hydraulic without Constructed from lightweight aluminum. kits sure no matter whichflanges component routine tools. maintenance is being performed on, you will always have the exact Easyofon, easy off.™*Offers to hydraulic system and environmental number FlangeLocks and capsatoleakproof help reducesolution contamination. cleanliness. FlangeLock™ Tools stop the mess! ™ *Note: FlangeLocks are not to be used under pressure

SAVE SAVE SAVE SAVE

TIME MONEY LABOR OIL

• No tools required • One hand installation Call you local Hitachi Muswellbrook representative or • No expensive hardware needed • Eliminate hydraulic oil spills & clean up onhoses 02 6541 6300 for installation more information. • No more the rags branch stuffed into • Quick & ease of usage • No more messy plastic caps • Safe for personnel & environment • The ultimate contamination control tool • Industry acclaimed

This product is Patented, other Patents pending.

For more information, call 203-861-9400 or email sales@flangelock.com. www.flangelock.com 10

APRIL 2021

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

January 2021

Newly Certified Professionals CONNECTOR & CONDUCTOR Robert Bertenshaw, The Boeing Company Alex Ng, The Boeing Company John Osko, The Boeing Company Jonathan Summers, The Boeing Company Chris Wilkie, The Boeing Company ELECTRONIC CONTROLS SPECIALIST John Bills

Precision Machining for Quality Hydraulics Contact us today 419.496.0964, ext. 203 Sales@TahomaEngineeredSolutions.com ISO 9001:2015 532 County Road 1600 • Ashland, Ohio 44805

SPECIALIST holds HS and PS Certifications John Bills HYDRAULIC SPECIALIST Nathan Bariel, The Boeing Company Kevin Dugan, Gates Corporation Jesse Holmes, CERES Jonathyn Lamont, Curry Fluid Power MOBILE HYDRAULIC MECHANIC Ryan Bisarra, Altec Industries, Inc. Ivan Bojoruez, Southern California Edison Corey Boynton, Cleveland Electric Illuminating Tyson Dahlgrin, Altec Industries, Inc. Michael Gudehus, Southern California Edison Jason Harper, Southern California Edison Cory Heath, Altec Industries, Inc. Fuasalli Iose, Southern California Edison Sean Mahannah, Southern California Edison John Mathews, Altec Industries, Inc. Robert Nava, Altec Industries, Inc. David Navarro, Altec Industries, Inc. Carlos Pelaez, Altec Industries, Inc. Brett Roeder, Altec Industries, Inc. Alexander Shelley, Southern California Edison Francisco Tabullo, Southern California Edison Clinton Tinsley, Altec Industries, Inc. John Weber, Altec Industries, Inc.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

delivers solutions

Helical Hydraulic Rotary Actuators GENERAL DATA • Torque output from 45 LB-Ft to 44.000 LB-FT • Rotation up to 720 degrees • Cantilever mount • Straddle mount • Special design available Contact Us 3060 Plaza Dr. #108 • Garnet Valley, PA 19060 Telephone: 610-558-0760 • E-mail: info@youngpowertech.com www.youngpowertech.com

APRIL 2021

I F P S U P D AT E

Spring Meeting Dates Changed

Maximizing the Use of PowerPoint and PDF Files Thursday, May 6, 8 a.m. - 2 p.m. includes lunch Discover your inner designer during Dan Helgerson’s deep dive into the underutilized tools of PowerPoint. Learn how to spice up your slide show by adding animation, motion paths, morphs, and how to work with graphic reproduction. You’ll also learn how to link and bookmark in PDF files. This is a hands-on workshop, where attendees will be “doing” as Dan “teaches.” Register by visiting ifps.org or call 856-424-8998.

SCHEDULE OF EVENTS

THE INTERNATIONAL Fluid Power Society’s in-person spring meeting, previously scheduled May 4-7, has been rescheduled and will take place May 3-6 at the Embassy Suites San Antonio Riverwalk Downtown in San Antonio, Texas. IFPS set a technical workshop for the meeting:

Monday, May 3 2:00 PM - 4:00 PM 6:30 PM - 11:00 PM Tuesday, May 4 8:00 AM - 9:00 AM 9:00 AM - 11:00 AM 11:00 AM - 12:00 PM 12:00 PM - 12:30 PM 12:30 PM - 1:30 PM 1:30 PM - 5:00 PM 6:00 PM - 9:00 PM Wednesday, May 5 8:00 AM - 10:30 AM 10:30 AM - 12:00 PM 12:00 PM - 12:45 PM 1:00 PM - 2:30 PM 2:30 PM - 3:00 PM 3:30 PM - 5:00 PM 6:00 PM - 9:30 PM Thursday, May 6 8:00 AM - 2:00 PM * invitation only

CELEBRATING 60 YEARS

New Board Member Orientation* Board of Directors Dinner* Strategic Planning Committee Meeting Education Committee Meeting Membership Committee Meeting Hosted Lunch Membership Committee Meeting (cont’d) Certification Committee Meeting Dinner Marketing Committee Meeting Finance Committee Meeting Hosted Lunch Board of Directors Meeting Strategic Planning Committee Meeting Riverwalk Boat Tour Reception & Trivia Night Technical Workshop & Box Lunch

OUR HOSES & EQUIPMENT HELP KEEP YOU AND YOUR PRODUCTS MOVING! • High Quality Hose & Couplings • Inventory & Fast Response • Crimping Equipment • Crimp Spec. Software • E-Commerce

APRIL 2021

Jason Industrial well known for its Industrial Hose business has expanded to offer Hydraulic Hose, Couplings and Equipment. As you have come to know, we are all about high quality and service. Our Nationwide Distribution Centers have stock and are ready to ship.

www.JasonIndustrial.com | 630.752.0600

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

IFPS CERTIFICATION

A New Road to Hydraulic Specialist Certification

IFPS RELEASED THE hydraulic specialist (HS) certification test, designed to be comprehensive, in 2017. The test benchmarks competencies showing that, as a fluid power specialist, you are at the top of your craft, whether you’re in sales, engineering, or system designing. After reviewing the design, layout, and content of the HS Study Manual, the IFPS certification committee decided to update and better streamline the manual by: • rewording complex topics for easier comprehension; • rewriting the equation formulas and subsequent text describing how to compute complex formulas for ease of calculation; • carefully rewriting some outcomes to provide the necessary information to prepare for the test and provide industry best practices paramount to our industry; and • adding “bar” whenever pressure units are used to reflect the industry’s more common use of both metric units of pressure (bar and Pascal). Preparation is the key to a successful outcome. For those who were unsuccessful the first time around, don’t give up! You can find the streamlined study manual in your IFPS account under downloadable products. IFPS wants you to succeed. There are several ways to prepare. Visit ifps.org to access these resources: • Master the online and study manual pretests. • Access recorded web seminar outcome presentations. • Consider a paid one-year access to the HS interactive study manual. • Form a study group – an excellent way to share strengths and knowledge. • Use our animated circuits for a visual understanding of schematics. • Certification review training classes (see page 15). WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Joining IFPS and gaining my CFPHS has truly helped round out my fluid power knowledge and create an excellent foundation for personal growth. The greatest benefit has been the ability to apply those skills across multiple industries and in widely varying applications, giving me the confidence to deliver the best solution to my clients for the job at hand. Ben Cusack, CFPHS, OneHydraulics Engineering Manager

Smart Hydraulics. Easy Business. Precise, Flexible and Safe Load-holding valves type CLHV

Versatile and Flexible Mobile controller type ESX

Efficient, Reliable and Durable Variable displacement axial piston pump type V30D Industry Leading Performance Proportional directional spool valve PSL-CAN

HAWE Hydraulik manufactures the highest quality hydraulic components, constructed to minimize space and maximize product durability for the mobile, industrial and oilfield markets. Partner with HAWE to always have the right solution! We are Partners. www.hawe.com | info@haweusa.com | 704-509-1599

Field Sales and Operations opportunities available now. Visit the HAWE Job Market online to apply today.

APRIL 2021

I F P S U P D AT E

Certification Testing Locations Individuals wishing to take any IFPS written certification tests can select from convenient locations across the United States and Canada. IFPS is able to offer these locations through its affiliation with The Consortium of College Testing Centers provided by National College Testing Association. Contact headquarters if you do not see a location near you. Every effort will be made to accommodate your needs. If your test was postponed due to the pandemic, please contact headquarters so that we may reschedule.

TENTATIVE TESTING DATES FOR ALL LOCATIONS: May 2021 Tuesday 5/4 • Thursday 5/20 June 2021 Tuesday 6/1 • Thursday 6/24 July 2021 Tuesday 7/13 • Thursday 7/29 August 2021 Tuesday 8/3 • Thursday 8/26

ALABAMA Auburn, AL Birmingham, AL Calera, AL Decatur, AL Huntsville, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloosa, AL ALASKA Anchorage, AK Fairbanks, AK ARIZONA Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Scottsdale, AZ Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ ARKANSAS Bentonville, AR Hot Springs, AR Little Rock, AR CALIFORNIA Aptos, CA Arcata, CA Bakersfield, CA Dixon, CA Encinitas, CA Fresno, CA Irvine, CA Marysville, CA Riverside, CA Salinas, CA San Diego, CA San Jose, CA San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA Tustin, CA Yucaipa, CA COLORADO Aurora, CO Boulder, CO Springs, CO Denver, CO Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO DELAWARE Dover, DE Georgetown, DE Newark, DE FLORIDA Avon Park, FL Boca Raton, FL Cocoa, FL Davie, FL Daytona Beach, FL Fort Pierce, FL Ft. Myers, FL Gainesville, FL Jacksonville, FL Miami Gardens, FL Milton, FL New Port Richey, FL Ocala, FL Orlando, FL Panama City, FL Pembroke Pines, FL Pensacola, FL Plant City, FL Riviera Beach, FL Sanford, FL

APRIL 2021

Tallahassee, FL Tampa, FL West Palm Beach, FL Wildwood, FL Winter Haven, FL GEORGIA Albany, GA Athens, GA Atlanta, GA Carrollton, GA Columbus, GA Dahlonega, GA Dublin, GA Dunwoody, GA Forest Park, GA Lawrenceville, GA Morrow, GA Oakwood, GA Savannah, GA Statesboro, GA Tifton, GA Valdosta, GA HAWAII Laie, HI IDAHO Boise, ID Coeur d ‘Alene, ID Idaho Falls, ID Lewiston, ID Moscow, ID Nampa, ID Rexburg, ID Twin Falls, ID ILLINOIS Carbondale, IL Carterville, IL Champaign, IL Decatur, IL Edwardsville, IL Glen Ellyn, IL Joliet, IL Malta, IL Normal, IL Peoria, IL Schaumburg, IL Springfield, IL University Park, IL INDIANA Bloomington, IN Columbus, IN Evansville, IN Fort Wayne, IN Gary, IN Indianapolis, IN Kokomo, IN Lafayette, IN Lawrenceburg, IN Madison, IN Muncie, IN New Albany, IN Richmond, IN Sellersburg, IN South Bend, IN Terre Haute, IN IOWA Ames, IA Cedar Rapids, IA Iowa City, IA Ottumwa, IA Sioux City, IA Waterloo, IA KANSAS Kansas City, KS Lawrence, KS Manhattan, KS Wichita, KS KENTUCKY Ashland, KY Bowling Green, KY Erlanger, KY Highland Heights, KY Louisville, KY Morehead, KY

LOUISIANA Bossier City, LA Lafayette, LA Monroe, LA Natchitoches, LA New Orleans, LA Shreveport, LA Thibodaux, LA MARYLAND Arnold, MD Bel Air, MD College Park, MD Frederick, MD Hagerstown, MD La Plata, MD Westminster, MD Woodlawn, MD Wye Mills, MD MASSACHUSETTS Boston, MA Bridgewater, MA Danvers, MA Haverhill, MA Holyoke, MA Shrewsbury, MA MICHIGAN Ann Arbor, MI Big Rapids, MI Chesterfield, MI Dearborn, MI Dowagiac, MI East Lansing, MI Flint, MI Grand Rapids, MI Kalamazoo, MI Lansing, MI Livonia, MI Mount Pleasant, MI Sault Ste. Marie, M Troy, MI University Center, MI Warren, MI MINNESOTA Alexandria, MN Brooklyn Park, MN Duluth, MN Eden Prairie, MN Granite Falls, MN Mankato, MN MISSISSIPPI Goodman, MS Jackson, MS Mississippi State, MS Raymond, MS University, MS MISSOURI Berkley, MO Cape Girardeau, MO Columbia, MO Cottleville, MO Joplin, MO Kansas City, MO Kirksville, MO Park Hills, MO Poplar Bluff, MO Rolla, MO Sedalia, MO Springfield, MO St. Joseph, MO St. Louis, MO Warrensburg, MO MONTANA Bozeman, MT Missoula, MT NEBRASKA Lincoln, NE North Platte, NE Omaha, NE NEVADA Henderson, NV Las Vegas, NV North Las Vegas, NV Winnemucca, NV

CELEBRATING 60 YEARS

NEW JERSEY Branchburg, NJ Cherry Hill, NJ Lincroft, NJ Sewell, NJ Toms River, NJ West Windsor, NJ NEW MEXICO Albuquerque, NM Clovis, NM Farmington, NM Portales, NM Santa Fe, NM NEW YORK Alfred, NY Brooklyn, NY Buffalo, NY Garden City, NY New York, NY Rochester, NY Syracuse, NY NORTH CAROLINA Apex, NC Asheville, NC Boone, NC Charlotte, NC China Grove, NC Durham, NC Fayetteville, NC Greenville, NC Jamestown, NC Misenheimer, NC Mount Airy, NC Pembroke, NC Raleigh, NC Wilmington, NC NORTH DAKOTA Bismarck, ND OHIO Akron, OH Cincinnati, OH Cleveland, OH Columbus, OH Fairfield, OH Findlay, OH Kirtland, OH Lima, OH Maumee, OH Newark, OH North Royalton, OH Rio Grande, OH Toledo, OH Warren, OH Youngstown, OH OKLAHOMA Altus, OK Bethany, OK Edmond, OK Norman, OK Oklahoma City, OK Tonkawa, OK Tulsa, OK OREGON Bend, OR Coos Bay, OR Eugene, OR Gresham, OR Klamath Falls, OR Medford, OR Oregon City, OR Portland, OR White City, OR PENNSYLVANIA Bloomsburg, PA Blue Bell, PA Gettysburg, PA Harrisburg, PA Lancaster, PA Newtown, PA Philadelphia, PA Pittsburgh, PA Wilkes-Barre, PA York, PA

SOUTH CAROLINA Beaufort, SC Charleston, SC Columbia, SC Conway, SC Graniteville, SC Greenville, SC Greenwood, SC Orangeburg, SC Rock Hill, SC Spartanburg, SC TENNESSEE Blountville, TN Clarksville, TN Collegedale, TN Gallatin, TN Johnson City, TN Knoxville, TN Memphis, TN Morristown, TN Murfreesboro, TN Nashville, TN TEXAS Abilene, TX Arlington, TX Austin, TX Beaumont, TX Brownsville, TX Commerce, TX Corpus Christi, TX Dallas, TX Denison, TX El Paso, TX Houston, TX Huntsville, TX Laredo, TX Lubbock, TX Lufkin, TX Mesquite, TX San Antonio, TX Victoria, TX Waxahachie, TX Weatherford, TX Wichita Falls, TX UTAH Cedar City, UT Kaysville, UT Logan, UT Ogden, UT Orem, UT Salt Lake City, UT VIRGINIA Daleville, VA Fredericksburg, VA Lynchburg, VA Manassas, VA Norfolk, VA Roanoke, VA Salem, VA Staunton, VA Suffolk, VA Virginia Beach, VA Wytheville, VA WASHINGTON Auburn, WA Bellingham, WA Bremerton, WA Ellensburg, WA Ephrata, WA Olympia, WA Pasco, WA Rockingham, WA Seattle, WA Shoreline, WA Spokane, WA WEST VIRGINIA Ona, WV WISCONSIN La Crosse, WI Milwaukee, WI Mukwonago, WI

WYOMING Casper, WY Laramie, WY Torrington, WY CANADA ALBERTA Calgary, AB Edmonton, AB Fort McMurray, AB Lethbridge, AB Lloydminster, AB Olds, AB Red Deer, AB BRITISH COLUMBIA Abbotsford, BC Burnaby, BC Castlegar, BC Delta, BC Kamloops, BC Nanaimo, BC Prince George, BC Richmond, BC Surrey, BC Vancouver, BC Victoria, BC MANITOBA Brandon, MB Winnipeg, MB NEW BRUNSWICK Bathurst, NB Moncton, NB NEWFOUNDLAND AND LABRADOR St. John’s, NL NOVA SCOTIA Halifax, NS ONTARIO Brockville, ON Hamilton, ON London, ON Milton, ON Mississauga, ON Niagara-on-the-Lake, ON North Bay, ON North York, ON Ottawa, ON Toronto, ON Welland, ON Windsor, ON QUEBEC Côte Saint-Luc, QB Montreal, QB SASKATCHEWAN Melfort, SK Moose Jaw, SK Nipawin, SK Prince Albert, SK Saskatoon, SK YUKON TERRITORY Whitehorse, YU UNITED KINGDOM Elgin, UK GHAZNI Kingdom of Bahrain, GHA Thomasville, GHA EGYPT Cairo, EG JORDAN Amman, JOR NEW ZEALAND Taradale, NZ

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

AVAILABLE IFPS CERTIFICATIONS CFPAI Certified Fluid Power Accredited Instructor CFPAJPP Certified Fluid Power Authorized Job Performance Proctor CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPE Certified Fluid Power Engineer CFPS Certified Fluid Power Specialist (Must Obtain CFPHS & CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist

Tentative Certification Review Training IFPS offers onsite review training for small groups of at least 10 persons. An IFPS accredited instructor visits your company to conduct the review. Contact kpollander@ifps.org for details of the scheduled onsite reviews listed below.

CFPECS Certified Fluid Power Electronic Controls Specialist

HYDRAULIC SPECIALIST CERTIFICATION REVIEW September 13-16, 2021 - Fairfield, OH - CFC Industrial Training | Written test: September 16, 2021

CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT)

PNEUMATIC SPECIALIST July 27-29, 2021 - Fairfield, OH - CFC Industrial Training | Written test: July 29, 2021

CFPIHT Certified Fluid Power Industrial Hydraulic Technician CFPMHT Certified Fluid Power Mobile Hydraulic Technician CFPPT Certified Fluid Power Pneumatic Technician CFPMM Certified Fluid Power Master Mechanic (Must Obtain CFPIHM, CFPMHM, & CFPPM) CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMIH Certified Fluid Power Master of Industrial Hydraulics (Must Obtain CFPIHM, CFPIHT, & CFPCC) CFPMMH Certified Fluid Power Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC) CFPMIP Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC) CFPCC Certified Fluid Power Connector & Conductor CFPSD Fluid Power System Designer CFPMEC (In Development) Mobile Electronic Controls CFPIEC (In Development) Industrial Electronic Controls

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

ELECTRONIC CONTROLS CERTIFICATION REVIEW August 9-12, 2021 - Fairfield, OH - CFC Industrial Training | Written test: August 12, 2021 CONNECTOR & CONDUCTOR CERTIFICATION REVIEW May 18-19, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: May 20, 2021 November 16-17, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: November 18, 2021 MOBILE HYDRAULIC MECHANIC CERTIFICATION REVIEW Online Mobile Hydraulic Mechanic Certification Review (for written test) offered through info@cfcindustrialtraining.com. This course takes you through all chapters of the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written MHM test. Members receive 20% off. (Test fees are additional - separate registration required.) April 13-15, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: April 16, 2021 August 30 - September 1, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: September 2, 2021 INDUSTRIAL HYDRAULIC MECHANIC CERTIFICATION June 14 - 16, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: June 17, 2021 INDUSTRIAL HYDRAULIC TECHNICIAN CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio MOBILE HYDRAULIC TECHNICIAN CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio PNEUMATIC TECHNICIAN and PNEUMATIC MECHANIC CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio JOB PERFORMANCE TRAINING Online Job Performance Review - CFC Industrial Training offers online JP Reviews which includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members may e-mail askus@ifps.org for a 20% coupon code off the list price or get the code in our Members Only area for the entire IFPS Job Performance Review; test not included. LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW E-mail info@cfcindustrialtraining.com for information.

APRIL 2021

Going Electric? SHA is the dynamic choice

By Carl Richter, Vice President and General Manager, Kyntronics

recent years, with the push in many industries to switch to all-electric machines, electromechanical actuator (EMA) companies have gone after the hydraulics market. This can cause confusion and dissatisfaction for two reasons: EMA applications engineers may not understand the hydraulics industry and are challenged to properly apply an optimal EMA product. Further, hydraulics engineers may not be fluent enough with EMA technology to know what questions to ask. Both situations have led to premature product failures and dissatisfied customers. There have been two choices for powerful, accurate actuation: a central hydraulic system or an EMA. But a third technology combines the best features of both and is the choice for “going electric”: the smart hydraulic actuator (SHA). Today many of the EMAs that tried to replace hydraulics are failing due to several factors, including not fully understanding the machine and the applied hydraulics. Hydraulics is tough, powerful, and often plows through mechanical “inefficiencies.” Hydraulics encourages impact and shock loading, and it has the capability to compensate for some side loading. EMAs run away from these; 16

APRIL 2021

they cannot handle shock loading and do no warranty for side-loading mountings. EMAs promote a certain static IP rating. Once the EMA starts moving, the IP rating is no longer valid. With the roller screw moving, it sucks in whatever fluid is moving around the machine and causes premature nonwarranty failures.

Requirement

SHA

Central Hydraulic Cylinder

ElectroMechanical Actuator

Also, some advertised EMA efficiencies are inaccurate or incomplete and sometimes based on ideal or theoretical calculations. Kyntronics’ tests show the SHA to be 40% to 50% more efficient because of its smaller motor and drive. The roller screw actuator’s total efficiency is sometimes not promoted.

Feature/Benefit

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Hydraulic Live Swivels Inline & 90°

Heavy Duty Ball Bearing Design

Premature wear.

The same gears (mech connection) are under stress at the same force position.

reliability data for IP ratings when in motion, required maintenance, and inertia calculations, including the machine. Because hydraulics is so powerful, in most instances inertia is not an issue. Especially for the higher loads, the overall EMA actuator and machine inertia may need to be taken into consideration. An easy test is to understand the horsepower running the cylinders (load over distance and time). Does the EMA motor HP make sense? Many times, it does not. Ask for the HP calculations (moving x lbf, over a distance in y seconds). Another quick test is to compare the total EMA’s motor power to that of the hydraulic power unit. Usually the HPU is oversized. But if the EMA’s total power is over or significantly under, ask questions. Power is power, there is no getting around physics. Kyntronics makes both EMAs and hydraulic actuators. But an alternative path is to consider the Kyntronics SHA for an all-electric solution. The SHA is an all-inclusive servo hydraulic solution that is completely sealed, so there are no leaks. It takes advantage of the benefits of hydraulics while solving EMA issues. Because of the significant demand for the SHA, coupled with the diminishing demand for the EMA, the SHA is the future for Kyntronics and potentially the future for many companies’ actuation needs. 

Available In BSPP

® Switc h Your Swivel® Switch Your Swivel

Because hydraulics and electric are different technologies, they speak different languages and use different symbols. Hydraulics symbols look like hieroglyphics to an electric company, which likely will not understand the control dynamics. Closed loop servo control responds much differently than a flow control valve. The closed loop servo will respond to machine binding issues and resonances, which likely will not translate to smooth motion. The hydraulics are powerful and will be smooth with a simple flow control. It is also important to understand the true life of an EMA so there are not sudden failure surprises. Hydraulics has many advantages over EMA technology. A hydraulic cylinder requires no brakes, and its footprint is much smaller. Impact loads along with side loading are much more robust with hydraulics. EMAs require preloading for accurate solutions, leading to reduced efficiencies. EMAs require maintenance, need to be kept cool, and need to stay greased. They have continuous metal-to-metal contact that causes reliability issues. In a failure, if there’s been no maintenance, the warranty is voided, and the customer’s operation can go down, causing frustration. When looking at larger loads, e.g., greater than 8klbf, EMAs can get large and expensive, and reliability decreases. Especially when pressing a certain load at the same position over and over, EMAs can fail prematurely. Because hydraulics is just pressure and moving fluid, there are no major metal-to-metal wear parts. With hydraulics, the retract speeds are faster than the extend speeds, which is a cycletime benefit. EMAs need to oversize to properly compensate. It is also difficult and expensive for an EMA to perform accurate force control; for an SHA or hydraulic actuator, it is done with simply a pressure sensor (F = A & psi). When considering moving to an all-electric solution, be as educated as possible. Understand the machine’s existing needs and its possible future needs (speed, force, and duty cycle). Understand what your reliability is today and set those expectations with your actuation supplier. Challenge the EMA supplier to provide

Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime cutting the overall cost of hydraulics.

No Kinks No Hose Twisting

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APRIL 2021

TEST YOUR SKILLS

Understand the Application of Hydrostatic Systems The typical hydrostatic transmission consists of a closed circuit where a pump provides flow to a hydraulic motor without the use of directional valves. The ports of the pump are connected directly to the ports of the motor so that the flow from the pump drives the motor, and the discharge from the motor feeds the inlet to the pump. There are a number of valves included in the transmission package, but the main flow paths between the pump and motor are not restricted. The direction and speed of the motor is controlled by the flow from the pump. A bidirectional pump will provide a bidirectional motor. The pump and motor may be combined in a common housing or connected by plumbing when the motor is at some distance from the prime mover. The transmission produces a speed-torque ratio equal to the ratio of the motor and pump displacements. The motor can be a high-speed low torque, or a lowspeed high torque design. Fixed or variable displacement pumps and motors can be used to match the need of the application (see table). A common pump assembly consists of a hydromechanical, servo controlled, variable displacement, axial piston pump that is biased to zero displacement, with overcenter capabilities that allow it to vary and reverse the flow between the main two work ports while having a constant direction of input rotation. The pump assembly also includes a replenishing pump (sometimes referred to as a charge pump), a replenishing relief valve, and two replenishing check valves. The replenishing pump is typically 10% to 20% of the main pump displacement, although some applications may require greater replenishing displacement. The pump assembly may include ports to permit filtration of the replenishing flow and additional servo control valves. There are several ways to provide input to the servo displacement control: manually with a lever or linkage controlled by the operator, hydraulically using remote pilot pressure, or electrically using a proportional solenoid operated pressure reducing/relieving valve. Overpressure protection is accomplished by cross-port relief valves, a pressure compensator control that overrides the displacement 18

APRIL 2021

COMBINATION

APPLICATION

Fixed Pump + Fixed Motor

Constant speed. Torque and power vary with the load.

Fixed Pump + Variable Motor

Constant power. Flow to the motor is constant and motor displacement is varied to maintain the ratio of torque to speed. Increasing displacement to the motor increases torque capacity but speed decreases in inverse proportion (and vice-versa) so that the product of the two is constant power, proportional to the load pressure.

Variable Pump + Fixed Motor

Constant torque. Torque capacity is constant at any speed and is dependent only on the load pressure and motor displacement. Speed is a function of input flow. Variable power/torque/speed. Provides characteristics of both constant power and constant torque with nearly infinite ratios of both speed and torque to power.

Variable Pump + Variable Motor

With the pump at full displacement, decreasing motor displacement increases motor speed and torque decreases (and vice-versa) in inverse proportion (constant power). With the motor at maximum displacement, varying pump displacement varies speed and power output (constant torque).

Replenishing Relief Valve

Hot Oil Shuttle Directional Control Valve Hot Oil Shuttle Relief Valve

2 MPa (290 PSI) Main Pump

1.5 MPa (220 PSI) Replenishing Check Valves

Motor

Replenishing Pump

NOTE: Over-Pressure Protection and and NOTE: Overpressure protection servo control detailsdetails not shown. servo control not shown.

Figure 1: Simplified hydrostatic circuit in neutral.

command, or a combination of the two functions (figure 1). A hot oil shuttle package may be attached to the pump or motor or plumbed into the main work ports as an independent valve manifold. The hot oil shuttle package consists of a 3/3, closed center, pilot operated, spring centered, directional control valve and a low-pressure relief valve. The purpose of the hot oil shuttle is to allow some of the oil from the motor return to be directed to tank so additional fresh

replenishing fluid will be forced into the pump. This is necessary because the volume of fluid in the operating loop is usually a small fraction of the flow rate. In large systems, the fluid volume may be 1/10 of the flow rate. In close coupled pump-motor combinations, the ratio will be significantly smaller. Operating inefficiencies will quickly overheat the working fluid if it is not replaced by cool replenishing fluid (figure 2). During operation, when the main pump is in neutral at zero displacement, no fluid is flowing WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Replenishing Relief Valve

Hot Oil Shuttle Directional Control Valve

Replenishing Relief Valve

Hot Oil Shuttle Directional Control Valve

Hot Oil Shuttle Relief Valve 2 MPa (290 PSI) Main Pump

Hot Oil Shuttle Relief Valve 2 MPa (290 PSI)

1.5 MPa (220 PSI) Replenishing Check Valves

Motor

Main Pump

NOTE: Over-Pressure Protection and NOTE: Overpressure protection and servo control details not shown.

servo control details not shown.

Figure 2: Simplified hydrostatic circuit motor rotation forward.

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Motor

Replenishing Pump

out of or into the main pump ports. The motor is not turning. The replenishing pump is pressurizing the two work ports via the replenishing check valves to the pressure setting of the replenishing relief valve and providing flow for the servo control mechanism. The surplus fluid of the replenishing pump is flowing through the replenishing relief into the pump case and out the case drain back to the reservoir. It is best to filter the replenishing fluid before it enters the main flow loop. When the operator provides a displacement command to the pump, the flow produced causes the motor to rotate in the direction and speed proportional to the command. The load resistance causes the pressure in that work line to increase. The differential pressure between the two work lines causes the hot oil shuttle valve to shift, connecting the low-pressure work line to the hot oil shuttle relief. The hot oil shuttle relief pressure setting is slightly lower than the main pump replenishing relief valve. This causes the surplus replenishing flow to be exhausted out of the main flow loop through the hot oil shuttle valve assembly. Due to the relative locations of the replenishing check valves and the hot oil shuttle valve, oil from the replenishing pump is drawn directly into the main pump. The same amount of oil is diverted out the hot oil shuttle valve. The remaining motor return oil is combined with the replenishing pump flow to insure the main pump has adequate flow to prevent cavitation. The pressure on the return side of the main loop will be at the pressure setting of the hot oil shuttle relief valve. Reversing the operator displacement command will cause the motor to rotate in the opposite direction, the hot oil shuttle valve will shift in the opposite direction due to the differential pressure being inverted. This process ensures that a constant flow of cool filtered oil is being introduced into the main flow loop and the heat

1.5 MPa (220 PSI) Replenishing Check Valves

Figure 3: Simplified hydrostatic circuit motor reverse rotation.

and contaminants picked up are flushed out. The return line from the hot oil shuttle valve may be routed through the motor case, and is usually directed through the filtration and cooling part of the circuit (figure 3). Dynamic braking occurs when the load being driven has a high inertia and the displacement command is reduced. For example, if the displacement is reduced from 100% to 50%, the lower pump flow will cause the driving pressure to drop. However, because the motor is still rotating at the higher speed, the load inertia will try to drive it as a pump. Because the pump now has a lower displacement, it will not accept the high rate of flow, causing the pressure to increase on the return side of the motor to the pump. In this example, the pressure increase multiplied by the motor displacement will produce a braking effort to the motor shaft. The same pressure increase multiplied by the new pump displacement of 50% will cause the pump to develop an output torque on the shaft, effectively putting energy back into the power source. In the case of a conventional induction electric motor, the electric

TEST YOUR SKILLS The amount of torque that a fixed displacement motor can produce in a hydrostatic transmission is: a. Dependent on the input rpm of the hydraulic pump. b. Higher in the forward direction than in the reverse direction. c. Increased as the replenishing pressure is increased. d. Dependent on the motor displacement and the maximum pressure setting of the cross-port relief valves. e. Dependent on the pump displacement and the maximum pressure setting of the cross-port relief valves. See correct solution on page 39.

motor becomes a generator and puts the power back into the grid. In the case of a diesel engine, the engine will defuel and the hydrostatic drive will power any other components connected to the diesel. If the overrunning energy is too great and the tare engine load is too small, the diesel could be oversped because of the diesel engine's limited ability to accept overdriving loads. The magnitude of the dynamic braking is dependent on the inertia-drag of the load and how quickly the pump displacement is reduced. Slowly ramping the displacement down may not cause any dynamic braking because the drag of the load will slow it down at the same rate. Brake or counterbalance valves should not be used in a hydrostatic circuit because the heat generated is more than the replenishing circuit can easily dissipate. If brake valves must be used because of safety or other reasons, the replenishing flow will need to be increased to insure adequate loop cooling. If the hydrostatic drive uses cross-port relief valves for overpressure protection, stalling the motor at full pump displacement will quickly cause the system to overheat and result in severe damage to the components in a matter of seconds. The pump output flowing across the relief valve at the maximum setting will be converting 100% of the input power to heat. Because of the small volume of fluid in the loop, the high temperature oil will immediately flow through the pump and have its temperature increased as it again flows through the relief valve. When used in vehicle propulsion, two or more motors in parallel will act as a differential. The hydraulic flow will divide proportionally to the motors as the vehicle turns. Should one motor lose traction and have minimal load resistance, all the flow from the pump will try to pass through that motor. Some means of a flow divider or other antispin device may be required.  APRIL 2021

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2021 DIRECTORY

APRIL 2021

Check out the online matrix at www.fluidpowerjournal.com

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APRIL 2021

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CALL 24/7: 800-722-2630 WWW.CONFLUIDS.COM

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APRIL 2021

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APRIL 2021

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Stafford Manufacturing Corp. P.O. Box 2370 Woburn, MA 01888 Phone: 800-695-5651 Fax: 800-649-5101 Email: sales@staffordmfg.com Web: www.staffordmfg.com

Switches Unlimited 34-11 56th Street Woodside, NY 11377 Phone: 800-221-0487 Fax: 718-672-6370 Email: info@switchesunlimited.com Web: www.switchesunlimited.com

Stanley M. Proctor Company 2016 Midway Dr. Twinsburg, OH 44087 Phone: 330-425-7814 Fax: 330-425-3222 Web: www.stanleyproctor.com

Switching Solutions Inc. 380 Four Valley Drive Concord, ON Canada L4K 5Z1 Phone: 905-303-8700 Fax: 905-303-7256 Email: sales@switchingssi.com Web: www.switchingssi.com

Stauff Corporation 7 Wm Demarest Place Waldwick, NJ 07463 Phone: 201-444-7800 Email: sales@stauffusa.com Web: www.stauff.com Steelhead Composites 500 Corporate Circle, Suite 0 Golden, CO 83440 Phone: 720-524-3360 Email: sales@steelheadcomposites.com Web: steelheadcomposites.com Steffen Inc. 621 West 7th Street Sioux City, IA 51103 Phone: 712-279-8030 Fax: 712-279-8071 Web: www.steffenhydro.com

Sync-Lok, Inc. 407 Newburg Avenue Catonsville, MD 21228 Phone: 410-869-3480 Fax: 410-869-3482 Email: info@sync-lok.com Web: www.sync-lok.com System Seals, Inc. 24202 Aurora Rd. Cleveland, OH 44146 Phone: 440-735-0200 Fax: 440-735-0288 Email: info@systemseals.com Web: www.systemseals.com

call 800.231.7116 or email sales@texcelrubber.com

The FPDA – Motion + Control Network 105 Eastern Avenue, Suite 104 Annapolis, MD 21403 Phone: 410-940-6347 Fax: 410-263-1659 Email: aluckado@fpda.org Web: www.fdpa.org Tahoma Engineered Solutions 532 County Road 1600 Ashland, OH 44805 Phone: 419-496-0964 x203 Email: sales@ tahomaengineeredsolutions.com Web: www. tahomaengineeredsolutions.com Taiwan PU Corporation 760 Oak Grove Dr. San Jose, CA 95129 Phone: 408-839-2919 Email: sales@taiwanpu.com Web: www.TaiwanPU.com

The Paquin Company 9286 Mercantile Drive Mentor, OH 44060 Phone: 800-260-5664 Fax: 216-261-5705 Email: paquin@paquin.com Web: www.paquin.com Thermal Transfer Products 5215 21st St. Racine, WI 53406 Phone: 800-394-8330 Fax: 262-554-8536 Email: thermal_transfer_sales@ thermasys.com Web: www.thermasys.com

Sun Hydraulics Corporation 1500 University Parkway Sarasota, FL 34233 Phone: 941-362-1200 Fax: 941-355-4497 Email: stevetberlin@sunhydraulics.com Web: www.sunhydraulics.com

Tapeswitch Corporation 100 Schmitt Blvd. Farmingdale, NY 11735 Phone: 631-630-0442 Fax: 631-630-0454 Email: marketing@tapeswitch.com Web: www.tapeswitch.com

Sunfab Hydraulics Inc. 6426 Hendry Road, Suite A Charlotte, NC 28269 Phone: 704-509-6435 Email: sunfab-us@sunfab.com Web: www.sunfab.com/us

TE Connectivity 1050 Westlakes Drive Berwyn, PA 19312 Phone: 610-893-9800 Email: mary.manzo-ritchie@te.com Web: www.te.com

Thomas Products 987 West Street Southington, CT 06489 Phone: 800-666-9101 Fax: 860-621-1470 Email: thomsales@aol.com Web: www.thomasprod.com

SunSource 12800 Hwy 13 South #100 Savage, MN 55378 Phone: 952-563-1700 Email: mecsolutions@sunsrce.com Web: www.sun-source.com

Terex Utilities, Inc. 3400 NE 37th Place Wildwood, FL 34785 Phone: 352-330-4044 Fax: 352-330-4047 Email: mike.shannon@terexutilities. com Web: www.terex.com

Titan Inc. 9900 Durand Ave. Sturtevant, WI 53177 Phone: 262-884-2890 Fax: 262-884-8072 Email: tevans@titansystems.com Web: titansystems.com

Super Swivels 7917 Beech St. NE Minneapolis, MN 55432 Phone: 763-784-5531 Fax: 763-784-7423 Email: sales@superswivels.com Web: www.superswivels.com SVF Flow Controls, Inc. 13560 Larwin Circle Santa Fe Springs, CA 90670 Phone: 562-802-2255 Fax: 562-802-3114 Email: Jeanette@svf.net Web: www.svf.net Swanson Industries 2608 Smithtown Road Morgantown, WV 26508 Phone: 800-327-6203 Fax: 304-292-8151 Email: industrialsales@ swansonindustries.com Web: www.swansonindustries.com

Texacone 4111 Forney Ave. Mesquite, TX 75149 Phone: 800-235-2727 Fax: 972-289-6285 Email: information@texacone.com Web: www.texacone.com Texas Hydraulics, Inc. 3410 Range Road Temple, TX 76504 Phone: 254-778-4701 Fax: 254-774-9940 Email: sales@texashyd.com Web: www.texashydraulics.com Texcel Rubber 4444 Homestead Rd. Houston, TX 77028 Phone: 800-231-7116 Fax: 800-759-4673 Email: sales@texcelrubber.com Web: www.texcelrubber.com

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T-Lon Products, Inc. 1110 Richards Road Hartland, WI 53029 Phone: 262-367-2333 Fax: 262-367-8159 Email: dolson@t-lon.com Web: www.t-lon.com

TR Engineering Inc. 1350 Green Hills Rd. #10 Scotts Valley, CA 95066 Phone: 831-430-9920 Fax: 831-430-9989 Email: rromero@trengineering.com Web: www.trengineering.com Transcom Inc. 3451 W. Burnsville Pkwy. Burnsville, MN 55337 Phone: 800-328-2840 Fax: 952-894-1588 Trelleborg Sealing Solutions 2531 Bremer Road Fort Wayne, IN 46803 Phone: 260-749-9631 Fax: 260-749-4844 Email: tssusa@trelleborg.com Web: www.trelleborg.com/seals Triad Technologies, LLC 985 Falls Creek Dr. Vandalia, OH 45377 Phone: 800-420-8575 Fax: 800-420-4324 Email: sales@triadtechnologies.com Web: www.triadtechnologies.com Trident 408 Defiance Ave. Hicksville, OH 43526 Phone: 419-542-7721 Fax: 419-542-8717 Email: trident@ tridentconnection.com Web: www.tridentconnection.com Triple R America 60/040 Industrial Pkwy. Cheektowaga, NY 14227 Phone: 800-668-8671 Fax: 416-413-9387 Email: sales@triple-rrr.com Web: www.triple-rrr.com Tubes n’ Hoses 820 N. Dallas Ave Lancaster, TX 75146 Phone: 972-923-0766 Fax: 972-332-4119 Email: sales@tubesnhoses.com Web: www.tubesnhoses.com

Tobeyco Mfg. Co., Inc. Federal Brass Division 165 Cedar St. Corning, NY 14830 Phone: 607-962-6054 Fax: 607-962-8871

Turck Inc. 3000 Campus Drive Minneapolis, MN 55441 Phone: 800-544-7769 Fax: 763-509-7797 Email: turckusa@turck.com Web: www.turck.us

Tobul Accumulator, Inc. 61 Innovation Drive Bamberg, SC 29003 Phone: 803-245-2400 Fax: 803-245-2636 Email: sales@tobul.com Web: www.tobul.com

Tuthill Coupling Group 1000 West Bagley Rd. Berea, OH 44017 Phone: 440-826-1115 Fax: 440-826-0115 Email: hansencoupling@tuthill.com Web: www.tuthill.com

Tuthill Pump Group, Concord Operator 5143 Port Chicago Hwy. Concord, CA 94520 Phone: 925-676-8000 Fax: 925-676-8151 Email: concord@tuthill.com Web: www.pumptales.com

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Suco Technologies 6560 W. Rogers Circle, Suite 22 Boca Raton, FL 33487 Phone: 561-989-8499 Fax: 561-989-8816 Email: info@suco-tech.com Web: www.suco-tech.com

FOR YOUR BUSINESS

Sterling Hydraulics, Inc. 850 Arthur Ave. Elk Grove Village, IL 60007 Phone: 847-690-1333 Fax: 847-690-1334 Email: shi@sterling-hyd.com Web: www.sterling-hyd.com Strong Forge & Fabrication, LLC 20 Liberty Street Batavia, NY 14020 Phone: 585-343-5251 Fax: 585-343-5829 Email: info@strongforge.com Web: www.StrongForge.com

making a difference

Tuxco Corporation 4300 Grove Ave. Gurnee, IL 60031 Phone: 800-613-6979 Fax: 847-244-7335 Email: moreinfo@tuxco.com Web: www.tuxco.com U UFI - Hydraulic Filter Division 9337 Ravenna Rd., Unit G Twinsburg, OH 44087 Phone: 330-405-1800 Fax: 330-405-1801 Email: sales@uhiltd.com Web: www.uhiltd.com UHI LTD 9337 Ravenna Rd. #G Twinsburg, OH 44087 Phone: 330-405-1800 Fax: 330-405-1801 Email: sales@uhiltd.com Web: www.uhiltd.com

TECHNOLOGIES CORP.

Ultra Clean Technologies Corp. 1274 Highway 77 Bridgeton, NJ 08302 Phone: 856-451-2176 Fax: 856-453-4975 Email: briley@ultracleantech.com Web: www.ultracleantech.com Ultraflo Corporation, A subsidiary of BRAY International, Inc. #8 Trautman Industrial Drive Ste. Genevieve, MO 63670 Phone: 800-950-1762 Fax: 573-883-8882 Email: ultraflo@ultraflovalve.com Web: www.ultraflovalve.com Unique Automation LLC 612 East Main Street Palmyra, NY 14522 Phone: 315-597-4900 Fax: 315-597-4953 Email: C.Schaufelberger@ uniqueautomation.com Web: www.uniqueautomation.com United Electric Controls 180 Dexter Ave. Watertown, MA 02478 Phone: 617-926-1000 Fax: 617-926-4354 Email: marketing@ueonline.com Web: www.ueonline.com

APRIL 2021

TECHNOLOGIES CORP.

Western Hydrostatics, Inc. 1956 Keats Dr. Riverside, CA 92501 Phone: 951-784-2133 Fax: 951-784-8423 Email: pjmaluso@weshyd.com Web: www.weshyd.com Western Integrated Technologies, Inc. 13406 SE 32nd St Bellevue, WA 98005 Phone: 425-747-0927 Fax: 425-747-0940 Email: jjohnston@westernintech.com Web: www.westernintech.com

Hose, Tube, Pipe Cleaning & Sealing

Contamination Control Systems www.UltraCleanTech.com | 800-791-9111

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Universal Grinding Corporation 1234 West 78th Street Cleveland, OH 44102 Phone: 216-631-9410 FPJ.2inchDirectoryAd.indd 1 Fax: 216-631-5264 Email: monica@universalgrinding.com Web: www.universalgrinding.com Universal Hydraulics Intl., Ltd. 9337 Ravenna Rd. Unit G Twinsburg, OH 44087 Phone: 330-405-1800 Fax: 330-405-1801 Email: sales@uhiltd.com Web: www.uhiltd.com

Viatran 199 Fire Tower Drive Tonawanda, NY 14150 Phone: 1-800-688-0030 Fax: 716-693-9162 Email: solutions@viatran.com Web: https://www.viatran.com

Vogelsang Fastener Solutions 1790 Swarthmore Ave., Suite 1 Lakewood, NJ 08701 Phone: 732-364-4422 Fax: 732-364-8111 Email: bpappas@vogelsangfastner. com Web: http://www.vogelsangfastner. com/

V & P Hydraulic Products 1162 Peachblow Rd. Lewis Center, OH 43035 Phone: 740-548-5181 Fax: 740-548-6206 Email: mikeueber@vphyd.com Web: www.vphyd.com

Voith Turbo 25 Winship Road York, PA 17406 Phone: 717-767-3200 Fax: 717-767-3210 Email: bob.snopek@voith.com Web: www.voith.com

Validyne Engineering 8626 Wilbur Ave. Northridge, CA 91324 Phone: 818-886-2057 Fax: 818-886-6512 Email: sales@validyne.com Web: www.validyne.com

Von Ruden Mfg., Inc. 100B First St. NE Buffalo, MN 55313 Phone: 763-682-3122 Fax: 763-682-3954 Email: sales@vonruden.com Web: www.vonruden.com

Van Air Inc. 2950 Mechanic St. Erie, PA 16506 Phone: 814-774-2636 Fax: 814-774-0778 Email: info@vanairsystems.com Web: www.vanairsystems.com

Vonberg Valve, inc. 3800 Industrial Ave. Rolling Meadows, IL 60008-1085 Phone: 847-259-3800 x227 Fax: 847-259-3997 Email: dhenrich@vonberg.com Web: www.vonberg.com

Veethree Electronics & Marine LLC 2420 Trailmate Drive Sarasota, FL 34243 Phone: 941-538-7775 Fax: 941-755-1222 Email: sales@veethree.com Web: www.v3instruments.com

Ventura Hydraulic and Machine Works, Inc. 1555 Callens Rd. Ventura, CA 93003 Phone: 805-656-1760 Fax: 805-525-2739 Web: www.venturahydraulics.com Vescor Corp. 50 North River St. South Elgin, IL 60177 Phone: 847-742-7270 Fax: 847-742-5187 Email: sales@vescor.com Web: www.vescor.com VEST, Inc. 3250 W. Big Beaver Rd., #440 Troy, MI 48084 Phone: 248-649-9550 Fax: 248-649-9560 Email: sales@vestusa.com Web: www.vestusa.com

APRIL 2021

Wainbee Ltd. 5789 Coopers Avenue Mississauga ONT Canada L4Z 3S6 Phone: 905-568-1700 Fax: 905-568-0083 Email: marketing@wainbee.com Web: www.wainbee.com

Warren Electric Corporation. 36 Franklin St., P.O. Box 86 Warren, RI 02885 Phone: 401-245-3700 2/27/2019 11:55:50 Fax: 401-245-9331 Email: luann@warrene.com Web: www.warrene.com

Waterclock Engineering 342 N. Water St. #600 Milwaukee, WI 53202 Phone: 888-902-2297 Email: info@waterclockeng.com Web: www.waterclockeng.com

WEBTEC LLC 1290 E. Waterford Ave. St. Francis, WI 53235 Phone: 1-800-932-8378 Email: sales-us@webtec.com Web: www.webtec.com Weiss Instruments, Inc. 905 Waverly Ave. Holtsville, NY 11742 Phone: 631-207-1200 Fax: 631-207-0900 Email: sales@weissinstruments.com Web: www.weissintsuments.com Wen Technology, Inc. 8411 Garvey Drive, Suite 117 Raleigh, NC 27616 Phone: 919-954-1004 Fax: 919-954-1009 Email: wentec@wentec.com Web: www.wentec.com

Wandfluh of America, Inc. 909 High St. Mundelein, IL 60060 Phone: 847-566-5700 Fax: 847-566-5733 Email: sales@wandfluh-us.com Web: www.wandfluh-us.com

Wessel-Hydraulik GmbH 2144 Burbank Dr. Mississauga, Ontario CANADA L5L 2T8 Phone: 905-828-5579 Fax: 905-828-8189 Email: wesselhydraulics@ rogers.com Web: www.wessel-hydraulik.de

Warner Electric 449 Gardner St. So. Beloit, IL 61080 Phone: 815-389-3771 Fax: 815-389-2582 Email: info@warnerelectric.com Web: www.warnerelectric.com

West Coast Fluid Power 5370 S. Watt Ave. Suite 300 Sacramento, CA 95826 Phone: 800-532-8837 Fax: 800-370-0447 Email: info@comoso.com Web: www.comoso.com

White Drive Products, Inc. P.O. Box 1127 110 Bill Bryan Blvd. Hopkinsville, KY 42241 Phone: 270-885-1110 Fax: 270-886-8462 Email: info@whitedriveproducts.com Web: www.whitedriveproducts.com Whitman Controls Corp. 201 Dolphin Rd. Bristol, CT 06010 Phone: 860-583-1847 Fax: 860-583-5293 Email: info@whitmancontrols.com Web: www.whitmancontrols.com WIKA Instrument Corp. 1000 Wiegand Blvd. Lawrenceville, GA 30043 Phone: 770-513-8200 Fax: 770-338-5118 Email: info@wika.com AMWeb: www.wika.com Wilkes & McLean 600 Estes Ave. Schaumburg, IL 60193 Phone: 847-534-2000 Fax: 847-534-2016 Email: info@wilkesandmclean.com Web: www.wilkesandmclean.com Wilson Company 16301 Addison Road Addison, TX 75001 Phone: 972-931-8666 Fax: 972-248-7472 Web: www.wilson-company.com Winters Instruments Airport Commerce Park 455 Cayuga Rd., Suite 650 Buffalo, NY 14225 Phone: 716-874-8700 Fax: 716-874-8800 Email: usasales@winters.com Web: www.winters.com Wojanis Supply Company 1001 Montour West Industrial Park Coraopolis, PA 15108 Phone: 724-695-1415 Fax: 724-695-1203 Email: sales@wojanis.com Web: www.wojanis.com Womack Machine Supply Company 13835 Senlac Drive Farmers Branch, TX 75234 Phone: 800-569-9800 Fax: 214-350-9322 Email: sales@womack-machine.com Web: www.womackmachine.com World Wide Fittings, Inc. 600 Corporate Woods Parkway Vernon Hills, IL 60061 Phone: 847-588-2200 Fax: 847-588-2212 Email: sales@worldwidefittings.com Web: www.worldwidefittings.com

Y Yates Cylinders 23050 East Industrial Drive St. Clair Shores, MI 48080 Phone: 586-778-7680 Fax: 586-778-6565 Email: sales@yatesind.com Web: www.yatescylinders.com Youli America 222 S. Navigation Blvd. Corpus Christi, TX 78405 Phone: 888-330-8041 Fax: 713-461-9631 Email: service@youli-america.com Web: www.youli-america.com Young Engineering and Mfg. Inc. 560 W Terrace Dr. San Dimas, CA 91773 Phone: 909-394-3225 Fax: 909-394-3006 Email: sales@youngeng.com Web: www.youngeng.com

Young Powertech 3060 Plaza Drive #107 Garnet Valley, PA 19060 Phone: 610-558-0760 Fax: 610-558-0762 Email: info@youngpowertech.com Web: www.youngpowertech.com Yuken/ALA Industries Limited (North American Distributor) 1150 Southpoint Circle, Suite D Valparaiso, IN 46385 Phone: 877-419-8536 Fax: 219-477-4194 Email: alaindustries@yuken-usa.com Web: www.yuken-usa.com Z Zatkoff Seals & Packings 23230 Industrial Park Dr. Farmington Hills, MI 48335 Phone: 800-96-SEALS Fax: 298-428-3392 Email: info@zatkoff.com Web: www.zatkoff.com Zemarc Corporation 6431 Flotilla Street Los Angeles, CA 90040 Phone: 323-721-5598 Fax: 323-722-2220 Email: sales@zemarc.com Web: www.zemarc.com Zinga, A Filtration Group Company 2400 Zinga Drive Reedsburg, WI 53959 Phone: 608-524-4200 Fax: 608-524-4220 Email: zinga@zinga.com Web: www.filtrationgroup/brands/ zinga-industries-inc/ ZMC Corporation 6431 Flotilla Street Los Angeles, CA 90040 Phone: 323-767-2212 Email: caguirre@zmccorp.com Web: www.zmccorporation.com ZSI 42550 Executive Drive Canton, MI 48188 Phone: 800-323-7053 Fax: 734-844-0066 Email: twright@zsi-inc.com Web: www.zsi-inc.com

World Wide Metric 37 Readington Road Branchburg, NJ 08876 Phone: 732-247-2300 Fax: 732-247-7258 Email: sales@worldwidemetric.com Web: www.worldwidemetric.com Worthington AG Parts 122 St. George Lane Sikeston, MO 63801 Phone: 800-637-5165 Email: dbell@worthingtonagparts. com Web: www.worthingtonagparts.com

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Who, What, Where, How Much? WE WANT TO HEAR FROM YOU!

The biennial online salary survey from Fluid Power Journal and the International Fluid Power Society opens this month, and we encourage fluid power professionals from the C-suite to the shop floor to be counted. The survey provides a snapshot of compensation within the industry along with demographic data such as where employees live, their age and gender distribution, their levels of education and certification, and other details. We hope the findings give employers an edge in attracting and keeping qualified workers. Employees can also benefit as they decide about career choices and advancement. The 2021 survey opens April 1 and is live until June 30. We’ll publish the results in the September issue of Fluid Power Journal.

To take the survey, visit www.fluidpowerjournal.com/2021-survey.

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APRIL 2021

It’s OVER Breaking with Valve Position Tradition By Jerry Hines, Key Account Manager, Pepperl+Fuchs.

ank farms play a critical role in the oil and gas industry. They serve as way stations for crude oil before it is needed at the refinery, finished product before it is needed by the end user, and different products before mixing. These facilities are also home to large networks of pipes and therefore large numbers of valves. Valves are essential for controlling the flow of liquid petroleum into a tank-farm’s pipe networks and into and out of its tanks. Gate and expanding plug valves have been the primary valves in tank farms for decades; however, check valves, ball valves, and butterfly valves have also been introduced to provide backflow protection and emergency shutdown capabilities. With networks of different types of valves as far as the eye can see, monitoring valve position manually is nearly impossible. Fortunately, large-scale automation of these systems has created safer and more streamlined valve monitoring, preventing valve lineup errors and subsequent product mixing, overflow, fire, or explosion. Devices that ensure clear and consistent indication of valve position are a critical component for reliable monitoring from the control room (figure 1).

APRIL 2021

Figure 1

Traditional detection Valve position sensors are mounted on the actuators for both rotary-actuated valves and linear-actuated valves. Sensors transmit valve information directly to the control room using a wired or wireless connection. The connection between the sensor and the control room gives operating personnel feedback on valve position in real time, indicating when it is safe to start transferring product. This eliminates human error and improves the reliability of valve operations. The sensors are available in two basic switching options: mechanical and noncontact. Traditional mechanical valve position feedback systems depend on cams, mechanical linkages, and other physical components to detect valve position. Mechanical position sensors are mounted on the extended shaft of valve actuators and often come in large switchboxes (figure 2). The switching elements must make physical contact with a target

Figure 2

to actuate. Once the target is detected, mechanical systems send discrete electrical signals to the control center to indicate valve position. While traditional valve position solutions are often more affordable, they have multiple moving parts that are subject to wear and corrosion. Because of this, the systems often come in enclosures designed to protect the internal switching elements from direct exposure to the environment. Even so, dirt and moisture still enter many of these enclosures because they are not designed to completely shield the mechanical components inside. This means they do not provide lasting protection against gases, vapors, and atmospheres, which leads to corroded contacts and electrical components. In these often harsh conditions, data and power cables are subject to physical damage. In particular, severed or compromised cables can lead to unreliable readings of the valve’s position. Traditional approaches often involve additional circuitry to monitor these systems for situations in which the switch becomes unresponsive or the leads are damaged. Although still popular, traditional solutions are not ideal for the rugged environments in the downstream oil industry. Constant exposure to the elements, especially in locations near the ocean, decrease the reliability of mechanical feedback systems over time, which leads to detection errors and device failure.

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This, coupled with frequent replacement costs, power needed to keep the sensors does not provide the reliability that tank-farm active would occasionally cause a “false trip” due to leakage current operators are looking for. being detected by the input card. Breaking with tradition With advancements in electronic Noncontact solutions, on the other hand, can technology, many inductive sensors be directly mounted on the actuator with no can now cross that concern off the additional component considerations. Since they list. Sensors with low-leakage currely on inductive sensors, they are resistant to rent technology now offer off-state mechanical and environmental influences. This current leakage of <0.2mA, which is ensures convenient, wear-free operation, making well below the threshold of detection the sensor a durable, cost-effective, and reliable by an input card. alternative to traditional mechanical models. Within the family of inductive Inductive sensors are actuated by metallic position feedback sensors, dual targets; the influence of the actuator on an LC sensing solutions provide an extra resonant circuit is critical to this. When the actu- advantage. They combine two inducator changes its inductance, the frequency of tive sensors in one housing and the resonant circuit also changes. The sensor provide separate feedback signals electronics generate an output after detecting for open/closed position (figure 4). that the actuator has entered the magnetic field With a wide variety of electronic outputs (i.e., of the resonant circuit. 3-wire PNP, 2-wire DC, and AS-i) and direct Inductive noncontact solutions are designed for mount “targets,” the dual-sensor package offers most applications and the challenges they present. considerable flexibility when configuring posiBecause noncontact sensors do not have moving tion feedback for any application. These double components, the electronics can be hermetically sensors offer a wide range of connectivity options sealed, making them ideal for indoor, outdoor, integrated into the sensor package. For example, extreme use, and hazardous-area applications. integrated terminal compartments are a popular Being sealed, inductive sensors are also resistant option because they allow easy wiring installato dirt, dust, oil, moisture, and chemicals. tion, commissioning, and troubleshooting. One specific application where this benefit was recognized by a Pepperl+Fuchs customer Open solutions involved a salt-tank terminal in the Netherlands. Especially in environments with large numTraditional mechanical systems in enclosures bers of valves, high visibility and easy installation had been used for many years but were fail- are critical. Open-solution inductive valve posiing constantly due to condensation and water tion sensors were designed for these applications, ingress. The customer implemented a pilot offering more flexibility than their traditional project using inductive sensors (figure 3), and counterparts. Valve position sensors that follow the moisture issues were no longer a factor. this concept can be mounted directly onto autoSwitching from the traditional approach led mated and manual valves. Drives standardized to a reduction in downtime, maintenance cost, and error almost immediately. The benefit of electronic systems can be leveraged in many other ways, further differentiating them from mechanical systems. Unlike mechanical systems, monitoring for lead breakage or short-circuit conditions is inherently simple. Most contactless sensors offer a status monitor that alerts the user of these potentially dangerous conditions. In the past, electronic sensors were often viewed as a liability when connected directly Figure 3 to a control-system input card. The continuous

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Figure 4

Figure 5

to VDI/VDE 3845 and NAMUR mounting holes make this possible because they eliminate the need for mounting brackets. Once installed, two stainless steel targets mounted on an activator, or “puck,” activate the sensor. Combined LEDs allow tank-farm workers to check valve status from the field, ensuring clear indication of valve position at every level (figure 5). Since the sensor is mounted directly on the valve, wiring can be routed through the sensor so that no separate cable needs to be run to the field. Although open valve position solutions are often installed on valves that are remotely operated, they can also be used to indicate the position of manual valves (see figure 4). Position sensors can be directly mounted to valves that regulate shutoff or pipeline flow, like those found in tank terminals. When a hand wheel is turned to open or close a valve, the control room is alerted and an incorporated indicator signals the position of the valve. This provides a new level of certainty from the control room all the way to the field. Inductive valve position sensors bring a new level of reliability to tank-farm applications. With clear position indication, ruggedized components, and a standardized mounting, they are designed to operate in any environment. Noncontact valve position sensors ensure that natural gas liquids are transferred to storage and terminal operations safely and efficiently, which saves money and time for tank farms and their employees. 

APRIL 2021

SGH wire-actuated encoders can be fully integrated in hydraulic or telescopic cylinders.

MEASURING SGH TECHNOLOGY IN HYDRAULIC AND TELESCOPIC CYLINDERS By Mathias Roth, Manager, Business Unit Mobile Automation, Siko

ith the new wire-actuated encoders SGH25 and SGH50, Siko has expanded the spectrum of the SGH series, which can now measure lengths ranging from 0 to 5 meters. This is made possible by an innovative, cable-based functional and design concept that fully integrates sensors, electronics, and mechanics into the cylinder. This compact design is now also suitable for long cylinder strokes, including hydraulic and telescopic cylinders of construction machinery, agricultural machinery, or commercial vehicles. The sensors fulfill a central requirement that the cylinder length should ideally not increase when a sensor is installed. While the SGH10 wire-actuated encoder covers ranges between 0 and 1 meter, the SGH25 and SGH50 advance into larger ranges. With measurement lengths between 0 and 2.5 meters, the SGH25 is suitable for medium stroke paths, while the SGH50, with stroke lengths between 0 and 5 meters, is suitable for applications with relatively wide measurement ranges. To meet the manufacturer’s requirement for a cylinder design with as little change as possible after sensor integration, the larger drums on which 34

APRIL 2021

the cable is wound have been tilted 90° on the SGH25 and SGH50, so that the installation length of the three sensors is identical despite the different measuring lengths. SIKO drew on more than 30 years of experience in the development and production of wire-actuated encoders. This has resulted in the development of a core competence, which has also been incorporated into the development of SGH technology. With the SGH sensors, SIKO has a unique sensor technology that can even be used in piston accumulators and telescopic cylinders (a global first). Their compact design can be completely and space-efficiently integrated into a cylinder.

Considerable flexibility Instead of using a rod-based measuring principle, SGH sensors are based on a flexible wire-actuator mechanism. If the cylinder extends, the cable, which is wound up on a cable drum, is pulled out. The rotation of the cable drum is detected without contact by the sensor electronics and used to calculate the linear travel. This makes it possible to detect the position and speed of the cylinder precisely

and completely. The magnets used to detect the rotation are scanned by the electronics without contact through the pressure-resistant base plate of the SGH sensors. The electronics are fully encapsulated on the unpressurized side of the system. This means that the entire measuring system is built into the cylinder and is optimally protected from external environmental conditions. The advantage of this is that, in contrast to a measuring system mounted externally on the cylinder, the sensor system cannot be damaged, negatively influenced, or even destroyed by environmental influences.

Side attachment The cable-based concept enables solutions that were previously unthinkable. Forklift truck designs, for example, may not exceed specified vehicle heights, but nevertheless should have the longest possible stroke. SIKO meets these demanding requirements by intelligently delocalizing the SGH sensor in a housing laterally mounted at a 90-degree angle to the cylinder. As a result, the SGH sensors can “measure around the curve” and thus can be integrated into almost any cylinder. WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

SGH sensors, left to right: SGH10, SGH25, and SGH50.

Due to the unique lateral installation, SGH sensors can also be used in difficult applications, including those with zero stroke-loss tolerance, extremely small piston diameters, or cylinders with mechanical cushioning. External environmental factors also include shocks or vibrations that regularly occur with excavators or dump trucks, for example. If an excavator bucket collides with hard ground or the loading area of a dump truck locks in, these abrupt movements trigger vibrations. All SGH sensors are immune to them because the cable absorbs shocks, and the entire SGH system can also use the hydraulic medium as a “shock absorber.” SGH sensors are robust and resistant. To consistently maintain this level of quality, SIKO carries out the product-specific trim of all mechanical and electronic sensor components and designs power ratios, spring characteristics, or drum speed itself. In addition, SIKO developed a special housing plastic that achieves top performance even under the most extreme conditions and protects the entire system. One of these quality assurance measures is that SGH sensors are designed and tested for the service life of a cylinder.

No piston drilling

instead just the cable, which is fixed by a small thread on the piston head. The SGH50, for example, with a maximum stroke of five meters, offers the maximum potential for savings. A hollow bore required in rod-based sensors generally affects the structure and stability of the piston and thus the function of the entire cylinder. With SGH technology, cylinder manufacturers are not confronted with this disadvantage.

The cable-based concept enables solutions that were previously unthinkable. SGH sensors show their strengths especially in terms of variant diversity. The practical teach-in function is a valuable tool. It is standard in all SGH versions and offers a high level of functional and operating convenience. An SGH sensor can be programmed (“taught”) any measuring length. Within the measuring range of 0 to 1 meter, 0 to 2.5 meters, or 0 to 5 meters, this intelligent function maps all measuring

lengths with a single SGH sensor and thus significantly reduces the number of variations for the cylinder manufacturer. To ensure the transmission of position information to machine controllers of as broad a range of machines as possible, SGH sensors are characterized by a high variety of interfaces. Thus, the SGH technology can either be obtained with an analog interface for measured value transmission or, alternatively, with the digital interfaces CANopen or SAE J1939. Even safety-critical applications can be operated with CAT3 or PLd-compliant versions (according to EN 13849) and redundant analog interfaces, redundant CANopen, redundant SAE J1939, or CANopen Safety.

IP69K protection class Due to the complete SGH system integration in the cylinder, SGH sensors provide maximum protection against environmental influences such as dirt, dust, and water. Protection class IP69K guarantees this, and the SGH position sensors are equipped with IP69K-compliant KV1H connector systems. The modular nature of the universally applied KV1H connections significantly reduces effort and costs in manufacturing, service, design, and logistics, as the KV1H connector system is extendable. Thus, the sensor always remains the same for different cable lengths or connection types. Overall, the use of this variable function and design principle contributes significantly to minimizing the number of variations. SGH sensors cover entire measuring ranges and do not require a separate sensor per measurement length, as is the case with conventional sensor solutions. For cylinder manufacturers, SGH technology optimizes the entire development and production process as well as downstream services such as logistics. 

The innovative, cable-based design and functional concept of SGH technology ensures a significant reduction in system integration costs. Comparing SGH sensors with the construction of magneto-restrictive sensors, it becomes clear that for the use of magneto-restrictive sensors, which requires a different length of the sensor rod for each cylinder corresponding exactly to the measuring length, a hole must be drilled in the piston of at least that same length. This hole is not required for SGH technology. Ultimately, the saving of this manufacturing step with SGH sensors has a positive effect on cylinder production costs, since production times are shortened and the costs for piston drilling and assembly of the position magnet are completely eliminated. With SGH sensors there is WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

APRIL 2021

COVER STORY

Two Walls Are Better than One Multistage Telescopic Cylinders By Tony Casassa, Application Engineer, Aggressive Hydraulics

Hydraulic cylinders are the workhorses of fluid power systems in a variety of industrial and mobile machinery. They have high power density, are durable, and can be leak-free even in challenging environments, providing many operating cycles before requiring service. Today’s hydraulic cylinders have features that make machines productive and easy to use. They operate smoothly over a wide input flow range, including very low flows and speeds. Cylinders are quite efficient, with both high mechanical and volumetric efficiencies. The high mechanical efficiency means the pressure required to overcome internal resistance is low. The high volumetric efficiency means the leakage flow rate across the piston is extremely low, which provides an additional benefit. When paired with a load-control valve such as a counterbalance valve, pilot-operated check valve, or low-leakage directional valve, a cylinder can hold a set position against an induced load for extended time periods. Consider, for example, an equipment rental yard with aerial work platforms in the air and booms held in place for days on end via load-holding valves locking fluid in a hydraulic cylinder.

APRIL 2021

One potential drawback to hydraulic cylinders is that the retracted length is always greater than the stroke. In most applications this length can be accommodated, but in some instances a shorter retracted length is a firm requirement or provides significant machine design advantages.

Types of telescopics A potential solution for these applications is a multistage telescopic cylinder with two or more moving stages that can provide longer strokes relative to the retracted length. The most common type of telescopic cylinder is single acting, which extends with hydraulic power but requires gravity or some other external force to retract. If the cylinder must be hydraulically powered in both directions, the solution is a double-acting telescopic cylinder. However, a common mistake is expecting a double-acting telescopic cylinder to replicate the performance of a typical single-stage double-acting cylinder. If the different operating characteristics of a double-acting telescopic cylinder are not taken into consideration, the results can range from mild to serious machine malfunction. We will refer to the most common design of double-acting telescopic cylinders as “conventional.” This conventional design has a cross-drilled port hole in each moving stage to communicate flow and pressure in and out of the annular volume. Because crossing a hole while under pressure would cause failure to a typical elastomeric piston seal, split cast iron rings are typically used. Although these WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

cast iron rings are robust and durable, they allow some bypass leakage, which allows the cylinder to drift under load. In our rental yard example, if a cylinder is replaced with a conventional double-acting telescopic cylinder, a boom left up in the air would slowly come down to rest on the ground. Likewise, an induced tensile load would cause the cylinder to drift out.

Potential issues caused by leakage

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to as a “double-wall” telescopic, is that the intermediary stage or stages are comprised of two concentric tubes with a flow path between them to communicate from the retract port located near the head end of the main barrel to all the annular areas. In this design, the pistons do not cross port holes, so low-leakage elastomeric seals can be used. This design addresses the challenges previously discussed. • Hold a position against an induced load without drift when paired with a load-holding valve. • Move smoothly across a wide flow range, even down to very low flows. • Eliminate the potential for pressure intensification on the annular volume because the annular volume for all stages always has a free path to the retract port.

Illustration provided by Aggressive Hydraulics Engineering Department.

This leakage can cause other problems. The pressure required to move the cylinder against a load is dependent on the area and the load. The small gap between the cast iron piston rings and the bore is like an orifice of fixed size, in which the pressure drop across the orifice increases with flow. If the flow supplied to the cylinder is too low, the pressure drop across the “orifice” will be less than the pressure required to overcome the load. The machine operator may wonder why moving the control input is not causing motion. As the flow increases, the pressure drop also increases until there is enough pressure to move the load. Instead of a gradual increase, the initial cylinder movement may now be at a higher rate of speed. In addition to this instability or “jumpiness,” the operator or control system may be further confused as the relationship between control input and cylinder speed varies with load. Another potential issue with leakage is more complicated, but understanding it could avoid a serious malfunction in which the cylinder stalls and will not retract. First, we will start with certain details of conventional double-acting telescopic cylinder design and operation. During normal operation, the largest stage fully extends first, then the next largest stage starts to move, and as it does the piston rings pass over a port hole. If the first stage is fully extended with the piston mechanically stopped at the head gland, this does not pose a problem. However, because all stages are pressurized simultaneously, it is possible for the cylinder to misstage and for a smaller stage to start to extend before a larger stage is completely extended. This is more common at higher flow rates and lower loads. It can be exacerbated by undersized port holes or variations in vee packing compression from one stage to another. If misstaging occurs, when a cast iron ring covers the port, fluid in the annular volume is trapped. The pressure applied to the blind end compresses the trapped fluid at an intensification factor equal to the area ratio. For a typical telescopic cylinder, this can range from 3:1 to 10:1. Even with a relatively low input pressure, the trapped pressure can easily exceed the burst strength of the cylinder. For example, an input pressure of 1,000 psi (69 bar) and an area ratio of 8:1 would result in 8,000 psi (552 bar) of trapped fluid in

the annular volume. To prevent catastrophic failure, conventional telescopic cylinders often add a smaller port hole through each stage. If the cylinder misstages and the cast iron rings cover the main port, this smaller port allows the trapped fluid to escape. However, if the piston stops between the two ports and low flow is sent to retract the cylinder, the flow may bypass the piston by entering the smaller port and exiting the larger port to the extend side. The cylinder will stall and will not move the load until the flow increases and the pressure drop across the port holes exceeds the pressure required to retract the load and move past this point in the stroke. If the system does not have enough flow capacity, the load will remain stuck and require an external force to move.

One additional challenge with conven- • Eliminate the potential for stalling due to tional double-acting telescopic cylinders is bypass around the piston. the location of the working ports. On a typical • Both ports can be located on the barrel to single-stage double-acting cylinder, both ports simplify hose connections. If desired, one or are located on the barrel, and it is simple to both ports can be in the plunger end. connect to the system. With the conventional As an additional benefit for many applicadouble-acting telescopic cylinder, the retract tions, because of the positive piston seal and port must always be in the end of the smallest the location of the ports on the barrel, it is relmoving stage, also known as the plunger. The atively simple to integrate a load-holding valve extend port may be either in the main barrel into the cylinder. This component integration or in the plunger end with the retract port. In can eliminate hoses, adapters, and brackets. many applications, it is preferred for the larger, More importantly, it greatly reduces the risk heavier main barrel to be fixed to the machine of unintended motion due to failure of a hose and the smaller, lighter plunger to be attached or threaded fluid connector, providing an to the moving machine member. However, to increased level of machine safety. use the conventional design, a decision must be It should be noted that there are some aspects made between managing moving hoses or con- of the conventional double-acting telescopic necting the heavier main barrel to the moving that this design does not address. member while consolidating hose connections • Each stage has a different area. When supon the plunger. plied with a consistent flow, the cylinder speed will be different for each stage. Solutions to design challenges • To minimize the overall diameter of the Fortunately, there is a solution to these design cylinder, typically the clearance between challenges that has many of the same benefits the stages is minimized, leading to a higher as a standard, single-stage double-acting cylarea ratio than typical single-stage cylinders. (Continued on page 38) inder. The key to this enhanced double-acting telescopic cylinder design, which we will refer APRIL 2021

(Continued from page 37) This can lead to potential system design challenges: » The return flow when retracting will be much higher than the input flow, requiring larger hoses, valves, and filters. » If the extend side is pressurized and the exiting flow is restricted or blocked, there is a risk of pressure intensification. Further, this design has two trade-offs that must also be evaluated to determine if it fits the application. Because each intermediary stage has two concentric tubes, the overall outside diameter is typically larger than with a conventional double-acting telescopic cylinder. Because of application space constraints and reasonable material availability, the double wall design is typically limited to two moving stages. The second trade-off is the propensity to misstage during the retract phase. With a conventional telescopic cylinder, after the first stage fully extends, the piston of the subsequent stage extends, and the piston crosses the port hole. The annulus side of the first stage is now connected to the blind-end port instead of the retract port in the rod. As a result, when direction is reversed and the retract port is pressurized, the first stage cannot retract until the piston of the subsequent stage passes back over the port hole and pressurizes the annular volume of the first stage. The same is true for each stage, and this helps with consistent sequencing. On the other hand, with the double-wall design all annular volumes are always simultaneously pressurized. The retract sequence is primarily determined by the relative annular area of each stage. The stage with the largest annular area will retract first, then the next largest, and so forth. However, actual loading, backpressure, and pressure drop through the concentric tubes can alter the sequence. Before selecting a double-wall telescopic, the possibility of misstaging and related risks should be considered.

The value of double-wall telescopics There are many applications in which the benefits of the double-wall telescopic provide real, tangible value to the OEM and end user. For example, consider a cylinder used to raise and lower a large digging wheel on a railway ballast maintenance machine. Due to space limitations, a two-stage double-acting telescopic cylinder is required to meet the retracted length and long stroke requirement. The cylinder lowers the wheel into a digging position and should resist digging forces trying to raise the wheel. Likewise, when the cylinder raises the digging wheel to pass a road crossing or for transit, it should not drift down due to

APRIL 2021

APPLICATION REQUIREMENT

CONVENTIONAL TELESCOPIC

DOUBLE-WALL TELESCOPIC

Resist upward digging forces

Allows movement due to piston leakage

Holds position with positive piston seal

Hold digging wheel in raised position

Drifts down due to piston leakage

Holds position with positive piston seal

Precise positioning at low speed

Erratic and jumpy at low flow

Smooth operation at low flow

Reliable operation

Retract stalling at low flow and pressure intensification during misstaging are potential failure modes

Operates without stalling and without potential of pressure intensification

Port location

Retract port must be located on the moving plunger

Simplified plumbing with both ports on the barrel

gravity. The system uses a position sensor, PLC, and proportional valve to move the cylinder smoothly, often at low speed, to precisely hold or adjust wheel position. The railway must be closed to normal traffic during maintenance, so machine uptime is critical to complete the job in the set amount of time. Therefore, any potential risk of downtime-inducing stalls or pressure intensification is unacceptable. Because the main barrel is fixed to the machine and the plunger is fixed to the moving digging wheel, it is preferable for both ports to

be located on the main barrel. As detailed in the table above, the double-wall telescopic outperforms the conventional telescopic in all aspects of this application. When selecting or specifying double-acting telescopic cylinders, avoid accepting compromised performance to meet the retracted length and stroke requirements. Consider the option of a double-wall telescopic cylinder that provides the benefits of a telescopic cylinder with the performance of a single stage. 

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4. What is the primary business activity at this location? In the Fluid Power Industry, Outside the Fluid Power Industry 56  Manufacturer 57  Distributor 58  Education 59  Original Equipment Manufacturer (OEM) 61  Other: (please specify)__________________________________________ 5. Which of the following best describes your market focus? A  Aerospace A  Marine & Offshore Equipment B  Agricultural Machinery B  Material Handling Equipment C  Automotive C  Mining Machinery D  Civil Engineering D  Packaging Machinery E  Cranes E  Plastic Machinery F  Drills & Drilling Equip. F  Presses & Foundry G  Flame Cutting/Welding Equip. G  Railroad Machinery H  Food Machinery H  Road Construct/Maint. Equip. I  Forestry I  Simulators & Test Equipment J  Furnaces J  Snow Vehicles, Ski Lifts K  Gas & Oilfield Machinery K  Steel Plants & Rolling Mills L  Heavy Construction & Equip. L  Truck & Bus Industry M  Military Vehicles M  Textile Machinery N  Construction & Utility Equip. N  Woodworking Machines O  Machine Tools O  Other (specify)_____________ P  Government Related P  Fluid Power Industry

G  1000+

60  End User of Fluid Power Products

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SCAN HERE

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Fluid Power Journal April 2021

Articles inside

Fluid Power Faux Pas: Our Top Five Hydraulic System Mistakes Tips on avoiding costly hose, coupling, and tubing missteps

Who, What, Where, How Much? Let Us Know From the C-suite to the shop floor, be counted in our 2021 Salary Survey

It’s Over: Breaking with Valve Position Tradition Oil and gas tank farms are relying more and more on noncontact inductive sensors

Going Electric? SHA Is the Dynamic Choice A powerful actuation solution harnesses the best features of hydraulics and EMAs

Measuring Up: SGH Technology in Hydraulic and Telescopic Cylinders A cable-based concept integrates sensors, electronics, and mechanics into a cylinder

Test Your Skills