Fluid Power Journal December 2019

www.fluidpowerjournal.com

AUTOMATED FERROGRAPHY ANALYSIS

2019 

IN-HOUSE PRODUCTION

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IN THIS ISSUE

DECEMBER 2019

VOLUME 26 • ISSUE 12

Features

7

12 Thinking Outside the Box:

How In-House Manufacturing

Helps Fluid Power Distributors

Grow Their Business

34

16 Pascal's Law and Counterbalance Valves: Part 1 30 The Holy Grail Of Motion Software:

Easy and Flexible 34 Hydraulic Hose Maintenance 36 Integration of Ferrous Density

and Particle Count for Automated

Ferrography Analysis of Abnormal

Wear Conditions

18 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.

Departments 4 6 14 15 18 20 39 39

Notable Words IFPS Update Winter Literature Review Air Teaser NFPA Update Tech Directory Listing Industry News Classifieds

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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

Mentorship is the Way Forward

By Timothy White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM, The Boeing Company

»

I CAN’T BELIEVE it has been a year since I took over as President of the IFPS. Time sure does fly. The annual meeting in Seattle has just wrapped up and it was another productive one. At this meeting, I had the pleasure of witnessing the first inductions to the Fluid Power Hall of Fame. What an awesome experience seeing and hearing these fine gentlemen speak!

There was one common theme among them: mentorship. In my previous article (in the January 2019 issue), I talked about ways to give back. Mentorship is another way to accomplish that. All the Hall of Fame inductees spoke about how important mentors were in their careers and how it was extremely important to pay it forward.

The gentlemen have all reached a point in their lives that they are now mentors for many of us in the industry.

Mentoring can be done with industry Mentoring can be peers as well as those in the community.

Mentoring, if done correctly, has the ability done with industry to help an individual grow by showing them peers as well as those they aren’t alone and it gives the mentee in the community. somebody to bounce ideas off of. According to mentoring.org, young adults who were at risk of falling off track, but have a mentor are 130% more likely to hold leadership positions, and are 78% more likely to volunteer regularly. These are staggering statistics.

Just yesterday (as I am writing this), my daughter told me that her robotics club teacher would love it if I would come in and mentor the club in pneumatics and robotics. I am excited about the opportunity to introduce these young people to the world of fluid power. It will be fun to help them understand what is possible.

I challenge everyone reading this to find somebody to mentor. Some may not realize they want/need a mentor, but I know the research shows it helps so many grow. Somebody taught us the ways of the world, and now it is time to follow in the footsteps of the gentlemen that I mentioned previously and pay it forward.

Congratulations to those inducted in the Fluid Power Hall of Fame class of 2019! 

Founders: Paul and Lisa Prass

Associate Publisher: Bob McKinney Editor: Candace Nicholson

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 2019 BOARD OF DIRECTORS

President & Chairperson: Timothy M. White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM - The Boeing Company

Immediate Past President: Dean Houdeshell, PE, CFPAI/AJPP, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM - Cemen Tech Inc.

First Vice President: Jeff Kenney, CFPIHM, CFPMHM, CFPMHT - Hydradyne, LLC

Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. Vice President Certification: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC Eaton Corporation

Vice President Marketing

& Public Relations: Scott Nagro, CFPS HydraForce, Inc.

Vice President Education: Kenneth Dulinski, CFPAI/AJPP, CFPECS, CFPHS, CFPMIH, CFPMMH - Macomb Community College

Vice President Membership: Rocky Phoenix, CFPMHT, CFPMHM - Open Loop Energy, Inc. DIRECTORS-AT-LARGE Chauntelle Baughman, CFPHS - OneHydrauics, Inc. John A. Bibaeff, Jr., CFPHS, CFPCC - Lamb Services, Inc. Randy Bobbitt, CFPHS - Danfoss Power Solutions Cary Boozer, PE, CFPE, CFPS - Motion Industries, Inc. Elisabeth DeBenedetto, CFPS - Argo-Hytos Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. Garrett Hoisington, CFPAI, CFPS, CFPMHM - Open Loop Energy, Inc. James O’Halek, CFPAI/AJPP, CFPMM, CFPCC - The Boeing Company Edwin Rybarczyk, CFPAI/AJPP, CFPS - E. R. Consultants, Inc. Scott Sardina, PE, CFPAI, CFPHS - Waterclock Engineering Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPS - Northrop Grumman Corp.

HONORARY DIRECTORS Paul Prass - Innovative Designs & Publishing Elizabeth Rehfus, CFPE, CFPS, Robert Sheaf, CFPAI/AJPP - CFC Industrial Training

IFPS STAFF Executive Director: Donna Pollander, ACA Communications Manager: Adele Kayser Technical Director: Thomas Blansett, CFPS, CFPAI 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 bi-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.

4

DECEMBER 2019

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I F P S U P D AT E

IFPS 2020 Spring Meeting »

REGISTRATION COMING SOON for the IFPS 2020 Spring Meeting February 24-27, 2020 - Embassy Suites USF, Tampa, Florida

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MONDAY, FEBRUARY 24, 2020 8:00 AM - 2:00 PM

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2:30 PM - 5:00 PM

Board Orientation

6:00 PM - 8:00 PM

Board Dinner

TUESDAY, FEBRUARY 25, 2020 8:00 AM - 9:00 AM

Strategic Planning Committee

9:00 AM - 11:00 AM

Education Committee Meeting

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Membership Committee Meeting

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Hosted Lunch

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WEDNESDAY, FEBRUARY 26, 2020 8:00 AM - 12:00 PM

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I F P S U P D AT E

Why You Need the New Fluid Power Reference Handbook

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THE ULTIMATE RESOURCE for hydraulic, pneumatic, and motion control professionals.

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FLUID POWER

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4/3 Tandem cen ter - Four port, three pos itio control with spr n, solenoid ing center

4/3 Closed cen ter, with dual proportional solenoid contro ls

1/7/16 - Study Manual

lves

P

Same as 4/3 Closed center, except all the ports are connected and ope port T in the neu n to tank tral position.

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Electronic Con trols Specialist • 10-9

Pump Control

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Sample Pages

ed.

PU MP S

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DBOOK

Directional Va

SY MB OL OGY

FLUID POWER REFE

REF ERENCE HAN

10.00 FLUID Valves - Hy POWER SYST draulic symbol EMS s use letters Hydraulnum ic symber for port identi bolss.use letters for por t identific fication while ation while pne pneumatic sym uma tic bol sym Descr ipti s bols use scription on use numbers.

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3/2 NC - Thr ee port, two position, soleno 3 active full flow id control wit ports, 2 distin h spring return ct positions (eithe r power P to por A or port A to t A tank port), spring offset to normally clo sed (NC) from P to A in the at-res t position, soleno 4/2 NC - Fou id actuated. r por P position, soleno t, two 4 active full flow T id control wit por ts, h spring return 2 distinct pos itions, A B spring offset to normally clo sed (NC) in the atrest position, solenoid actuat ed.

4/3 Closed cen P ter - Four por T t, three position, 3 distinct pos direct solenoid itions, controlled wit 4 active full flow h spring center ports, A ing B spring center ed to a closed center in the at-rest position, soleno id actuated.

4/3 Float cen ter - Four por P T t, three position, Same as above, sol except work with spring cen enoid control ports A and B ter are open to tan A k B port T in the neu tral position.

Directional

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I F P S U P D AT E

International Fluid Power Society Announces 2020 President

»

THE INTERNATIONAL FLUID Power Society (IFPS) is pleased to announce Jeffrey Kenney, CFPMHM, CFPIHM, CFPMHT was elected 2020 president and chair during the IFPS annual meeting in Seattle, Washington. Mr. Kenney is the 60th president of the IFPS and will take office in January 2020.

Mr. Kenney served as the IFPS first vice president and IFPS treasurer, and has served on many committees. He is currently Director of Operations and Sales at Dover Hydraulics South. Mr. Kenney is a Navy Veteran and served in the U.S. Navy from 1988 to1997 as Mate Third Class Petty Officer where he received several awards, including Desert Storm/Desert Shield Medal and Navy Good Conduct Medal.

“I am humbled to be selected by the IFPS membership to serve as the 2020 president and chair. I look forward to supporting the Board of Directors and steer the IFPS in advancing education in the fluid power industry through certification,” said Mr. Kenney.

IFPS WELCOMES THE FOLLOWING NEW DIRECTORS-AT-LARGE:

• Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT - Altec Industries, Inc. • Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics • Brian Kenoyer, CFPHS - Five Landis Corp.

THE FOLLOWING DIRECTORS-AT-LARGE WERE RE-CONFIRMED DURING THE ANNUAL MEETING:

• Chauntelle Baughman, CFPHS - OneHydraulics, Inc. • Randy Bobbitt, CFPAI, CFPHS - Danfoss Power Solutions • Cary Boozer, PE, CFPE - Motion Industries, Inc. • Lisa DeBenedetto, CFPS - Argo-Hytos • Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. • Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM - Open Loop Energy • James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM - The Boeing Company • Mohaned Shahin, CFPS - Parker Hannifin • Randy Smith, CFPHS - Northrop Grumman Corp.

HONORARY DIRECTORS-AT-LARGE AND EX-OFFICIO WERE ALSO RE-CONFIRMED DURING THE ANNUAL MEETING:

THE FOLLOWING OFFICERS WERE CONFIRMED AT THE MEETING: • Ex-Officio

- Donna Pollander, ACA, Executive Director • First

Vice President - Rocky Phoenix, CFPMMH - Open Loop Energy, Inc. • Elizabeth Rehfus, CFPE, CFPS • Immediate

Past President - Timothy White, CFPAI/AJPP, CFPS, CFPECS, • Paul Prass, Fluid Power Journal CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM - The Boeing Company • Robert Sheaf, CFPAI/AJPP, CFC Industrial Training • Treasurer

- Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. President Certification - Denis Poirier, Jr., CFPAI/AJPP, CFPHS, A special thanks to outgoing past president, Dean Houdeshell, PE, • Vice

CFPIHM, CFPCC - Eaton Corporation CFPAI, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM – Cemen Tech Inc., President Marketing and Public Relations - Scott Sardina, PE, outgoing Vice President of Marketing and Public Relations, Scott Nagro, • Vice

CFPAI, CFPHS - Waterclock Engineering CFPS - HydraForce, Inc. and outgoing Director-at-Large, Ed Rybarczyk, President Education - Kenneth Dulinski, CFPAI/AJPP, CFPECS, CFPAI/AJPP, CFPS – E.R. Consultants, as they complete their tenures on • Vice

CFPHS, CFPMIH, CFMMH, CFPMT - Macomb Community College the IFPS Board. Their many years of service, commitment, and expertise President Membership - John Bibaeff, PE, CFPAI, CFPE, CFPS helped steer the Society in its mission.

• Vice

Cad Control Systems

Congratulations to Newly Certified Fluid Power Accredited Instructors!

»

CONGRATULATIONS TO OUR newly Certified Fluid Power Accredited Instructors (CFPAI) and Authorized Job Performance Proctors (CFPAJPP). The approved applicants, who hold at least one certification, conducted a pre-planned presentation, and were evaluated by a panel of subject matter experts and peers during the recent Instructor Training Workshop in Houston, Tex. • John

Bibaeff, PE, CFPE, CFPS, CFPAI, CAD Control Systems • Will

Biberdorf, CFPMHM, CFPAI, CFPAJPP, Terex Utilities, Inc. • RandALL

Bobbitt, CFPS, CFPAI, Danfoss Power Solutions (U.S.) Co. • Clinton

Davis, CFPMHM, CFPAI, CFPAJPP, Terex Utilities, Inc. • Alan

Ramsey, CFPCC, CFPAI, CFPAJPPCC, Bridgestone Hose Power

If you would like to become an AI or AJPP, register for our upcoming Instructor Training Workshop being held in Detroit, Mich.

Register by visiting www.ifps.org or by calling 800-308-6005.

8

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I F P S U P D AT E

Certification Testing Locations ndividuals wishing to take any IFPS written certification tests can select from convenient locations across the United States and Canada. The IFPS is able to offer these locations through its affiliation with The Consortium of College Testing Centers (CCTC) provided by National College Testing Association (NCTA).

I

TESTING DATES FOR ALL LOCATIONS: January 2020 Tuesday 1/7 • Thursday 1/23 February 2020 Tuesday 2/4 • Thursday 2/20 March 2020 Tuesday 3/3 • Thursday 3/26 April 2020 Tuesday 4/7 • Thursday 4/23 May 2020 Tuesday 5/5 • Thursday 5/21

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

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DECEMBER 2019

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

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 CFPECS Certified Fluid Power Electronic Controls Specialist CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT) 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

Certification Review Training In-house Review Training – an IFPS Accredited Instructor will come to your company (minimum 10 individuals) HYDRAULIC SPECIALIST (HS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details March 23-26, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: March 26, 2020 April 20-22, 2020 - Mukwonago, WI - wanke@msoe.edu | Written test: April 23, 2020 August 17-20, 2020 - Houston, TX - Eaton Hydraulics | Written test: August 21, 2020 September 14-17, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: September 17, 2020 November 2-5, 2020 - Houston, TX - Eaton Hydraulics | Written test: November 6, 2020

ELECTRONIC CONTROLS (ECS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details August 3-6, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: August 6, 2020

PNEUMATIC SPECIALIST (PS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details July 13-16, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: July 16, 2020 CONNECTOR & CONDUCTOR (CC) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details May 18-19, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: May 20, 2020 November 16-17, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: November 18, 2020 MOBILE HYDRAULIC MECHANIC (MHM) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details 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 14-16, 2020 - Fairfield, OH - CFC Industrial Training | Written and JP test: April 17, 2020 September 21-23, 2020 - Fairfield, OH - CFC Industrial Training | Written and JP test: September 24, 2020

INDUSTRIAL HYDRAULIC MECHANIC (IHM) CERTIFICATION Onsite review training for small groups – contact kpollander@ifps.org for details August 10-13, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: August 13, 2020

INDUSTRIAL HYDRAULIC TECHNICIAN (IHT) CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

MOBILE HYDRAULIC TECHNICIAN (MHT) CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

PNEUMATIC TECHNICIAN (PT) and PNEUMATIC MECHANIC CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

JOB PERFORMANCE (JP) TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details 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 Onsite review training for small groups – contact kpollander@ifps.org for details E-mail info@cfcindustrialtraining.com for information.

DECEMBER 2019

11

THE BOX

OUTSIDE

THINKING

By the Epicor Distribution Team, Epicor

T

he days of distributors succeeding based on being able to pick, pack, and ship are over. The “Amazons” of the world have mastered that. For example, a search on Amazon for “1/2 hose fittings and adapters” returns more than 1,000 results of items that can be delivered as soon as tomorrow. Distributors must be more than just a clearing house for products. They must provide further value to their customers by offering something their competitors cannot— expert staff, exemplary customer service, and custom solutions. Not only does this set the business apart from the competition, but it also generates customer loyalty, draws in new customers, and helps grow the business—not to mention standing out from the “smiling boxes” in customers’ receiving departments.

12

DECEMBER 2019

It’s now become very common for fluid power distributors to offer manufacturing to add value to their customers. They’ve been so successful that a significant portion of the business comes from manufacturing activities, in other words they’ve morphed themselves into “distrifacturers.” Manufacturing in this context may mean anything from simple kitting to complex assemblies that require CAD design and take months to complete.

Offering manufacturing services is a strategic decision that must align with company goals and objectives since it requires realigning your resources, including operations, staff, and facilities. It must also be carefully weighed against other company objectives. If your business has yet to offer manufacturing services, you must decide whether it can become a core competency or if it will only become a drain on your resources.

To successfully add manufacturing to your distribution business, you need the resources to design and complete the manufacturing work. But you also need an enterprise resource planning (ERP) system that can combine the distribution functionality you need with the ability to enter and track your manufacturing projects. This includes the ability for material requirements from manufacturing WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

jobs to feed into forecast and replenishment calculations, as well as tracking job status and work in process. For example, many fluid power distributors provide light manufacturing for hose configurations—from taking the order, to determining the lengths/cuts and the required hardware, and finally processing the order. It’s vital to have an ERP system that can accommodate these requirements.

Not all ERP systems designed for distributors can handle manufacturing tasks, and it’s not practical to deploy multiple ERP systems just to add manufacturing services to your distribution business. Separate ERP solutions for distribution and manufacturing require tight integration, which costs more money, requires more resources, and runs the risk of

THERE ARE A LOT OF ASPECTS TO CONSIDER WHEN SELECTING ERP SOFTWARE TO MANAGE DISTRIBUTION & MANUFACTURING. Here Are The Top Eight

1 2 3 4 5 6

AGILITY: You can’t always predict the direction future growth will take. A software vendor that can keep pace is essential.

INNOVATION: An ERP partner who supports innovation is useful. One who understands the risks—and helps you navigate them— is invaluable.

data falling out of sync. In addition, fluid power distributors can more easily solve daily challenges when they deploy an ERP system that’s built specifically for their unique needs.

Utilizing a single, industry-specific ERP solution that’s capable of managing both distribution and manufacturing functionality provides economy of scale and allows you to maximize the return on your investment. It lets you streamline assembly processing, ensure real-time communication and visibility across the entire assembly production cycle, improve inventory management, enhance the customer experience, and provide complete data analytics for informed decision making—both on the individual transaction level and more long-term business trends.

Standing out from the competition hinges on exceeding customer expectations. Offering manufacturing services helps you outshine the Amazons of the world. Make sure the strategy behind this decision includes creating the infrastructure to simplify managing distribution and manufacturing processes together.  About Epicor: Epicor Software Corporation drives business growth.

We provide flexible, industry-specific software designed to fit the precise needs of our manufacturing, distribution, retail, and service industry customers. More than 45 years of experience with our customers’ unique business processes and operational requirements are built into every solution—in the cloud or on premises. With this deep understanding of your industry, Epicor solutions dramatically improve performance and profitability while easing complexity so you can focus on growth. For more information, connect with Epicor or visit www.epicor.com. And if you want to know more about selecting the best ERP for your business, visit http://bit.ly/2lx7b7R.

IMPLEMENTATION: If you have problems at this stage, it can have a lasting effect on your ERP system’s performance as well as your profits.

Look for a partner with a proven record.

INDUSTRY EXPERTISE: A partner with specialized industry expertise can bring useful perspective and insight to your ERP system.

SCALABILITY: An ERP system built on scalable architecture will help you manage growth. And the fewer customizations a system requires to meet your specific needs, the better.

DEPLOYMENT OPTIONS: On-premises, cloud, or hybrid deployment options—combined with mobile access for your employees—help ensure that your organization remains flexible and responsive.

7 8

EASE OF USE: Nobody wants to wade through a difficult and unfriendly learning curve. An ERP system with an intuitive user interface will increase employee satisfaction and productivity.

FUNCTIONALITY: An ERP system requires the capability to do everything that your ERP strategy demands of it. It must be fast, reliable, and easy to integrate with your other systems.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

DECEMBER 2019

13

SPECIAL AD SECTION

Hydraulex Product Line Overview HYDRAULEX

LITERATURE REVIEW

We re-freshed our company line card into a more informative and better looking document. It covers our aftermarket product line (Genuine Metaris) and all of the manufacturers that we stock reman units for, supply replacement parts for, or provide repair services for. View or download it by visiting our website at www.hydraulex.com.

Hydraulex Toll Free: 800.422.4279 • Tel: 586.949.4240 Email: sales@hydraulex.com www.hydraulex.com or www.ahx1.com

Compressed Air Filtration

A Reliable Means of Equalizing Pressure

LA-MAN CORPORATION

OIL-RITE CORPORATION

WINTER

Brochure offers a comprehensive overview of the company’s complete line of compressed air filtration products. Highlighted is the patented family of Extractor/Dryers. These two-stage, point of use filters remove contaminates to a 5-micron rating with flow ranges of 15 to 2,000 scfm.

Additional products available include the SuperStar Membrane Dryer, .01 Micron Filter, Refrigerated Extractor/ Dryer, and much more.

Vent Plugs relieve pressure or vacuum on bearing housings, gear boxes, and reservoirs. Air flows through a hole angled upwards to restrict contaminants from entering the tank. Some styles include a 40 micron filter. Another option is a deflector at the bottom to help contain sloshing liquids.

Made in the USA.

(920) 682-6173 sales@oilrite.com www.oilrite.com

La-Man Corporation 800.348.2463 www.laman.com

Hydraulic Live Swivels Catalog

Your Cylinder Source

SUPER SWIVELS

YATES INDUSTRIES, INC.

Inline and 90° hydraulic live swivels.

Available in sizes from 1/8" to 2-1/2", rated to 10,000 PSI, heat treated, superior quality alloy steel, chrome or stainless steel ball bearings, withstands heavy side loads, burnished (micro smooth) barrel bores, Viton®, Aflas®, or Teflon® encapsulated seals, zinc or nickel plated, available in 304 and 440 stainless steel, full flow - low pressure drop, rebuilding kits available.

Super Swivels Phone: 763.784.5531 Fax: 763.784.7423 Website: www.superswivels.com

14

DECEMBER 2019

Yates Industries, Inc. 23050 Industrial Dr. E. St. Clair Shores, MI 48080 Ph: 586.778.7680 Fax: 586.778.6565

All Designs, All Sizes, One Result.

Yates Cylinders – an ISO-9001:2015 company with facilities in Michigan, Alabama and Georgia – is your top-quality supplier for all cylinder applications.

Hydraulic, pneumatic, NFPA, mill grade, or custom engineering – you name it, Yates can handle it. Complete catalog available.

We also maintain an unmatched repair program used by the biggest names in the American Industry.

Yates Georgia Yates Alabama 7750 The Bluffs 55 Refreshment Place Austell, GA 30168 Decatur, AL 35601 Ph: 678.355.2240 Ph: 256.351.8081 Fax: 678.355.2241 Fax: 256.351.8571

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

When troubleshooting for an air leak that didn't seem to be in the system, a check was added between the separator and the receiver. Then every 10 minutes the compressor would try to start and immediately shut off. A new larger air tank was installed and the pressure switch was replaced with no change A I R in operation. When pressure was lower in the tank everything worked properly. What is the problem?

Pressure Switch

TEASER

To System

Ball Valve

Filter/separator

Compressor

New Problem:

Calculating The Effect Of High Wind Force

By Ernie Parker, CFPAI, CFPSD, CFPS, CFPMM, CFPMT, CFPMIP, CFPMMH, CFPMIH

Âť

THERE HAVE BEEN some very strong winds in the eastern United States with upwards of 70 to 90 MPH. How much force and horsepower would the wind produce pushing straight on to a 4-foot x 8-foot piece of plywood at...

70 MPH? and 90 MPH?

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Receiver

Filter

S

olution to the Previous Problem: Compressor Shuts Off When Pressure Rises

The check valve was placed between the pressure switch and the main circuit. When the air pressure dropped between the air compressor and the check valve, high pressure remained downstream from the check valve. The air compressor turned on and immediately hit high pressure and shut off. The solution was to put the check valve between the separator and the pressure switch. Now the pressure switch will sense system pressure and not just the pressure between the check valve and the compressor.

Visit www.fluidpowerjournal.com to view previous problems.

DECEMBER 2019

15

By Pat Jones, P.Eng., CFPAI/AJPP, CFPMM, CFPHS, TRC Hydraulics COUNTERBALANCE - VERB: “TO OPPOSE OR BALANCE WITH AN EQUAL WEIGHT OR FORCE”

Counterbalance valves serve a very important role in hydraulic system applications because they are used to “counterbalance” the weight of the load to control it when lowering, and can also be used to trap fluid to hold a load indefinitely. These valves are particularly important in safety applications where the uncontrolled movement of the load could cause injury or death.

SOME KEY THINGS TO UNDERSTAND ABOUT COUNTERBALANCE VALVES: •A counterbalance valve (also called a brake, holding and/or overcenter valve) is a normally closed-pressure control used to oppose the pressure created by a load. They are typically either internally piloted or internally and externally piloted.

When used for holding, these valves must be • direct acting, poppet-type pressure controls so valve leakage is essentially “zero.” use these valves for holding because • We

From these symbols, we can see that pressure at the inlet (internal pilot) area A1 and at the external pilot area A2 can force the valve open and pressure at the spring chamber area AD will oppose the force on the opposite side of the poppet to hold the valve closed. The spring chamber can be drained to the exhaust port of 16

DECEMBER 2019

spool-type direction valves are a clearance fit, and therefore, leak. Spool-type valves cannot be used to hold a load. are not speed controls. The setting on the • They

valve is to hold the load and prevent it from moving uncontrolled (runaway). The lower speed is controlled by the flow supplied to the actuator when lowering.

•A cylinder circuit with counterbalance valves controls the load when moving and can also hold a load indefinitely because cylinders can have zero internal leakage.

• In a motor circuit, counterbalance valves control the load when moving, but because motors have a clearance fit in their moving parts, they cannot be used to hold a load with trapped fluid. A mechanical brake must be used in motor circuits.

• Because

we have to force fluid across a counterbalance valve to lower the load, they generate heat.

This is the trade-off for having good load control.

So with all these things in mind, how do we specify the correct counterbalance valve for a

given application? There are two key aspects to specifying counterbalance valves that will be covered in two articles. Article one is about selecting the pressure setting range, when to use a valve with internal pilot only, and understanding release pressure. Article two is about how to size the valve for optimal load control. These two are related, the first is a static calculation based on load, actuator size, and circuit layout, and the second is based on dynamic conditions so flow resistance through the valve, load dynamics, and system stiffness must be considered. For this article, I will deal with the static side of this issue.

First, let's take a look at the basic symbols so we can understand the working areas in a typical counterbalance valve. Shown below are the pressure control symbols. The check valve has been omitted for clarity, but is always used to allow free flow around the pressure control to raise/move the load in the opposite direction.

the valve (internal drain), drained separately to tank (external drain), or referenced to atmosphere (seal poppet to spring chamber and spring chamber in air).

Next, we need to understand the force balance on the counterbalance spool to determine the pressure required to open the valve and start

to move the load (called the release pressure). In order to hold the load, the valve cracking pressure setting must be set higher than the load pressure. Because of the hysteresis (friction) of the valve moving parts, there is a difference between cracking and reseat pressure (the pressure at which the valve closes) with the reseat WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

pressure being lower than the cracking pressure.

For this reason, the setting on the valve for the typical counterbalance valve setting is roughly 30% above the load pressure to insure the reseat pressure will be high enough to hold the load.

The images on the right show the working areas of the counterbalance poppet and corresponding force balance.

From this, we can derive equations for release pressure based on the actuator type, area ratios, and the load conditions. Keep in mind that from basic statics pressure at the inlet of the actuator can build pressure at the outlet of the actuator across the internal working areas. The following is an example with a single-rod cylinder with rod pointing down and load pulling the rod out: Now consider four load states with a single-rod cylinder, load pulling the rod out so we can understand where an external pilot can be used to decrease the release pressure and increase system efficiency, especially with varying loads:

So you can see that for the internally pilot valve, when the load is high, the release pressure is low, but when the load gets light, the release pressure is high. We should always let gravity do most of the work of lowering, if possible, while still being in control of the load, this is the most efficient. We should not be using high power to lower a load. So if the load is constant, then an internally piloted counterbalance valve is the correct choice, as it will always be set the same amount above the load.

For the externally and internally piloted valve, you can see that even at maximum load, the release pressure is lower than the internally piloted valve because the pressure pushing the load down is acting on the internal and external areas at the same time, and the total area is four times just the internal area. Again, we should not be building to high pressure to WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

INTERNAL PILOT

INTERNAL & EXTERNAL PILOT

Case 1

Case 2

Case 3

Case 4

PLoad

3000

500

3000

500

PCB

3900

3900

3900

3900

PR

n/a

n/a

3

3

Ap/Aa

2

2

2

2

PD

100

100

100

100

Prelease

500

1750

260

760

lower a load—efficiency wise is does not make sense—so an internally and externally piloted counterbalance valve will work more efficiently with varying loads.

For each of these cases, pressure at the exhaust of the valve was assumed to be 100 psi.

You will see from the force balance above that for an internally piloted valve that any pressure at the exhaust of the valve is directly additive to the spring setting of the valves, meaning its cracking pressure is increased by that amount.

For the internally and externally piloted valve, pressure at the exhaust of the valve will add to the spring setting by a factor of four for a 3:1 pilot ratio valve. For this reason, the designer must determine the pressure at the exhaust of the counterbalance to make the decision whether to use an external spring chamber drain to lower Prelease.

SO TO SUMMARIZE: • The

counterbalance valve setting should be 30% higher than the load, so select a valve spring range that allows for this setting.

• Internal

pilot, direct acting valves are typically used for constant loads. They can be used with varying loads, but system efficiency will suffer. and externally pilot direct acting • Internally

valves are used varying loads. This will improve the system efficiency.

• An external spring chamber drain must be used when there is excessive pressure build up at the exhaust of the valve to lower the release pressure, (i.e., a meter out flow control or proportional dcv).

We have covered one part of the puzzle regarding counterbalance valves. The next part will review the dynamic operation of the valve once it has opened and the load starts to move.  DECEMBER 2019

17

N F PA U P D AT E

See Who’s Exhibiting at IFPE 2020 March 10-14, 2020 Las Vegas Convention Center Las Vegas, Nevada

»

IFPE 2020 IS set to provide exhibitors and attendees alike countless opportunities to learn about what’s new and what’s coming soon in fluid power technology.

The floor plan is already filled to the brim with more than 400 industry-leading companies ready to showcase their latest and most efficient fluid power solutions, plus more companies are on the wait list hoping to pick up a spot at the show. Industrial hydraulic, mobile hydraulic, and pneumatic solutions will all be represented.

There will also be more than 170 education sessions available at the show plus two innovative education tracks specific to fluid power: Hydraulics and Pneumatics at Work and The Business of Fluid Power.

Whether coming to the show to staff one of the 400+ booths or as a show attendee, early-bird registration ends January 17, 2020. Visit IFPE.com to learn more and plan your time at the show.

» WEH® QUICK CONNECTORS

Pressure-tight connections in SECONDS

» Just PUSH to connect -

No hand tightening, no tapes, no thread sealants » Direct connection to threads, beads, tubes etc. » Pressure range of up to 14,500 psi WEH Technologies Inc. Katy, TX Call us: 832-331-0021 sales@weh.us 18

Anzeige_ADT_US_7.625x4.875_Systems Integrator Directory_FINAL.indd 1 DECEMBER 2019

» www.weh.us 12.01.2016 07:04:01 WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

N F PA U P D AT E

NFPA Programs Connect Members to New Hires

»

ONE OF THE goals NFPA works to accomplish with our workforce programs is to connect students in our educational programs to careers in the fluid power industry at NFPA member companies. It’s always great to hear the success stories!

NFPA member, Jim Kaas, of Iowa Fluid Power (IFP), recently hired two students that he met through NFPA programs: Caleb Cobb was hired for a summer internship after Jim met Caleb through NFPA’s Fluid Power Vehicle Challenge program.

Caleb was a part of the Murray State University team that Jim mentored.

In his internship at IFP, Caleb was a valued member of the engineering team and contributed to a number of projects. Caleb started the summer on the production floor building custom power units and working with the technicians to understand the build process. From there he assisted multiple project engineers in multiple phases of the sales and design process.

Caleb spent a good deal of his time with IFP’s manufacturing division researching component pricing for project cost estimates, as well as working with bill of materials in Excel spreadsheets. Caleb also participated in documenting and testing many of the production power units built by IFP’s manufacturing division during his time there.

Chandlar Armstrong was hired after Jim met him at the Milwaukee School of Engineering for an NFPA meeting regarding a new educational program. The second day on the job in a full-time position at IFP, Chandlar was sent to Sarasota, Florida to participate in a three-day supplier training at Sun Hydraulics. Chandlar has been working on the valve manifold team quoting custom manifolds and hydraulic circuits. The team designs solutions for customer applications that range from single cartridge manifold assemblies to custom valve packs with cartridge, ISO, and sectional valve interfaces. According to Jim, Chandlar has been a great addition to WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

the IFP’s manufacturing division team and an immediate contributor with his fundamental hydraulic training.

Connect with New Talent!

There are many opportunities to connect with students. One way is just around the

corner: mentoring and judging for the Vehicle Challenge competition. To mentor or judge for the Vehicle Challenge, or for information about more ways to connect, contact Lynn Beyer at lbeyer@nfpa.com or (414) 778-3364.

Luis Javier Berné, Engineer, ihBER S.L., Zaragoza, Spain

Complex hydraulics at your command.

Hydraulics innovator ihBER S.L., Zaragoza, Spain, uses a Delta highperformance RMC200 motion controller to gather 40 points of sensor data with high precision and at great speed for analysis to maximize energy efficiency.

Luis Javier Berné leads the hydraulics development project.

“I chose the RMC200 because it is easy to use and the software provided with it has powerful plotting capabilities.”

Delta RMC motion controllers and graphical RMCTools software make testing applications using hydraulics repeatable, flexible and precise.

Find your competitive edge. Call 1-360-254-8688 or visit deltamotion.com Find the ihBER case study or one about your own industry or application.

Watch a training video to see how Delta puts precise, flexible, complex hydraulic motion at your command.

Delta RMC Motion Controller Family

1-2 Axis

Up to 8 Axis

Up to 32 Axis

DECEMBER 2019

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TECH 2019 DIRECTORY Check out the online matrix at www.fluidpowerjournal.com

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the hectic world of industrial automation, engineers have little patience for inefficient software.

Easy-to-use is coveted, but not at the expense of flexibility, especially when thorny situations arise.

Given that every manufacturer claims their software is easy-to-use and boosts productivity, it’s difficult to weed through the marketing fluff to find out whether a certain piece of software is truly easy

to use and whether it has the flexibility to handle not only the machine requirements, but also the inevitable feature creep and unexpected problems.

THE HOLY GRAIL OF

EASY AND FLEXIBLE

By Jacob Paso, Motion Product Development Manager, Delta Computer Systems, Inc.

Easy-to-use software may not have enough functionality to handle anything other than a few situations, however. Conversely, flexible software may have so much flexibility that the user must go through a lot of work to set up the solution to a particular problem. Developers should beware of software that the vendor calls “freely programmable.” That usually means the customer is required to write a whole lot of difficult code.

If he or she is an expert with lots of programming experience, this may be acceptable, but for many automation engineers who need to use many different software packages, a tool package that includes many pre-canned components tailored for relevant application functions is much more useful.

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DECEMBER 2019

MOTION APPLICATIONS ARE SPECIAL A related problem occurs when designers try to use a general-purpose controller like a PLC to do a specialized function like motion control. PLCs are good for machine control and status monitoring, but for real-time motion control tasks where sub-millisecond responsiveness is required, many PLCs may not have the speed to close control loops fast enough, nor the motion features or troubleshooting tools to quickly and accurately program the motion. The machine cycle times and instruction repertoire of today’s advanced motion controllers are tailored for the task of making highspeed motion decisions.

But ease-of-use and high performance must also be balanced with the flexibility to enable the

growth of applications over time.

In this regard, it is helpful for the motion controller to be supported by a vast list of functions in its programming library. A helpful motion control supplier is one that adds functionality to its products over time, motivated by experience in solving innovative applications in the marketplace.

System integrators who are looking to make their lives easier will also do well to consider in their selection process how much training the company has for their software, as well as how much help, forums, and design examples they provide. They should also ask whether the company charges for support, and how difficult is it to find a support person with the expertise they need.

APPLICATION FEEDBACK DRIVES FUNCTIONALITY For example, Delta Computer Systems, the motion controller manufacturer based in Battle Ground, Washington, offers its RMCTools software precisely for high-performance motion control using the company’s RMC family of electro-hydraulic controllers.

Based on feedback from customers, Delta’s technical support team, sales personnel, and marketing staff, the company’s software developers have put together a toolset that they know will work in real applications. With continuous feedback, the company continues to improve the software to increase efficiency for customers.

RMCTools software has been designed to make motion sequences easy. The flexibility of Delta’s

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programming model has allowed advanced types of motion to be possible, even when those types of motion were not specified in the original design scope.

Experienced designers know that motion application development isn’t finished when the control algorithm is programmed. The control loop gains must be tuned to remove the error between target and actual motion caused by physical characteristics of the system.

For this purpose, advanced motion controllers are supported by automated tuning software. While other vendors provide the ability to tune a single set of gains, Delta Computer Systems’ Tuning Wizard provides a range of gain alternatives, allowing the designer to tweak the system’s responsiveness using an intuitive slider bar on the computer screen (see Figure 1). To graphically display how the system performs in real time, the company provides a plot manager (Figure 2) that shows actual versus target motion parameters versus time.

REAL WORLD EXAMPLES Most motion applications for RMC motion controllers can be programmed by filling in forms and selecting options from drop-down

menus. Figure 3 is an example showing how complex multi-axis synchronization is very straightforward to set up using Delta’s RMCTools programming software.

If the functionality that a user wants to set up is not directly supported by the software, it can be accomplished using Delta’s user program feature. The following are two examples of how the software can be used to simplify some complex application tasks using the user programming feature.

ADAPTIVE AMPLITUDE CONTROL Motion controllers typically generate a target profile that must be followed precisely. In cyclic testing, where thousands and even millions of sinusoidal cycles are run at various frequencies, following a precise target is difficult or impossible. In such systems, only the amplitude is important, so a different algorithm is employed that adaptively adjusts the commanded amplitude so that the actual amplitude reaches the desired amplitude.

This results in much easier setup for the customer.

The user program shown in Figure 4 starts a sine wave motion (step 1 in the code box at right in the screen

Figure 1 (top): Delta’s Tuning Wizard simplifies control loop gainsetting to ensure precise motion.

Figure 2 (middle): Delta’s Plot Manager shows motion parameters versus time.

Figure 3 (bottom): Most Delta RMC applications are programmed by filling in boxes and selecting options from drop-down menus.

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shot), and then executes a continuous loop with the period of the sine wave. During each cycle, the controller initializes variables (step 2), and then detects the max and min values of the actual position (step 3).

In step 4, the controller calculates the maximum and minimum output values that are to be produced and updates the amplitude of the target motion profile before jumping back to re-run the loop. The result is that the actual amplitude always reaches the desired amplitude without overshooting or undershooting.

This user program, while not for novices, offers great flexibility for semi-advanced customers to modify it to control a combination of position, pressure, force, openloop signals or closed-loop signals, or to adjust some other value

besides amplitude such as offset or phase. Some software packages that offer a similar feature don’t have the flexibility to modify the basic functionality to specific needs without requiring expensive engineering time from the manufacturer.

Motion controllers that do not have the high-level functionality of Delta’s RMCs may require complex machine-level programming, at the cost of reduced flexibility and extended time-to-market.

SYNCHRONIZED OPEN LOOP CONTROL Open loop motion is not typically associated with any type of synchronized motion, since it cannot control to a target position. However, when trying to synchronize the cylinders of one of Delta’s customers’ systems,

a hay press, application engineers discovered that any normal closedloop algorithm did not work, since the cylinders needed to give all the force they had to compress the bales, with compression times varying greatly based on bale density. The application engineers developed an algorithm that gave an open loop signal to each cylinder valve, continuously determined which cylinder was furthest behind, and modulated the signals to the rest of the cylinders so that they would stay with the slowest cylinder.

Figure 5 contains the user program step that calculates the position difference between each axis and the slowest axis, and performs a proportional gain and integral gain calculation to modulate the voltage going to

Figure 4: The code segment for adaptive amplitude example

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each axis. The first expression in the code box deals with ramping up the open loop signal to its full value. The second expression runs each millisecond and finds the position of the axes that is furthest behind. This expression also calculates other values to report just for troubleshooting and calculates the difference (OLError) between the axis furthest behind and each of the other axes.

Next, the expression performs a proportional and integral gain calculation for each axis to stay where the slowest axis is. And finally, the program applies the calculated signal voltages to each axis. Once the axes have reached a desired position, the user program will continue on to some step that stops the axes.

This user program demonstrates the programming of visuallyoriented motion sequences that also offers the ability to add sections of code. The flexible and relatively easy-to-read code makes it easy for semi-advanced customers to modify the code, for example, to add or remove the number of axes involved. This type of code would be very difficult to program in ladder logic or other general-purpose programming languages, and hence may scare off many automation engineers.

The first time this program ran, the cylinders remained synchronized with 0.005 in., although the requirement was only 0.25 in.! Other customers have modified this example to suit their specific needs. ď Ź

It should be obvious from the previous discussion that selecting a motion controller for a fluid power application is serious business, with software considerations having an enormous amount of leverage on development time, system performance, and future design extensibility. Developers should do their homework before making a decision, including understanding how prospective motion product suppliers support their products. If you would like to see more coding examples and learn more about tools that can be adapted to your business needs, visit www.deltamotion.com.

Figure 5: A synchronized open loop code example

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oses are aligned and secured to achieve maximum possible performance. The pressure rating and quality of a hose can be used to predict its service life. Not much can be done to extend the life of a hose, but improper mounting and alignment contribute to shortma in t en anc e ening the life of a hose.

Align hoses and fittings.

IMPORTANT: Two conditions

that contribute to shortening Recognizes consequences of twisting a hydraulic hose during the service life of a hose are installation.

for the hose to burst. Never tie down a vibrating hose with a wire, rope, or any material that might wear through the hose cover. Hoses must be routed to flex in no more than a single plane. If a compound bend is called for (this is a bend in two directions), the path must be divided into two segments with a clamp, or a coupling and a clamp where the bend changes direction, to be sure that each hose segment flexes only in one plane.

installing it twisted or installing

IMPORTANT: Avoid putting is measured in degrees from the a twist in a hose when it is Distinguishes between properly and improperly mounted lay line, which is a line printed installed. Twisting or torquing hydraulic hoses. on the hose that runs parallel to will shorten the life of the hose. the hose The bend a hose Hoses are aligned and secured to achieve maximum possible performance. theaxis. pressure ratingofand quality Some technicians report putting of a hose can be used to predict its service life. not much can be done to curvature extend theof lifea of a hose, is the hose frombut a slight twist in hoses during improper mounting and alignment contribute to shortening the life of a hose. a straight line expressed as the installation so that the hose IMPORTANT: two conditions that contribute to shortening the service life ofof a the hosebend. are installing it twisted will miss an obstruction or lay radius The bending or installing it over bent. the twist of a hose is measured in degrees from the lay line, which is a line a hose is measured printed on the hose that runs parallel to the hose axis. the bend of aradius hose isof the curvature of a hose to from against the machine frame. This a straight line expressed as the radius of the bend. the bending radius a hose is measured to on thethe outer practice is incorrect. Instead, theofouter wall of the hose wall of the hose on the inside turn. (see Figure 10). inside turn (see Figure 1). the hose should be secured with a tie-down. Make sure twisting avoid sharp twists or bends in a hose by using proper hose angle will not occur after installation, adapters. Do not bend the hose in an arc that is less than the for example as a result of relaminimum bend radius of the hose given in the application table.

Be especially careful of sharp bends where the hose connects to tive motion between machine the fitting. never kink a hose or clamp a hose at the bend. this elements. Avoid temporary prevents the hose from expanding and contracting at the bend. never allow the outside of the bend to be aimed at the equipment twisting, called transient twistoperator because this is a likely place for the hose to burst. never ing, even during installation. tie down a vibrating hose with a wire, rope, or any material that might wear through the hose cover. Hose must be routed to flex Remember that mounting a in no more than a single plane. if a compound bend is called for hose with as little as 10 degrees (this is a bend in two directions), the path must be divided into of twist can shorten its service two segments with a clamp, or a coupling and a clamp where the bend changes direction, to be sure that each hose segment flexes life by as much as 90%. only in one plane.

All hoses should be secured.

IMPORTANT: avoid putting a twist in a hose when it is Figure 10. Bending radius of Be careful to avoid extensive Figure 1: Bending radius of a installed. twisting or torquing will shorten the life of the hose. a hydraulic hose. flexing and contact with moving Some technicians report putting a slight twist in hoses during hydraulic hose. installation so that the hose will miss an obstruction or lay against machine members. Once the machine frame. this practice is incorrect. instead, the hose Avoid sharp twists or bends should be secured with a tie-down. make sure twisting will not occur after installation, for example as a installed, hoses must be bled result of relative motion between machine elements. avoid temporary in atwisting, hose bycalled usingtransient proper twisting, hose of air and pressure checked for even during installation. Remember that mounting a hose with as little as 10 degrees of twist can shorten angle adapters. Do not bend the leaks. As a safety precaution, if its service life by as much as 90%. hose in an arc that is less than there is any bending movement all hoses should be secured. Be careful to avoid extensive flexing and contact with moving machine the for minimum radius of at the coupling, install a spring members. Once installed, hoses must be bled of air and pressure checked leaks. as bend a safety precaution, if there is any bending movement at the coupling, install a spring guard at hose the fitting to in keep the hose from guard at the fitting to keep the the given the applicakinking at the fitting. tion table. Be especially careful hose from kinking at the fitting.

IMPORTANT: a bursting hose is dangerous. it spreads fluid at high pressure which can cause serious of sharp bends where the hose connects to the fitting.

Never• 27 IMPORTANT: A bursting hose MHT Manual # 401 - 08/09/12 Mobile Hydraulic Technician Certification • Study Guide kink a hose or clamp a hose is dangerous. It spreads fluid at at the bend. This prevents the high pressure, which can cause hose from expanding and con- serious injury as well as leave tracting at the bend. Never allow illegal oil spills that contamithe outside of the bend to be nate the environment. Fittings aimed at the equipment oper- that can be positioned, such as ator because this is a likely place elbows and branch tees, should Computes minimum "bending radius" of a ithydraulic hose. over bent. The twist of a hose

Hydraulic

Maintenance 34

DECEMBER 2019

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Review: 2. the bending radius of a hydraulic hose is measured from the: a. center line of the terminal fittings. be positioned in the direction to charts. What is important to b. Outer wall of the inside bend. accept hose fittings before the remember is that minimum c. center line of the tube. lock nut is tightened against the bend radius is affected by hose d. Outer wall of the outside bend. back-up washer. Finally, most diameter, operating pressure, e. terminal fitting to the inside bend.

Test Your

manufacturers of SAE straight thread fittings advise limiting their use to lines no larger than 7/8 inch O.D. Anything above 7/8 inch O.D., flange connectors are recommended.

and flexing conditions. Moreover, if the minimum bend radius is exceeded, that is the hose is bent too short, the Figure 12.hose Figure for below Review 7.2. service life of the hose will be Installing a hose twisted Which shown reduced and the hose may burst as little as 10 degrees can had a twist put in it during at the outside of the bend or at shorten its service life as installation?

IMPORTANT: The minimum one of the fittings. much as: bending radius of a hose is taken Hoses are checked for proper a. 20%. d. 75%. a. from manufacturer's charts. The mounting by visual inspection. b. 40%. e. 90%. bending radii increases as the Assemblies should be compact c. 50%. dash size diameter of the hose and properly assembled. Use increases. It also increases as the elbows and adapters to elimiThe bending radius of a b. pressure increases. When a hose nate excess hose lengths, and hydraulic hose is meais subjected to bends smaller possible interference or abrasured from the: than recommended, hose oper- sion. Using the correct fitting a. Center line of the ating pressures must be reduced. also facilitates future mainteterminal fittings.

Similarly, if the hose is subjected nance. Hoses should be long b. Outer wall of the Review: 1. c. to lower operating pressures, to prevent pulling installing a hose twisted as littleaas enough 10 degrees can shorten its service life as inside muchbend. as: Review: a. 20%. smaller bend radius may be3. when they are assembled. This c. Center line of the Which hose shown a twist put in it during installation? b. 40%. reduces had the bend radius at the used. The minimum bending tube. c. 50%. a. a.hose fitting, which will cause it to radius for typical hydraulic d. Outer wall of the d. 75%.

B.can fail at the fitting. Hoses should in dash sizes from -4c.to -16 outside bend. e. 90%. e. be mounted with brackets or be read from Figure 2. c. e. Terminal fitting to d.

D. is insulators away from heated Minimum bendc.radius the inside bend. e. e. related to hose diameter and surfaces and machine memoperating pressure. A typical bers that could damage them well as leave illegal oil spills that contaminate the environment. Fittings that can be positioned, mechanically.

-8 (l/2 single as wire braid Review: 2. inch)injury such as elbows and branch tees, should positioned in the direction to accept hose fittings before the the bending radius of a hydraulic hose is measured from be the: hose that has a 2-1/2 inch lock nut is tightened against the back-up washer. Finally, most manufacturers of Sae straight thread fittings a. center line bending of the terminal fittings. determine if the 7/8 inch O.D. above 7/8 inch O.D., flange connectors are minimum radius for advise limiting their IMPORTANT: use to linesTono larger than b. Outer wall of the inside bend. operating pressures of 750 psi, hose is twisted, look for the lay recommended. e. c. center line of the tube. would have almost a 5 inch min- line, and make sure that it fold. Outer wall of the outside bend.

IMPORTANT: minimum radius of hose is taken from manufacturer's charts. the bending imum bending radius 2000 the lows the axis ofbending the hose without e. terminal fitting to theatinside bend. radii increases as the dash size diameter of the hose increases. it also increases as the pressure increases. psi. Similarly, if the hose size twisting, even through bends in When a hose is subjected to bends smaller than recommended, hose operating pressures must be reduced. were increased from -8 -16hosethe  Similarly, if to the is hose. subjected to lower operating pressures, a smaller bend radius may be used. the (1 inch), the minimum minimumbending bending radius for typical hydraulic hose in dash sizes from -4 to -16 can be read from Figure Figure 12. Figure for Review 7.2.Figure 13. Figure for Review 7.3.

11. radius for operating pressures 12 of 750 psi would be have to be Using Figure 2 as a reference, -24 11 increased to 7 inches. what is the minimum bend 10 radius for a 1 inch diameter hose MHT Manual # 401 - 08/09/12 Mobile Hydraulic Technician Certification • Study Guide • 29 -20 9 IMPORTANT: The minimum operating at 800 psi? bend radius is figured for a staa. 5 in.

8 -16 tionary hose. If the hose is also b. 6-1/2 in.

7 -12 subject to flexing conditions, c. 7 in.

6 -10 the minimum bending radius d. 7-1/2 in.

5 -8 is multiplied by a bend factor, e. 9 in.

4 -6 which ranges from 1.1 to 1.5.

-5 3 For example, if a hose flexes 90 See page 39 for the -4 2 correct solutions. degrees, the minimum bend 1 Review: 3. radius might be increased 1.25 200 400 600 800 1000 1500 2000 2500 3000 Which hose shown had a twist put in it during installation? times. How much the bending Operating Pressure - Pounds / Sq. in. a. a. c. B.radius for a specific hose must Figure 2: Typical minimum bend radius hose Fig. 11. typical minimum bend radius for hydraulic hoseforathydraulic different operating pressures. e. c.be increased is determined at different operating pressures. c. D.directly from manufacturer e. e. minimum bend radius is related to hose diameter and operating pressure. a typical -8 (l/2 inch) single wire braid hose that has a 2-1/2 inch minimum bending radius for operating pressures of 750 psi, would have WWW.IFPS.ORGalmost • WWW.FLUIDPOWERJOURNAL.COM 2019 35 a 5 inch minimum bending radius at 2000 psi. Similarly, if the hose size were increased from -8 toDECEMBER -16 (1 inch), the minimum bending radius for operating pressures of 750 psi would be have to be increased to

1

3

2

ma in t enanc e

ma in t en anc e

Bend Radial in inches

4

Integration of Ferrous Density and Particle Count for Automated Ferrography Analysis of Abnormal Wear Conditions

By D. Walsh, K. Caldwell, and T. Barraclough, AMETEK Spectro Scientific, Inc.

INTRODUCTION

THE CHALLENGE

he presence of wear debris in machinery glass slide or a filter patch, remains a very inforlubrication oils is a significant indicator of the mative and powerful test. ASTM D7690, introduced condition of machinery health and indicative a few years ago, describes the method in detail. of equipment failure. Other oil analysis parameters The time to prepare a ferrogram slide (15 minutes) reflect oil condition, contamination, or normal coupled with a skilled examination (20 minutes) wear. These are sometimes leading indicators of is too long in terms of turnaround time for both abnormal machinery wear, but measuring wear laboratories or onsite programs to recommend all parameters directly allows trending of the most sig- samples to have the test, notwithstanding the cost, nificant indicators of incipient machinery failure. which can be over $300 per test.

The majority of machinery components lubriFerrous density meters have been in the marketcated are ferrous so trending the ferrous content place for some time, and all of them employ a slightly in oil over time provides evidence of progres- different aspect of traditional electromagnetism sive machinery wear. Not all wear is considered theory to take advantage of a change in electrical equal, however. signal when a ferromagnetic metallic particle is Large ferrous wear particles are most indicative sensed. Changes in magnetic flux, dielectric constant, of abnormal machinery wear, a sign that the “onset and magnetic inductance or capacitance techniques of failure” point of the P-F curve has been reached. have all been used in prior systems. The simplicity is It is important to predict when failure is about to use, without fluid opacity interferences of DR ferrogoccur, and identify transition of wear from small raphy allowed them to become the primary tool most (benign wear) to large (severe wear) particles as a analytical labs have recommended for total wear wear surface is broken down. It is very screening, with the dimensionless output important to remember large particles was a scalar representation of ferrous Figure 1: Wear particle contribute very little mass (ppm) to the material present, without detail to the size/quantity to overall concentration in the sample. size of the particles—not the most senvarious onset Ferrography was introduced in the sitive trigger for analytical ferrography. modes. (REF 4) 1970s to enable condition monitoring practitioners to augment elemental spectroscopy techniques to quantify the level of normal and abnormal wear present in an oil sample. Iron wear was, and remains, the most common elemental wear found in samples of machinery oil worldwide. Analytical Ferrography, where a skilled diagnostician familiar with wear particle morphology, microscopically examines separated wear debris on a

It is now well understood that onsite analysis provides the highest quality data if tested with lab grade technologies. As more equipment owners consider adopting the technology locally, replicating a laboratory environment, especially for ferrous wear debris analysis, is considered to be too complicated. Laboratories use elemental spectroscopy, optical particle counters, DR or ferrous density meters, and analytical ferrography to diagnose a severe wear situation in industrial machinery. The data is generated discretely, and takes up to 35 minutes to arrive at diagnostics from 3 sets of data from 3 discrete devices.

T

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DECEMBER 2019

Figure 2: Ferrography equipment and older DR device below.

(REF: TRICO)

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The LaserNet fine particle counter and image classifier is based on an innovative direct imager approach developed by the U.S. Naval Research Laboratory. The product was adapted by several condition monitoring laboratories and end-users, and the technology remains a standard product offering. In looking to provide ferrous information to shape based particle counts continuous model updates in 2017 to the LNF particle counter classifier result today in a ferrous debris monitor in series with the particle count, that only take 5 minutes to run, without dilution for oil less than 320Cst @ 40C. Dilution is employed for time savings above that value.

This magnetic susceptibility is then correlated to the concentration of ferrous debris in the lubricant by means of the known magnetic susceptibility of such debris. The new approach takes advantage of an innovative coil arrangement (Fig. 3), complete with advanced electronics to provide a very sensitive monitor for particles ranging from sub ppm to % concentration in under a minute.

Parameters are available based upon the calibrated measurements of the LaserNet ferrous monitor. The signals from the small magnetometer coil set which comprise the large ferrous particle counts (Fe>25u) are converted to report a single large ferrous parameter in addition to the individual counts. This “Large Ferrous” parameter is a calibrated ppm measurement of all ferrous particles > 25um. Combined with the “Total Ferrous” measurement of the large magnetometer coil set also reported in ppm, we now have units of measurement that allow presentation of NIST traceable indices that can be trended and interpreted in a meaningful way.

Ferrous parameters are derived from these two measurements similar to DR Ferrography: Percentage large ferrous particle (PLFP) = Large Fe/ Total Fe Ferrous Wear Severity index (FWSI) = Large Fe *Total Fe Wear Particle Concentration (WPC) = Total Fe a. The magnetometers are calibrated to NIST traceable standards so the LaserNet ferrous wear parameters are more accurate due to the accuracy and precision of the sensing coils compared to the DR Ferrography technology. b. The LaserNet threshold for Large Ferrous is 25 microns, more representative of an abnormal wear condition than the nominal 5 micron DL.

Oil Flow

THE SOLUTION

CCD Detector

Flow Cell

Particle size distribution ISO 4406 cleanliness codes

x4 Lens

1.6mm 1.2 mm

Artificial intelligence

Automatic shape classification

Large coil set Total ferrous content (PPM) Small coil set Large ferrous particle count and size distribution

Figure 3: A drive coil creates a magnetic field, and the sense coil measures it. When ferromagnetic material is present, it affects the sense coil, thus allowing the magnetic susceptibility to be measured. The measurement occurs all within one test cycle.

Figure 4: LNF Output screens. Data is uploaded to TruVu or excel for report and diagnostics.

CASE STUDY: HYDRAULIC SYSTEM COMPARISON

A

series of mobile hydraulic system samples were analyzed using the magnetometer option when performing a particle count. There were no trends, simply a comparison of large ferrous wear to total ferrous wear and compared.

In cases where no large ferrous was found, and only total ferrous debris, the wear was predominantly normal rubbing wear. In cases where the large ferrous wear result was greater than total ferrous, the early onset of severe wear was observed. Having the information with wear debris maps provides the onsite user with a significant set of trendable values that are very sensitive to the onset of abnormal wear.

Figure 5: Comparing the samples set to severe wear events.

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Normal

Abnormal

Sample #8 <5p/ml,>25μm 60ppm Total Ferrous

Sample ID

Distance Km

PQ Index

LNF (Ferrous) ppm

Spectrometer ppm (Fe)

Sample #38 90p/ml>25μm

LNF Ferrous >25um, p/ml

32131

0

0

0

0

0

<10ppm Total Ferrous

32138

150

7.4

72

35.07

46

32132

406

15.6

176

62.3

65

32134

819

17.2

86.74

45.69

0

32139

1159

14.2

90.02

42.72

0

32141

1799

26.8

258

93.19

123

32143

2594

32

260

69.07

84

32144

2894

38.4

319

97.08

28

32146

3100

35.8

476

199.35

158

The problem?

Large Ferrous particles contribute very little to the overall Fe ppm 100 x 10μm spheres only contribute 1ppm in mass of total ferrous

Figure 6: Dakar rally sample set.

DAKAR RALLY ENGINE FAILURE

SUMMARY

Dakar rally vehicle was sampled in the field, right through to an engine failure due to a coolant leak. Samples were retained and analyzed, along with RDE/ICP spectroscopy and PQ index ferrous density standalone meter.

Applying Ferrous Wear severity index and % ferrous large particle evaluation show that samples drawn at 150, 2,594, 1,799, and 3,100 km had the highest ferrous wear severity indexes. The engine failed at the 3,100 km mark, however the data suggests that if the engine was inspected at the 1,799 km point, it may have avoided failure at 3,100 km. Even though the PQ and spectrometer data did register a trend increase, the increase would not be at the order of magnitude the ferrous wear provides. Having the ability to provide the data immediately onsite and compare to established alarms can provide the critical data at the point of repair opportunity.

With the additional ferrous data being provided real time with particle count and shape classification, it is now possible to provide guidance to common wear onset events, summarized in Table 1.

End-users monitoring equipment at equipment site locations now have sophisticated data to enable early warning of abnormal wear events without having to wait for external services. 

A

REFERENCES [1] Hunt, T.M., Handbook of Wear Debris Analysis and Particle Detection in Liquids, Elsevier Press, 1993, pp148-153 [2] Michaels, P., Barraclough, T., “Detection of Abnormal Wear Particles via Electromagnetic Sensors and Particle Imaging Technologies,” MSOE Research Presentation to STLE Annual Meeting, 2018 [3] Levi, O., Eliaz, N., Failure Analysis and Condition Monitoring of an Open-Loop Oil System Using Ferrography Tribol. Letters (2009) 36:17–29 [5] Poley, J., Complexity in IISTA Fluid analysis, part XXXV, \STLE Tribology & Lubrication technology, Nov 2017, p119

Table 1: Diagnostics based on an array of data from 1 LNF device

38

DECEMBER 2019

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Clippard Introduces Electronic Proportional Pressure Controls

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KNOWN FOR RELIABILITY, innovation and focus on miniature pneumatics, Clippard’s new revolutionary micro-controllers utilize the proven EVP and DVP lines of Clippard proportional valves allowing for steady, repeatable downstream pressure as demand or processes change. The result, a precise linear pressure control within a closed-loop system with ultra-high resolution (≤5 mV) and repeatability.

With unparalleled performance and flexibility not possible with current analog proportional controllers, the Cordis makes everything from calibration to sensor variety acceptance to future development opportunities more accessible and less complicated.

The future of proportional control has arrived, and it’s digital. www.clippard.com

Endress+Hauser Secures MIV Contract at Large Texas Refinery

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ENDRESS+HAUSER AND ITS representatives, Vector CAG, secure the Main Instrument Vendor (MIV ) contract at a large Texas refinery. The company defines MIV services as a contract placed with a single instrumentation specialist partner to provide a total solution for a project including valves. From feed to operation, customers can save time, reduce cost, and mitigate risk with one partner to ensure consistency and avoid ambiguities. As the industry implements IMO 2020 regulations aiming to reduce sulfur content in fuel of marine vessels and limit future greenhouse gas emissions, expansions such as these help refiners add capacity to meet the needs of the industry. www.us.endress.com

HYDRAULIC FLANGES and COMPONENTS THE “SPECIAL” YOU WANT IS PROBABLY ON OUR SHELVES MAIN Mfg. Products, Inc. 800.521.7918 fax 810.953.1385 www.MAINMFG.com/fpj

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