Fluid Power Journal January 2021

JANUARY 2021

www.fluidpowerjournal.com

SEE THE

ROBOTICS AND AUTOMATION ISSUE

BionicSoftArm IN ACTION P.16

No More Fluid

’WEEPAGE' P.20

The Right Hydraulic Fluid Reduces Fire P.26

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

PNEUMATICS in Robotic Tooling Applications

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IN THIS ISSUE

JANUARY 2021 VOLUME 28 • ISSUE 1

Features 8

Pneumatics Gets a Grip on Robotic Tooling Applications Traditional grippers do not always get the job done.

16 Cover Story

BionicSoftArm Lifts and Grips

Like Nature Intended

The pneumatically powered robot

is based on the kinematics of an

elephant’s trunk.

8 26

20 Seal of Assurance: Zero-Leak

Systems Wipe Fluid ‘Weepage’

Manufacturers shift to versatile

hydraulic-electric-pneumatic

hybrid robots.

24 Test Your Skills

Size a Rotary Actuator 26 The Right Hydraulic Fluid

Reduces Fire Risks in

Aluminum Plants

The need for significant heat

increases the threat of a blaze.

28 4 Common Misconceptions

About Cobots

Collaborative robots can be

inexpensive, enhance safety,

and even add jobs.

28 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 6 10 12 18 22 30 31

Notable Words Figure It Out All About Vacuum IFPS Update Component Showcase Product Spotlight Product Review Classifieds

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N OTA B L E WO R D S

New IFPS Board President: It’s Go Time for Recruiting

By Rocky Phoenix, CFPMMH, IFPS Board of Directors President

»

I suggest that each and every one reading this column go out and recruit just one person (or more) who may not have had that “essential” job, or may not be currently employed, and may not be aware of the potential that a successful career in the fluid power industry offers.

4

JANUARY 2021

THE YEAR 2020 was a great one – to put behind us! I won’t talk about all of the problems and issues that occurred then; rather I would like to talk about the fantastic opportunity that has been presented to us, which is the potential to recruit talent to our industry that might not have been available previously.

You will recall that the pandemic created high unemployment and massive layoffs in the nonessential segments of many industries during the spring of 2020. However, if you were involved in fluid power, you were most likely considered an essential worker, keeping this country’s economy from crashing like it was 1929. And you probably retained your job, although you might have been working from home! For the 23 million people who became unemployed because they were considered nonessential, they might be rethinking their career choice, and here is the fantastic opportunity for the fluid power industry.

Nonessential. Nobody wants that label, and people from all walks of life want the promise of a successful and fulfilling life that only the United States can offer. This is where you, the business owner, supervisor, or individual comes in. Recruit for our industry! I suggest that each and every one reading this column go out and recruit just one person (or more) who may not have had that “essential” job, or may not be currently employed, and may not be aware of the potential that a successful career in the fluid power industry offers. She may not be the typical person you would interview for a position within your company, but think of the possibilities of bringing that bright and innovative mind to our industry with guidance and mentoring.

The fluid power industry is an amazing group of talented and intelligent individuals, but let there be no mistake: if we do not recruit for the future we will be left behind. We need diverse and innovative people who are available and hungry for a new career now. We will need this new and diverse group if we are to succeed in the future as the primary leader in motion control.

The idea is to pull this person into your life and be generous with your time and guidance, and if financially possible sponsor a membership in a fluid power organization to get them involved right away. If this candidate shows exciting promise, then lead them through a training and certification program, and sponsor them for that too. If you don’t think you can afford to help someone bring their talent and innovations to our industry, you will be disappointed when you become that nonessential worker because you didn’t look toward the future.

The U.S. education system is one of the best in the world, but it doesn’t do well at providing vocational and trade opportunities to learn and grow. The formal schools and courses available for fluid power have not been increasing but, in fact, are dwindling. We have been left to our own devices to train people for the industry. We need to help those who have been left behind in our education system and show them there is an alternate route to a successful career. A four-year degree in history might not be useful in the future as a career path, but experience and certification in fluid power will be. You are needed to help fill this education gap, so let’s take advantage of this opportunity and start recruiting.

We will need to think outside of the box when looking for that new person to recruit. Stereotyping a person because of their background or appearance will not help our cause. You must be willing to look at a person’s potential and what they can bring to the industry. We want people with aptitude and a willingness to learn. A person with mechanical or analytic thinking skills will bring new ideas to the industry. Dig a little deeper into that person’s background. What are their hobbies? Custom cars, computers, woodworking?

We are looking for people willing to learn and think on their own. Think outside of your normal recruiting parameters. We are a country of innovation and an ability to make the impossible possible, and you are part of that process!

As my favorite coach, Chuck Knox, would say, “Its go time!”  WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

PROUDLY SERVING THE INDUSTRY FOR OVER 60 YEARS

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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JANUARY 2021

5

FIGURE IT OUT

Filter press 8,000 psi

New Problem Intensifier Drops from Required Pressure after Several Hours

By Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM, CFC Industrial Training

»

Air-over-oil intensifier 100:1 ratio Air supply circuit 85 psi

WE WERE CALLED in to look at a filter press that, when closed, needed to hold 8,500 psi (586 bar) for several hours. Used in various industries, a filter press separates liquids and solids using pressure filtration. A slurry is pumped into the filter press and dewatered under pressure. The press can be used for wastewater treatment in a variety of different industries and applications. Basically, the press is used to squeeze water out of the product waste with pressures as high as 10,000 psi (690 bar).

They did not have a circuit on this machine, which was 25 years old, so the sketch on the left is what I felt the circuit to be.

They described the normal cycle as follows: • They would shift the 4-way directional valve to close the press.

• Pressure was applied using an air-over-oil intensifier to build the pressure up to 8,500 psi (586 bar).

Robert Sheaf has more than • After 8 to 10 hours, the filter media would be fully 45 years troubleshooting, loaded with a cake-like waste material. training, and consulting in • They would shift the directional valve to open the the fluid power field. Email press and unload the caked filter media. rjsheaf@cfc-solar.com • The air-over-oil unit would hold for 1 to 2 minutes before or visit his website at www. cfcindustrialtraining.com. resetting, (the piston would retract), and cycle once again.

The problem they were having was that the pressure applied would hold at 8,500 psi (586 bar), but after 2 to 3 hours, it would start dropping down to 5,000 psi (345 bar) in less than an hour and hold there with the air/oil intensifier cycling constantly. The side of the directional valve stack that included the pilot-operated check module was hot to the touch.

Nothing else showed any hot spots. If the ball valve on the back of the cylinder was closed, the 8,500 psi (586 bar) would start very slowly to decay and reach the 5,000 psi (345 bar) reading after 3 to 4 hours with the intensifier turned off. The cylinder had a small leak path across the cylinder piston.

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JANUARY 2021

Solution to November 2020 problem: Cylinder Speed Increases on a Forming Press Increasing extension speed of a cylinder with meter-out flow controls is normally due to a leaking piston seal. Since the area on the rod side is smaller than the cap end, pressures are higher than the cap, causing it to leak past the piston increasing the cylinder’s extension speed. The cylinder needed to be repaired or replaced.

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Pneumatics Gets a Grip on

ROBOTIC

Communication between the customer and PHD is important at all stages of the design process, particularly when determining space and weight constraints.

Tooling Applications

Pitch-change applications

By John Ross, Vice President of North America Sales, PHD Inc.

The technologies used vary depending on the pitch-change requirements. Some use piston-stroke variations, while another may be a cam or mechanical linkage change. Larger pitch changes require a different style of actuator similar to an accordion design. This type uses linkages between the saddle as the pneumatic cylinder extends. The linkages act as a hard stop for each saddle position until the accordion is 100% open.

Most applications today incorporate both robotic and fluid power components. These two technologies produce the fastest return on investment (ROI) in today’s manufacturing marketplace. When considering robot applications, evaluate how to pick up the product using the robot. This is where many electrical and pneumatic actuators come into the design process.

WE

have solved most types of end-ofarm tooling (EOAT) solutions you can think of on a robot. We use pneumatic grippers to keep the force and momentum high, while keeping the weight down. But this is just one way. Often, we create elaborate designs with pneumatic slides, rotaries, and cylinders. With more and more applications, we find that traditional grippers alone are not going to solve the problem.

The mix of these various product families work like an erector set.

With standard products, you can easily pull from the CAD library and start to layout the concept.

Nontraditional EOAT applications There are instances when we are faced with picking up products from fixed positions when the products are randomly placed or spread out. These applications 8

JANUARY 2021

are opportunities to solve problems for the customer. In these cases, it is important to understand the product and process flow prior to choosing the actuators. Many times, the product pieces will be in lanes with set positions. To get the best ROI, we want to pick up as many pieces as possible per cycle. Here are a few examples of these nontraditional types of EOAT applications.

When picking up multiple pieces of the product each cycle, it is typical to then place them at different spacing. We refer to the device that does this as a pitchchange actuator. Visualize medical vials that must be picked up from lanes and placed with different spacing into a tray. This is where a pitch change must occur. Most of these actuators are designed per application. These special pick heads are designed and built to the customer requirements by PHD’s Unlimited department.

In this example the requirement was to pick up six vials at a time from lanes with 4-millimeter center spacing and then place them into the tray at 8-millimeter center spacing. This would require an actuator that can house six horizontal saddles, each with a mounted pneumatic gripper. The technology used on short pitch change will vary from that of a larger pitch change. We would use an existing slide extrusion to house the pitch-change saddles. Once this is completed, we would mount a gripper onto the saddle, the best gripper and tooling to fulfill the weight and force requirements to grip the vials effectively.

Two examples of pitch-change applications PHD has done in the past are golf-ball packaging, in which the balls were picked up and placed into a sleeve, and the loading of medical vials into trays for automated testing. There are applications that require multiple pitches out of the same actuator. These are typically done with a variable pick head. This would be done with belts and a motor for controlling positions, providing near-zero change-over times between the different product sizes and spacing. These are more complex and higher-priced units, but the payback is there for both the pneumatic and electrical designs.

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Another common application requires picking up several parts at once but placing one part at a time. This is done to reduce the steps the robot takes between the part-picking area and the part placement, increasing the robot’s output. Typically, one part is picked up and delivered to its end location. Picking up multiple pieces at once and placing each at a different location substantially reduces cycle time.

This device creates better ROIs for the entire robot cell.

The primary angular motion is done by known angular gripper-cam technology. The part is picked up, then the cam motion rotates it 90 degrees.

Imagine the gripper fingers at 12 o’clock with the gripper fingers straight up, then the cam moves the finger to 3 o’clock with the fingers facing out. Now you can place eight parts before cycling back to reload from the part pickup location.

Two- and three-jaw designs Recently, PHD’s Pneu-Connect product family was developed as standard end effector packages.

This allows for two- and threejaw designs. It also allows for a combination of one two-jaw and one three-jaw in the same package.

These Pneu-Connect packages are used frequently in the collaborative robot space. The Pneu-Connect package incorporates a control board to communicate to the robot along with built-in valves and switches for each gripper. This is a plug-and-play device. Bolt up to the robot head, connect the cable for communication to the robot, and you are off to the programming stage. One additional feature in the package is the freedrive button, which allows you to press the button on the Pneu-Connect package and move the robot around by hand. This option is not available for all robots.

As more of PHD’s products are used in the robot space, we will continue to develop new ones for the robot market. As industry continues into the automation boom, as I have heard it called, we will be ready for the new challenges the robot market presents. 

In the last example, two grippers are mounted to the robot head opposing each other at 45-degree angles from the vertical center. This configuration is ideal for load-unload applications. The last thing you want is to spend a lot of time loading and unloading. Picture a CNC lathe loading application in which a part has just finished being machined. Gripper A removes the finished part from the CNC chuck, then the robot head rotates gripper B to place the new blank part into the chuck for machining. This maximizes the CNC machine run time each day. The process is optimized. When the CNC door opens, the finished part needs to be removed and the new one placed as fast as possible. PHD has done this type of solution for years.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

JANUARY 2021

9

A L L A B O U T VAC U U M

The Vacuum Cup Holds the Key

By Dane Spivak, Engineering Manager, Davasol Inc.

T

here are countless types of vacuum cup models in existence, and choosing the right one for an application has never been more difficult. The selection process can be overwhelming to say the least. With so many options that can get the job done, what is the best way to determine the ideal fit? It helps to understand the features of a vacuum cup and the purpose behind the designs.

The gripping force generated by vacuum is solely dependent on the pressure over the area, which is the definition of an applied force. Given that most cups are round, this translates to the diameter and vacuum level being the criteria related to the gripping force. Manufacturers usually advertise vacuum cup diameters as the maximum outside diameter (OD) of the cup.

However, when a vacuum cup seals against a surface, the diameter of the applied pressure region is often smaller because the cup lip requires space to generate the seal. Other features may further reduce the area of pressure. The actual area under vacuum pressure is referred to as the effective area. Figure 1 illustrates an example of gripping forces using the OD measurement versus the effective gripping area diameter.

The difference in the measured area based on the OD versus effective area varies with the cup model and how it seals. Some manufacturers publish this data while others rely on built-in safety factors during the system-design process.

Luckily, safety factors in vacuum are usually substantial. Lifting forces in data sheets may vary depending on the use of effective area, vacuum levels, safety factors, and other aspects considered by the manufacturer. It is important to understand how the lifting force numbers are finalized. However, by the laws of physics, cups with the same effective area offer the same vacuum gripping forces.

The bellows of vacuum cups are often used to describe cups since they are a prominent visual feature. Figure 2 illustrates a multiple-bellows cup. Although only one example is shown, cups come with ranging numbers of bellows in all shapes and sizes. Bellows compress the vacuum cup like a spring, which helps the

10

JANUARY 2021

Figure 1: Effective and outer cup diameters.

Figure 2: Compressed bellows, plus lip and web thickness.

Cleats Figure 3: Cleats and final vacuum passage of a vacuum cup.

Final Vacuum Passage

cup seal against uneven or curved surfaces and offers basic machine height compensation. The number of bellows, compression distance, and bellows width allow the cup to compensate vertically and angularly to different degrees. If we consider real-world examples, a flat or single bellows could be used for glass, a single or double bellows could be used on curved molded products, and multiple bellows could be used on packaged product such as plastic bags. Usually more bellows are required as the gripping surface becomes more uneven or inconsistent. Multiple bellows cups could also be used on glass, though they are less stable than a flat or single-bellows cup, so the latter is chosen. A sturdier grip allows for a smoother controlled process and increased cup life. Not to mention, flat cups are comparatively lower in cost. That said, larger or a high number of bellows should only be used if the machine or application benefits from their compensation characteristics.

A pattern among cups is that models with more bellows typically have a thinner lip and web thickness that allow the cup lip to deform to rough or uneven surfaces for a better seal (see figure 2). This is a fundamental design mainly because bellows cups are used on these types of surfaces, though flat and single-bellows cups may offer similar lip features for industry- or application-specific models. While the lip itself generates the seal, bellows help the lip engage with the product surface.

Although they may go unnoticed, internal features of vacuum cups can have a significant impact on the performance, as figure 3 illustrates.

Internal cleats or ribs on vacuum cups provide a clear datum point where the product is held securely. Additionally, they provide increased frictional support for fast lateral movement or gripping in shear. Cup ribs can have specific designs such as channels to enable displacement of oil or liquid on the grip surface. This type of cup feature is popular in the steel-stamping industry, in which oil is present on product surfaces.

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The flow through inner diameter (ID) of a vacuum cup can be insignificant, or it can make or break the system. Refer to the final vacuum passage in figure 3. Cups are mostly designed with fair ID sizes to support enough flow for its particular design. But if the application is high flow, to create a good, efficient seal on the product surface it is crucial to select a cup with an ID that can handle the maximum flow provided by the pump. Conversely, in a system with cups potentially not sealing on the product, it is advantageous to select a cup or cup fitting with a smaller ID to reduce unwanted leakage into the system. More leakage results in a lower final vacuum level.

Figure 4 illustrates two common ways to mount a vacuum cup using a cup fitting. The loose-fitting approach is popular for smaller cups since the cup can be easily replaced by pulling it off the fitting and pressing a new cup onto the fitting. As obvious as it may seem, it is important to replace the cups correctly by pushing and twisting the cup onto the fitting, so they are installed well to maximize their life and performance. Cups with molded fittings are targeted to larger models and heavy-duty use. They are also useful for applications in which there is a significant resisting force against the cups, such as pulling stacked parts out of clamps or molds,

Figure 4: Loose and molded fittings.

or vacuum hold down for machining processes.

The downside is that there is more work and cost involved to replace molded fitting cups since the cups need to be unscrewed to be replaced.

Depending on the manufacturer or cup model, the thread types can differ between NPT, NPSF, BSPT(R), or BSPP(G). Sometimes metric threads are used as well. BSPP(G) is often the preferred thread type for vacuum cups because it uses an O-ring seal that allows the cups to be installedTMat equal heights. Universal threads can also be used because they offer the same benefit.

More information on pipe threads can be found in a tutorial you can access at https://vimeo. com/428544383 or by scanning the QR code.

Applicable machines Number of parts Weight (kg) This article discussed the basic features of EX3600, EX5600, EX8000 16 how x 2062U -to red consider FlangeLock 6.7 vacuum cups and each based on the application.

There are- cap a multitude of4.5cups EX3600, EX5600, EX8000 16 x 2062 that work for most applications. Scrutinizing EX3600, EX5600, EX8000 16 x 2462U - purple FlangeLock 7.7 every feature down to the last detail is unnecessary, butEX8000 selecting and16using an appropriate EX3600, EX5600, x 2462 - cap 6.4size and model has clear value. profession14 x 3262U - blackQualified FlangeLock EX3600, EX5600, EX8000 8.9 4 x 3261U - black & silver FlangeLock als can help find the right cup for an application.

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14 x 3262 - cap 4 x 3261 - cap

9.5

This article is the opinion of the author, Dane Spivak TM EX3600, EX5600, EX8000 20 x 3262U - black FlangeLock 9.9firm BOOMARCHFLGLCK3262 of Davasol Inc., an industrial brand management See a tutorial on pipe threads with many clients. One of Davasol’s clients,Vacuforce LLC, BOOMARCHCAP3262 Boom arch hose cap kit EX3600, EX5600, EX8000 20 x 3262 - cap 11.3 at https://vimeo.com/428544383 based in Indianapolis, partners with the author on this or by scanning this QR code. article. Contact Dane Spivak at dspivak@davasol.com.  Boom arch hose FlangeLockTM kit

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

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• 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 WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

JANUARY 2021

11

I F P S U P D AT E

CELEBRATING 60 YEARS

IFPS Announces Spring Meeting Visit www.ifps.org to register

»

THE INTERNATIONAL FLUID Power Society plans to meet in person next year for its spring meeting, scheduled for March 8-11 at the Embassy Suites San Antonio Riverwalk Downtown in San Antonio, Texas.

SCHEDULE OF EVENTS

Monday, March 8, 2021

Wednesday, March 10, 2021

8:00 AM - 02:00 PM

Technical Workshop

8:00 AM - 12:00 PM

12:00 PM - 02:00 PM

AI Presentations

Meeting

02:00 PM - 05:00 PM

Board Orientation

12:00 PM - 12:45 PM

Lunch (On Own)

6:00 PM - 8:00 PM

Board Dinner

01:00 PM - 04:00 PM

Offsite Tour

06:00 PM - 09:30 PM

Dinner

TE IN A M O !

N NOW

Certification Committee

Tuesday, March 9, 2021 8:00 AM - 9:00 AM

Strategic Planning

Thursday, March 11, 2021

Committee Meeting

8:00 AM - 10:30 AM

Marketing Committee Meeting

9:00 AM - 11:00 AM

Education Committee

10:30 AM - 12:00 PM

Finance Committee Meeting

Meeting

12:00 AM - 12:45 PM

Hosted Lunch

11:00 AM - 12:00 PM

12:45 PM - 02:30 PM

Board of Directors Meeting

Meeting

02:30 PM - 03:30 PM

Strategic Planning

12:00 PM - 12:30 PM

Hosted Lunch

Committee Follow-up

12:30 PM - 01:30 PM

Membership Committee

Meeting (cont)

01:45 PM - 05:00 PM

Offsite Tour

06:00 PM - 07:00 PM

Welcome Reception

07:00 PM - 10:00 PM

Offsite Tour

Membership Committee

The ULTI M hydrau ATE resource motion lic, pneumatic, for control professio and nals

Fluid

ReferPeonwer Handbo ce ok FIR ST

ED ITI ON

IFPS is accepting nominations for its 2021 Fluid Power Hall of Fame awards. The Hall of Fame acknowledges individuals who have made significant contributions to fluid power technology and dedicated their careers to the industry.

Anyone can nominate one living and one deceased individual.

The nominee must have 25 or more years of service in the fluid power industry. Living nominees will be asked to complete an application. A panel of judges will select the inductees, who will be announced on Fluid Power Professionals Day, June 19, 2021.

380 Pages of Must-Have Information

Nominations are accepted until April 15, 2021, and can be made at www. fluidpowerhalloffame.org.

Order by visiting ifsp.org.

12

JANUARY 2021

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

IFPS MEMBERSHIP

October 2020

Newly Certified Professionals

I became an IFPS member in 2004, having been directed by my company to get certified. I brought a few hundred of my colleagues along on the IFPS certification journey! Since then, the IFPS has been an important supporter of me personnaly and our industry.

ENGINEER

Jon Jensen, CFPAI, CFPPS, CFPECS, Energy Conservation Group Manager, SMC Corporation of America

Kirkrai Yuvamitra SYSTEM DESIGNER

Darren Lieser - Graco, Inc. HYDRAULIC SPECIALIST

Sarah Gaehring - Airline Hydraulics Corp John Hilton Hannah Kendrick - Airline Hydraulics Jeremy Shubert - Controlled Motion Solutions MOBILE HYDRAULIC MECHANIC

Mark Altieri - Duquesne Light CO Shawn Bittinger - Duquesne Light CO James Bowers - Altec Industries, Inc. Joshua Clarke - Altec Industries, Inc. Steven Courtney - Altec Industries, Inc. Courtney Deacon - Altec Industries, Inc. Earl Foley - Altec Industries, Inc. Scott Ford - Altec Industries, Inc. Jack Gibson - Altec Industries, Inc. Joseph Hamilton - Altec Industries, Inc. Michael Hegstad - Altec Industries, Inc. Tyler Huss - Altec Industries, Inc. Michael Krieble - Altec Industries, Inc. Andrew Kutcher - Altec Industries, Inc. Gene Leyk - Altec Industries, Inc. John Mathews - Altec Industries, Inc. Jerry McClain - Altec Industries, Inc. Daniel Muncy - Altec Industries, Inc. Brian Perston - Duquesne Light CO Michael Sanford - Duquesne Light CO Robert Smith - Duquesne Light CO Timothy Smith - Altec Industries, Inc. Jesse Tuck - Altec Industries, Inc. Steve Valent - Duquesne Light CO

WE’VE GOT THE COMPONENTS. HYDRAULIC PUMPS. MOTORS. VALVES. SERVO VALVES. PROPORTIONAL VALVES. PARTS. Unmatched inventory of replacement units ready to be put to work from manufacturers like: Abex, Atos, Bosch/Racine, Continental, Denison, Eaton, Kawasaki, Linde, Moog, Oilgear, Parker, Rexroth, Schenck Pegasus, Staffa, Sundstrand and Vickers. Fast shipping and industry-leading warranty—purchase with peace of mind. Make Hydraulex your first call when you need replacement hydraulic components for your equipment.

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JANUARY 2021

13

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: March 2021 Tuesday 3/2 • Thursday 3/25 April 2021 Tuesday 4/6 • Thursday 4/22 May 2021 Tuesday 5/4 • Thursday 5/20 June 2021 Tuesday 6/1 • Thursday 6/24

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

14

JANUARY 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 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

Tentative Certification Review Training In-house Review Training – an IFPS Accredited Instructor will come to your company (minimum 10 individuals) HYDRAULIC SPECIALIST CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details March 23-26, 2021 - Fairfield, OH - CFC Industrial Training | Written test: March 26, 2021 September 13-16, 2021 - Fairfield, OH - CFC Industrial Training | Written test: September 16, 2021 PNEUMATIC SPECIALIST Onsite review training for small groups – contact kpollander@ifps.org for details July 27-29, 2021 - Fairfield, OH - CFC Industrial Training | Written test: July 29, 2021 ELECTRONIC CONTROLS CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details August 9-12, 2021 - Fairfield, OH - CFC Industrial Training | Written test: August 12, 2021 CONNECTOR & CONDUCTOR CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details 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 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 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 Onsite review training for small groups – contact kpollander@ifps.org for details June 14 - 16, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: June 17, 2021

INDUSTRIAL HYDRAULIC TECHNICIAN 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 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 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 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.

JANUARY 2021

15

COVER STORY

LIFTS

D E D N E T E IN R U T A N E K I L S P I AN D G R

Inherent flexibility and the low dead weight allow the BionicSoftArm to be used without a protective cage.

JANUARY 2021

, Head

äfen ne von H

By Karoli

Like its two predecessors – the Bionic Handling Assistant (2010) and the BionicMotionRobot (2017) – the Festo BionicSoftArm robot’s movements and functionality were inspired by the elephant’s trunk. Whether supple and gentle or powerful and dynamic, elephants can not only lift heavy loads with their trunks and move them flexibly, they can also grip objects sensitively and precisely.

With its pneumatic bellows structures, the BionicSoftArm effortlessly masters the flowing motion sequences of its natural role model. Depending on the desired action, the robot’s pneumatically powered bellows can freely bend. The bellows are sheathed with an innovative 3D-printed textile knit fabric that allows expansion of the bellows structures in the desired direction of movement while simultaneously limiting movement in the opposite directions, which in effect creates

16

DHAS adaptive gripper fingers conform to odd shapes and were inspired by the behavior of the fishtail fin.

cts, Festo

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rate Bio of Corpo

the point of pivot in a nonmechanical hinge.

The BionicSoftArm is one of the latest developments of the Festo Bionic Learning Network, an initiative to further industrial design by looking to nature for inspiration.

The natural-looking movements of the BionicSoftArm robot create a sense of familiarity for the user, which can increase acceptance for a collaborative work environment. In the event of a collision, the pneumatic kinematics automatically ease off. This inherent flexibility and

The biomimicry derived chameleon tongue gripper, the DELP, folds its silicone cap over objects of virtually any shape.

the low dead weight allow the BionicSoftArm to be used without a protective cage.

Depending on the requirements, the arm’s length can be altered by adding or subtracting modular pneumatic sections. As many as seven degrees of freedom are possible with the BionicSoftArm. The robot can move around obstacles and work in tight spaces, giving it an exceptional work envelope.

Paradigm shift in robotics The strengths of pneumatic drives have always been their robustness, low cost of acquisition, and high power density. These attributes enable pneumatics to apply comparatively high forces with a low dead weight.

The kinematics make it easy to adapt the BionicSoftArm to various tasks and locations within a production environment. The elimination of costly safety devices such as cages and light barriers shorten and simplify installation. The BionicSoftArm points the way toward cost-effective alternatives to classic robots and fits the needs of a collaborative work environment.

The BionicSoftArm is operated intuitively via the Robotic Suite, a graphical user interface that was developed specifically for lightweight robots. With a tablet, the user can easily teach actions and set parameters. Defined work steps can be arranged in a time line.

Sequence changes are as simple as dragging and dropping the step to another position of the workflow.

Targeted motion dynamics The pneumatic bellows are made of sturdy elastomer. Each bellows is covered with a 3D-printed textile featuring a two-layer knit fabric. The fibers are oriented so that the bellows can expand in the direction of movement while resisting movement in the opposite direction. The hoses for airflow are positioned on the outside of the robot so that they

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Key systems of the soft arm.

The main sections of the motion terminal. do not disturb movement or become constricted when the arm moves. A textile cover pulled over the arm protects the tubing from damage and keeps it in place.

The control and regulation of complex kinematics is made possible by the Festo motion terminal, the world’s first cyber-physical pneumatic-motion-control system. The motion terminal’s digital valves change functionality based on various combinations of downloadable motion apps. Through the internal control algorithms of the motion apps and the piezobased valves, flow rates and pressures can be exactly dosed and also varied to any setting in multiple channels simultaneously.

Every part of the robot is considered a model, and position control is achieved through modeling. The required parameters are either calculated or determined using parameter identification. The necessary control algorithms run in real time. The condition of the BionicSoftArm is monitored continuously through pressure and absolute position sensors.

The robot operating system (ROS) is an open source platform for calculating the kinematic path. ROS provides the interface between the tablet and the motion terminal. The ROS also interprets the incoming code from the tablet and forwards the resulting axis coordinates to the motion terminal. On the basis of these coordinates and the incoming sensor data, the motion terminal controls the respective pressure in the pneumatic actuators and thus determines the positions of the individual segments and axes.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

BionicSoftHand uses artificial intelligence to learn how to manipulate a polygon so that a specified color comes out on top.

Adaptive grippers The range of applications of the modular robot arm can be further expanded by combining the BionicSoftArm with various grippers with designs also inspired by nature. These grippers were designed to provide the widest possible adaptivity to a variety of objects and shapes.

The BionicSoftHand, for example, consists of flexible pneumatic bellows structures and soft materials. The BionicSoftHand not only grips but can also manipulate objects similar to the way a human hand does. It learns manipulation through artificial intelligence and was developed through the Bionic Learning Network.

Thanks to its modular design, there are BionicSoftHand variants with three or four fingers that function like soft pincers.

The biomimicry-inspired chameleon tongue gripper DELP and fish-fin grippers DHAS are former Bionic Learning Network projects that have since been commercialized.

The BionicSoftArm is the synthesis of a design inspired by nature and the latest control technology and 3D-printed materials. This innovative robot illustrates how fluid power is evolving in the 21st century and points the way to future developments.  JANUARY 2021

17

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AGI’s Gripper/Rotary Pre-Assemblies AGI’s Gripper/Rotary Pre-Assemblies AGI’S GRIPPER/ROTARY PRE-ASSEMBLIES

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CLIPPARD CORDIS ELECTRONIC PRESSURE CONTROLS Precise, linear pressure control within a closed-loop system with ultra high resolution and repeatability.

Clippard’s Cordis is a revolutionary microcontroller primed for escape velocity from a proportional control market. Built with the highest quality Clippard EVP and DVP proportional valves at its heart, the Cordis is designed to outperform the competition in every way. 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 pressure control has arrived, and it’s digital. Made in the USA.

For further information on the Cordis Pressure Controls or any of Clippard’s line of electronic and pneumatic valves, visit www.clippard.com.

Proudly made in the USA.

18

JANUARY 2021

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SPECIAL AD SECTION

COMPONENT SHOWCASE AMERICAN-MADE COMPONENTS—READY TO SHIP Know what you’re getting and when you’re getting it.

Our component parts are proudly American-made with domestically sourced materials.

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RAM Smart Sensing hydraulic cylinders incorporate position sensing technologies for OEM equipment in any RAM single stage hydraulic cylinder. RAM Industries has the expertise designing and manufacturing smart sensing hydraulic cylinders with a variety of digital and analogue outputs. External or internal sensors can be incorporated depending on the use of the cylinders. An assortment of bore sizes, stroke lengths, and mounting options can be configured to meet your overall design and industry needs.

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RAM Industries Inc. 877-799-1005 www.ramindustries.com estimating@ramindustries.com JANUARY 2021

19

A variety of factors, such as a desire for higher efficiency, are driving manufacturers and hydraulic equipment operators toward robotic equipment. Agricultural robots, including tillers, harvesters, weed sprayers, and pruners, have led the way. But robots for assembly lines and warehouses are quickly gaining traction.

Assembly and transport robots used in manufacturing and warehousing operations usually combine hydraulic systems with electric or pneumatic ones. The reason for this is the weight of the loads.

Although electric systems eliminate the need for hydraulic fluid and generate more accurate motion, they can’t compete with hydraulic systems when the task involves moving heavy loads repeatedly for long periods, which is often the case in automotive and other heavy-equipment manufacturing.

Manufacturers, therefore, turn to hybrid robots in which hydraulics do the heavy lifting and an electric or pneumatic system does the clamping and holding. Being more easily retooled and repositioned, the electrics and pneumatics also increase system flexibility.

Hybrid hydraulic and electrical designs require special care when specifying hydraulic sealing systems because weepage of even a light coating of hydraulic fluid can negatively affect an electrical system’s performance, while indoor environmental factors, such as humidity and dust, can be detrimental to the operation of hydraulic systems.

But as this article shows, the design of systems in hybrid robots can reduce aerosolization of hydraulic fluid and mitigate the effects of humidity, ozone, and dust in the environment.

20

JANUARY 2021

Preventing weepage In traditional hydraulic systems, including many current agricultural applications, a small amount of fluid escape from hydraulic cylinders is acceptable. This is referred to as “weepage” to distinguish it from a fluid drip that indicates a leak. In hybrid robots, however, weepage can be problematic.

The solution to this issue is an extremely robust zero-leakage sealing system. These systems prevent hydraulic weepage from becoming aerosolized and coating the electric components of the robot or escaping into an environmentally sensitive area.

The design of systems in hybrid robots can reduce aerosolization of hydraulic fluid and mitigate the effects of humidity, ozone, and dust in the environment.

Zero-leakage sealing systems employ a highly sophisticated form of lubrication management that ensures the rod remains properly lubricated but reduces or eliminates weepage. The systems typically consist of two or three elastomer slipper seals that keep the shaft dry on the outside, while properly lubricating the shaft to ensure performance and durability.

Wipers and bearings Zero-leakage sealing systems frequently contain a single- or double-acting wiper. A single-acting wiper wipes off the rod as it re-enters the system to prevent contaminants from entering the back-pumping area of the system.

A double-acting wiper, in addition to wiping the rod, contains a U-cup seal to trap the small amount of fluid that may escape from the seal in front of it, keeping it in the system.

Good zero-leakage systems also employ bearings to improve alignment, relieving the seals of this function. The bearings enable the seals to function more efficiently and are often used in systems in which load or side load are a factor.

For example, a sealing configuration located at the end of a rod cylinder might consist of a U-cup seal, bearing, polytetrafluoroethylene (PTFE) seal, another bearing, and a final seal.

The bearings ensure proper alignment, enabling the seals to remain centered and provide maximum sealing effect.

Indoor environments For hybrid robots designed to operate indoors, humidity is problematic when levels are high enough to cause moisture to collect and enter the system. Water can quickly contaminate hydraulic fluid, potentially causing system failure.

The solution to this is two-fold. First, a high-quality, durable wiper will keep out as much moisture as possible. Second, if possible, a change to the system orientation will reduce the chance that water pools on the rod. To ensure WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

hydraulic-fluid drainage in a vertical hydraulic system, rather than the rod exiting the system at the top, the rod should be oriented to exit at the bottom.

If reorienting the rod is not an option, consider specifying a specialized wiper designed to push water away from the rod. In this case, the moisture that collects and drips down the shaft hits the wiper and deflects away from the system.

Environments like warehouses are extremely dusty, and dust can potentially contaminate a hydraulic system to the point of performance reduction or failure. Robots picking inventory from shelves, placing boxes on pallets, or transporting pallets are especially susceptible to dust-related issues.

A double-wiper sealing system containing standard pressure seals with a wiper, then an auxiliary cap with a second wiper, can mitigate such issues. Designed to be a robust initial barrier to ingress of dust, the second wiper does not contain a lip to retain fluid. Any small amount of fine dust particles getting past this wiper and entering the system are then cleared by the inner wiper.

Zero-leakage sealing systems are key to preventing small amounts of hydraulic fluid emission during a robot’s operation. This fluid can become aerosolized and cause damage or other issues of accuracy, quality, or performance by coating nearby electronic components. Specialty sealing configurations can ensure water and dust do not contaminate the hydraulic system.

Designers should consult with their seal suppliers about material and seal selection to achieve the ideal combination of seals, wipers, and bearings to maximize the performance of a hybrid robot. 

Selecting seal material Mitigating the effects of ozone is a matter of careful seal-material selection. Even in small amounts, ozone can cause rubber seals to crack. If a hybrid robot is exposed to ozone (e.g., from a nearby welding operation), choose an ozone-resistant material such as ethylene propylene diene methylene or fluorocarbon to prevent ozone damage.

Stick slip may occur in hydraulic systems running at low speeds. Therefore, hybrid robots designed to perform short, precise movements at slow speed may encounter this phenomenon.

Using PTFE seals rather than rubber can alleviate this issue because of their low-friction attributes.

Some hybrid robots require an alternative to traditional hydraulic fluid. For example, a robot performing a mining task near a river or other water source requires a biodegradable fluid to eliminate the possibility of hydraulic fluid entering the water in the event of a catastrophic failure. These environmentally friendly fluids need chemically compatible sealing to prevent premature wear or even failure. Sealing suppliers can help recommend the appropriate seal material for such applications.

Although electrical systems can be extremely advanced and play an important role in robotic equipment, hydraulic systems are still the best solution for consistently moving heavy loads.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

JANUARY 2021

21

SPECIAL AD SECTION

HITACHI FLANGELOCK AND CAP KITS AVAILABLE

PRODUCT SPOTLIGHT

TM

Part number

Part description

Applicable machines TM

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EX3600, EX5600, EX8000

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Travel circuit cap kit

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Number of parts

Weig TM

16 x 2062U - red FlangeLock 16 x 2062 - cap

4 TM

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14 x 3262U - black FlangeLockTM EX3600, EX5600, EX8000 TM kit pneumatically actuated angle 4 x 3261U - seat black & silver FlangeLockTM FlangeLock Zeus 2-way

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The of the piston unique 20 tox the EX3600, EX5600,is EX8000 3262U - black FlangeLock 9 BOOMARCHFLGLCK3262 M3 series-Heavy Duty Multi-Stage Air Cylinders, market, enabling the plug to retract farther from the 3.25” Bore to 10” Bore, strokes 1/4” to 8”.

BOOMARCHCAP3262 Boom arch hose cap kit EX3600, EX5600, EX8000 20 x 3262 - cap 1 flow path, ensuring the highest flow capacity. The All NFPA mountings available, even the ME5 dual packing design, and a large diameter selfrectangular head mount. These cylinders have CONTAMINATIONaligning CONTROLstem insures the highest cycle life. Over 5 a High Flow design, which allows a fast cycle Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavat cycles been achieved.machine downtime, it can also expose the hydraulic maintenance plays themillion largest role in the have prevention of unnecessary rate. Using multiple pistons in the extend stroke TM

to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is so

to increase force in a small foot print. Theyoverlooked also when performing This competitively valve maintenance due topriced incorrectangle practices beingseries used. is save air consumption on every cycle by retracting available in 3/8” to 2” with NPT & Tri-clamp end ™ TOOL AND CIRCUIT BLANKING CAPS with a single piston. All seal are heavy dutyTHE FLANGELOCK Body contamination available incontrol bronze The FlangeLock™ tool connections. and caps are the ultimate toolsor for 316SS. protecting your hydraulic system. The Flan special Urethane, we also offer bumper seals infor the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange con allows Visit our unique valve configurator to build, view, price ™ this special Urethane. Custom designs canEasy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock tools a stop the mess. or order your valve package easily and quickly online. be done on request.

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23

TEST YOUR SKILLS

SIZE

A ROTARY ACTUATOR

inside the bladders doesn’t come in contact with the mechanism inside the housing, it Rotary actuators are used to provide a partial rotation or pivoting action to a is not sensitive to contamination that may component where the space available is not practical for a cylinder and mechanbe present. The bladder must, however, be compatible with any material that may be ical linkages to achieve the rotational movement. Rotary actuators are used for used as a lubricant. rotating, mixing, opening and closing, toggle clamping, providing constant tension, Sizing a rotary actuator is similar in conbending, oscillating,Stransferring dumping, and indexE L E C T and C Oflipping, M P O Npositioning, ENTS FO R PNE UM AT I C Scept Y Sto TE MS sizing any linear actuator. The first ing operations. They rotate from a few degrees to several complete revolutions, step is determining the torque and amount of rotation required. The torque requirement although most commonly they are less than 360˚ of rotation. come 3.17: Size a rotary actuator. is in two parts: breakaway or starting torque as well as running torque of the application. y actuators are used to provide a partial rotation or pivoting action to a component where the space There are five major design types of rotary high degree of accuracy and is therefore used Once that is known then a specific type of ble is not practical for a cylinder and mechanical linkages to achieve the rotational movement. Rotary actuator can be selected. For example – a rackactuators (figure 1): mixing, opening and closing, in many precision applications. providing constant tors are used for rotating, toggle clamping, tension, and-pinion double-acting assembly is shown A less commonly found rotary actuator is • Helical spline. ng, oscillating, transferring and flipping, positioning, dumping, and indexing operations.

They rotate in figure 2 on a bladder type. does offer some • Enclosed pistoncomplete crank. a few degrees to several revolutions, although mostIt commonly theyinherent are less than 360˚ the of next page. advantages due to its design and operational The torque is a function of two pneumatic • Scotch yoke. on. characteristics. It operates on the principle of cylinders exerting a force on the pinion shaft • Rack-and-pinion. are five major design types of rotary actuators (Fig. 3-27): a pair of bladders in a housing that act against gear teeth. That force acting over the radius of • Piston-and-chain.

Helical spline. a lever arm to develop torque and rotary the gear pitch is the torque generated. Since • Bladder.

Enclosed piston crank.

Each of the types have key design features motion. Rotary motion is limited (typically two cylinders are exerting force at the same Scotch yoke. and operational characteristics that would dic- to 100˚ or less because of the design) and the time, the effective torque is doubled.

Rack-and-pinion. ial rotation or pivoting action to a component where the space tate where they are most appropriately applied. amount of torque that can be produced is The amount of rotation desired determines Piston-and-chain. mechanical linkages to achieve the rotational movement. Rotary For example – the Scotch yoke design provides less than from the other actuator types men- what the effective stroke length of the cylinders ening clamping, veryclosing, high at the beginning andand endproviding of tioned. Itconstant does offer thetension, advantage of the and types havetorque keytoggle design features operational characteristics that of having needs to be. Once that is known, the peak air positioning, dumping, and indexing operations.

They dg, dictate where they are most appropriately applied.

For example – the stroke (approximately double that of the running zero internal leakage androtate thus is extremely flow as well as air consumption rate can be calh yoke design provides very torque at the beginning andthan end of stroke torque), which is advantageous when the applicaaccurate.

Additionally, because the volutions, although mosthigh commonly they are less 360˚ of medium culated as can be done for any cylinder. oximately tion double that ofamount the running torque) requires a high of breakaway torque which is advantageous when pplication requires high amount breakaway to start andaaccelerate the load.of Any mechanical torque to start and accelerate oad. Any device mechanical device that employs gearing of some type must take that employs gearing of some type must actuators the (Fig. 3-27): onsideration effects of backlash during operation and size appropriately. take into consideration the effects of backlash during operation and size appropriately. fficiencies of the different types are comparable in range but the amount of The efficiencies of the different types are t torque and rotational capability differs between them. Because the rackcomparable in range, but the amount of output inion design typically offers the highest torque capability as well as degrees and rotational capability differs between ation (50 torque million lb-in of torque capability and 1,800˚ of rotation), it is one them. Because the rack-and-pinion design typi-the benefit of fail-safe holding e most commonly applied.

It also provides cally offers the highest torque capability as well bility, constant torque in each direction, and ability to withstand heavy side or es and operational characteristics thatand is therefore used in many as degrees of rotation (50 million of lb-in of torque oads.

It can provide a high degree accuracy capability and 1,800˚ it is one the priately applied.

Forof rotation), example –ofthe sion applications. most commonly applied. also provides the ue at the beginning and Itend of stroke (f) Bladder commonly found rotary actuator is a bladder of fail-safe holding capability, constanttype. It does offer some inhertorque)benefit which is advantageous when dvantagestorque due to its design and in each direction, andoperational ability to with-characteristics. It operates on eakaway torque to start and accelerate rinciple ofstand a pair of bladders in a act against a lever arm to Figure 1: Rotary actuators. heavy side or end loads. It housing can providethat a Fig. 3-27

T C O M P O N E N T S F O R P N E U M AT I C S Y S T E M S

actuator.

ploys gearing of some type must takeis limited (typically to 100˚ or op torque and rotary motion.

Rotary motion ecauseoperation of the design) and the appropriately. amount of torque that can be produced is less uring and size

Rotary Actuators

from the other actuator types mentioned. It does offer the advantage of having zero internal leakage 24 JANUARY 2021 WWW.FLUIDPOWERJOURNAL.COM hus is extremely accurate. Additionally, because the medium inside the bladders doesn’t come in con-

omparable in range but the amount of

• WWW.IFPS.ORG

tionally, because the medium inside the bladders doesn’t come in cone the housing, it is not sensitive to contamination that may be present. patible with any material that may be used as a lubricant.

n concept rst step is of rotation is in two as well as Once that tuator can and-pinion . 3-28.

2 in. pitch radius

Hydraulic S E L E C T C O M P O N E N rT S F O R P N E U M AT I C S YLive S T ESwivels MS

Inline & 90°

Heavy Duty Ball Bearing Design

The amount of rotation desired determines what the effective stroke length of the c Once that is known, the peak air flow as well as air consumption rate can be calculate any cylinder. 4 2

psi Eq. p = pressure psi P rackT ==ppressure • Ap • rpgMPa • Cn Ap = Area offrom cylinder piston in2 3.20 • Cnthe Arotary and-pinion of cylinder = Area of cylinder piston 2 put from actuator is apiston function ofApthe pinion gear radius, cylinder bore, air p • rpg p = Area in2 mm rpg = radius of pinionand gear rotary actuarpg = radius ofAs pinion rpg = radius of pinion gear in gear pneumatic motors, the it inis hat: in Cnmore =mnumberdifficult of internal cylinders Cn = number of internal cylinders Cn = number of internal cylinders tor.

cutting theMPa overall cost

® Switc h Your Swivel® Switch Your Swivel

umatic cylS E L E C T C O M P O N E N T S F O R P N E U M AT I C S Y S T E M S 2: Rack-and-pinion Oshaft M P Ogear N E N T S Figure FOR P N E U M AT I C S Y S T E M S SEL rotaryThe actuator.torque output from the rotary actuator is a function of the pinion gear radius, c 5 1 3 dius of the The such amountthat: of rotation desired determines what the effective stroke length of the cylinders needs to be.

Sincedesired two determinespressure tation what3-28 the effective stroke length of the cylinders needs to be.

Fig. Rack-and-Pinion Rotary Once that is known, the peak Actuator air flow as well as air consumptionAvailable rate can be calculated as can be done for ame wn, thetime, peak air flow as well as air consumption rate can be calculated can be done for The torque output from any the rotary actuator is a function of the pinionas gear radius, cylinder In BSPP cylinder.

T = Torque Nm T = Torque lb-in andFair C O M P O N Ebore, NTS Opressure R P N Esuch U Mthat: AT I C S Y S T E M S SEL The torque output from the rotary actuator is a function of the pinion gear radius, cylinder bore, and air p = pressure P = pressure Simplified hose configuration,MPa psiair Specialist Certification • 3 -and 51 t from the rotary actuator isEq. a function Pneumatic of the pinion gear radius, cylinder bore, pressure such that: T = p • A • r • C A = Area of cylinder piston A = Area of cylinder piston 2 at: p pg p lessinhose andpadapters combine rotation desired determines3.20 what the effective stroke length n of the cylinders needs to be. rpg = radius of pinion gear in rpg = radius of pinion gear m own, the peak air flow as well as air consumption rate can be calculated as can be done for reduceNm repairs and downtime T to = Torque T = Torque lb-in Torque output = number of internal cylinders internal cyli T = Torque Nm T = Torque lb-in Torque output p C = npressure P = pressure Cn = number of from rackAp = Area of cylinder piston mm2 and-pinion rotary actuar of = hydraulics. radius of pinion gear m toCpgnget an object start tor. to rotate, = number of internalto cylinders

to get the object to stop once in motion. This is due to the inertia that exists. The

t

No Kinks No Hose Twisting

T = Torque T = Torque lb-in As in pneumatic motors, difficult it is output to get an object to start to rotate, the more difficult it is Torque Nm the more (kinetic is a function the moment motors, the more is to getenergy) an object start to rotate,of the more difficult it of is inertia of the object being rotated and p in = difficult pressure itpsi Pobject = to pressure from get thedifficult totostop intomotion.

Thisrackis more due to the inertia that exists. The energy that develops As pneumatic motors,tothe more it is get anonce object start to rotate, the MPa to in This is due to 2the inertia that exists.

The energy that develops Ap stop • rpg •once Cn and-pinion Apmotion. = Area of(rotational cylinder piston A = Area of cylinder piston 2 speed). isis of too topic to object fully being describe but the velocity kinetic p mm (kinetic energy) is aThat function moment of a inertia of the rotatedhere and the angular difficult it is to get the object toinstop in motion.

This duethe tocomplex the inertia that exists. s a function of moment of inertia the once object being and the angular velocity rotary actuarthe gearof rpg = radius of rotated pinion gear pg = radius of pinion (rotational in m speed).

That is too complex a topic to fully describe here but the kinetic energy must be dissipated safely or damage may occur.

Another possible method to minimize the amoun The energy that energy) anumber function of thekinetic moment of inertia of thebe object tor.

C = number of internal cylinders C is=here internal cylinders ). That is too complex a develops topic to (kinetic fully describe but of the energy must dis-

n n or damage may occur. Another possible method to minimize the amount of rotational kinetic sipated safely rotated and the angular velocity (rotational speed).

That is tooand complex a topic to fully energy that can be generated needs to be dissipated, is to use an air-over-oil r damage maybeing occur.

Another possible method to minimize the amount of rotational kinetic energy that can be generated and needs to be dissipated, is to use an air-over-oil rotary actuator which describe here, but the kinetic energy must beuse dissipated safely or damage may occur.

Another c motors, the moreneeds difficult it is to get an object to start to rotate, the more difficult it is be generated and to be dissipated, is to an air-over-oil rotary actuator which can allow for for damping.

Typically, kinetic energy would Inbe usingwhich a sho can allow damping. Typically, the the kinetic energy would be •dissipated using absorber, is Available 304dissipated & a440shock Stainless Steel ct to stop once inthe motion. is due the thatkinetic exists. energy develops mping.

Typically, kinetic energy would be inertia dissipated using a The shock absorber, which possible method toThis minimize the to amount of rotational energy that can bethat generated andis covered in Outcome3.18.

3.18. covered in Outcome ) is 3.18. a function of the moment ofisinertia ofair-over-oil the objectrotary being rotated andcan theallow angular velocity me needs to be dissipated to use an actuator, which for damping.

• Rated To 10,000 P.S.I. ed). That is Typically, too complex a topic to fully describe here but the kinetic energy must be disthe kinetic energy would be dissipated using a shock absorber.

The formula for calculating the kinetic energy generated is Eq. • 3.21: Custom Design & Sizes Available r damage may occur. energy Anothergenerated possible method to minimize the amount of rotational kinetic alculating the The kinetic Eq. 3.21: formula for calculating theis kinetic energy generated is:the kinetic energy generated is Eq. 3.21: The formula for calculating n be generated and needs to be dissipated, is to use an air-over-oil rotary actuator which • Rebuildable Ball Bearing Design Kineticabsorber, energy ft-lb E= Kinetic energy amping. Typically, the kinetic energy would be dissipated usingE a=shock which is Joules Kinetic energy E = Kinetic energy ft-lb E = Kinetic energy Joules Kinetic energy ome 3.18.

I = Moment of inertia kslugsft2 I =• Full Moment of—Low inertia kgm 2 1 Eq. developed 2 Flow Pressure Drop I = Moment of inertia kslugsft2 IE= =Moment 2 Kinetic • I •of ω inertiaωkgm developed E= = energy E = Kinetic energy ft-lb ω = Angular velocity Joules 3.21 by rotational Angular velocity (rotational (rotational I • ω2 2 by rotational = Angular = Angular velocity (rotational calculatingωthe kinetic velocity energy (rotational generated is ωEq. 3.21: • Superior Quality Alloy Steel force/torque.

I = rad/sec Moment of inertia kslugsft 2rad/sec I = Moment of inertia kgm2 speed) speed) Eq. force/torque.

2

speed)rad/sec

3.21 E = Kinetic energy

ft-lb

• I •ω

2

I = Moment of inertia

1 E =speed)•rad/sec I •ω • Side Load Resistant ω = Angular velocity (rotational ω = Angular velocity (rotati E2 = Kinetic energy Joules Kinetic energy

kslugsft2

I = Moment of inertia

developed speed) kgm2 rad/sec

ω = Angular velocity (rotational

ω = Angular velocity (rotational

speed)rad/sec

speed)rad/sec

by rotational force/torque.

TEST YOUR SKILLS What is the total torque produced on the pinion gear shaft of a dual cylinder rotary actuator that has twin bore diameters of 25 mm each and a pitch radius of 50mm? The supply pressure to the rotary actuator is 0.7 MPa. a. 17.18 Nm. c. 34.36 Nm. e. 54.63 Nm. b. 24.54 Nm. d. 49.08 Nm.

• Heat Treated speed)rad/sec

Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423 Email: sales@superswivels.com

Review What is the total torque produced on the pinion gear shaft of a dual cylinder rotary 1-763-784-5531 See page for 3.17.1: the solution. : What is the total torque produced on31the pinion gear shaft of a dual cylinder rotary actuator that has twin bore diameters of 25 mm each and the pitch radius is 50mm? The supply preswww.SuperSwivels.com as twin bore diameters of 25 mm each and the pitch radius is 50mm? The supply pressure to the rotary actuator is 0.7 MPa. ry actuator is 0.7 MPa. a. 17.18 Nm. Nm. b. 24.54 Nm. Nm.What is WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM JANUARY 2021 25 .1: the total torque produced on the pinionNm. gear shaft of a dual cylinder rotary c. 34.36 Nm.twin bore diameters of 25 mm each and the pitch radius is 50mm? The supply preshas

The Right Hydraulic Fluid Reduces

Studying a heat map of the operation will show how temperatures in many areas can reach between 400°C (752°F) and 700°C (1292°F). In most of these processes, hydraulic units are used to operate the equipment.

A mineral-oil-based hydraulic fluid is often chosen to operate these hydraulic units, a choice based on the definite advantage of a good cost-performance ratio. Yet a clue to the danger lies in the name: such fluids are a distillate from crude oil and not always the safest choice due to their tendency to catch fire easily.

Oil-based hydraulic fluid risks

Risks in Aluminum Plants

By Ronald Knecht, Global Strategic Product Line Manager, Hydraulics & Lubricants, Quaker Houghton

Whatever the manufacturing facility, a fire is among the worst accidents that can take place. The most obvious harm is the death or injury of employees. Beyond that, there is always likely to be a loss in both capital and production. These losses not only include damage to the building and equipment but also the immediate interruption in production, which might see lines idle for days or even months.

S

uch dangers are inherent within the aluminum production and manufacturing process, given the fundamental requirement for significant heat to produce the finished products. Fire hazards at just about every stage of the process requires a “safety first” approach throughout. Beyond the obvious approaches toward cooling, eliminating oxygen, removing fuel, or breaking potential chemical reactions, there’s one aspect that is relatively neglected: the use of combustible hydraulic fluids across the factory.

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Consider where hydraulic fluids are used and might come into contact with hot surfaces or materials, and you’ll quickly realize that many fire hazards exist in aluminum plants. This includes areas such as the heating or melting furnaces, billet or slab casting, or hot strip mills.

For example, most furnaces in the aluminum industry are operated using hydraulic power for moving the slabs and for opening or closing doors. And around an aluminum hot strip mill, several processes are driven by hydraulic power, like the automatic gauge control system.

The presence of hydraulic hoses or components near a hot slab or aluminum strip is a clear risk, with the potential to cause uncontrollable fires if a hydraulic hose bursts

or leaks, resulting in significant damage or downtime.

It is the ignition of mineral-oil-based hydraulic fluids that can lead to a fire. There are two main causes for this type of ignition: firstly, where the lubricants spill or leak onto a very hot surface and, secondly, when hot liquid metal or sparks land in a pool of lubricant.

The problem is that the mineral oil evaporates easily and tends to build a vapor of oil droplets. Once ignition takes place, these oil droplets can catch fire and result in an explosion or fire ball. The resulting fire can travel quickly to the roof or to cables and ignite other areas of the factory, making it hard to control.

The science behind the ignition is simple but has worrying implications. Essentially, a hydraulic fluid derived from mineral oil combines three chemical properties which, in conjunction, make a fire more likely: a relatively low specific heat, a relatively low auto-ignition point, and a high heat of combustion.

In other words, it does not take much energy to heat mineral-oil-based lubricant to the temperature at which it will auto-ignite, which is also relatively low. At that point, the fluid combusts at a heat of about 43-44 kJ/g, causing a swift catalysis for explosive ignition and propagation of the flames. The mineral oil’s properties also mean it has the ability to keep itself burning.

Choosing a fire-resistant fluid Fortunately, there are alternatives to mineral-oil-based hydraulic fluids, but make a careful analysis of their relative properties before choosing a replacement. The first consideration, of course, is the level of fire resistance. The term "fire resistant" is often thought to mean the same as "fire retardant," but they are not the same thing. Almost all fire-resistant hydraulic fluids will burn under certain conditions.

So why choose a lubricant that is only fire resistant rather than fully retardant? Other factors come into play here. One obvious point of difference is the cost of switching to an alternative hydraulic fluid.

Some will likely be more expensive than others, not only in the actual fluid price but in the potential impact on existing equipment.

Component life and operational reliability may need to be changed to suit a change in fluid. Consider instead the total cost of operation, comparing both upfront and ongoing costs to the long-term value derived from reduced fire risk.

The other element to investigate is the environmental impact of any hydraulic fluid. This might refer both to how a lubricant is sourced or manufactured, whether it is biodegradable, or whether any harmful chemicals are released on combustion.

By triangulating these oftenconflicting demands – cost, environmental impact, and level of protection – along with system reliability, it is possible to strike the optimum balance to protect productivity and profitability while managing an appropriate level of risk. If in doubt, it’s worth investigating the most common and generally accepted tests for fire resistance.

Differences in hydraulic fluids The basic distinction in choosing a hydraulic fluid is whether it is water-based or water-free. For each fluid type there are pros and cons. Procurement specialists and maintenance managers should consider the merits of five types.

The water-based fluids are HFA-E (mineral oil containing emulsion), HFA-S (a synthetic aqueous solution), and HFC (a water glycol solution). The water-free fluids are HFD-R (a phosphate ester-based) and HFD-U (mainly synthetic polyol esters and natural esters).

HFA-E and HFA-S fluids are used in special hydraulic systems and are generally not found in the aluminum industry.

How do the other fluid types stack up in comparison? HFD-R, the phosphate ester-based lubricants, have a negative reputation.

HFD-R fluids are fire resistant by chemistry, but they are reported to be carcinogenic, mutagenic, reprotoxic materials. Also, the combustion fumes they produce may be neurotoxic. HFD-R fluids

It does not take much energy to heat mineral-oil-based lubricant to the temperature at which it will auto-ignite. can be 10 to 15 times more expensive than mineral oil and need to be carefully maintained as these products generate aggressive acids as they age.

Of the remaining water-based fluids, both have good fire-resistant properties, meaning that other criteria also need to be considered. HFC fluids, the water glycols, are widely used in aluminum processing as well as other industries. They represent about 50% of the total fire-resistant hydraulic fluids market.

Their high water content makes them good for fire resistance. But while they are comparably priced to mineral oil, they do not measure up in performance attributes.

Additionally, hydraulic units for HFC are more expensive to purchase, the components typically have a shorter lifetime, more fluid management is needed, and

energy consumption is 10% to 20% higher compared to mineral oil or polyol ester-based fire-resistant hydraulic fluids.

That leaves HFD-U, the polyol ester-based fluids, which may be the best solution and alternative to mineral oil. Typically no changes need to be made to the hydraulic unit when converting from a mineral oil or water glycol hydraulic fluid to a polyol ester fluid. Compared to mineral-oil-based fluids, nothing is sacrificed in terms of the fluid’s performance, and HFD-U fluids have reduced environmental impact.

The actual price of fluids is around two to three times more expensive than mineral oil. But the crucial difference is that HFD-U fluids have a higher specific heat, a higher auto-ignition point, and a lower heat of combustion. There is no vapor or explosion, so a fire is limited to the place where it comes

in contact with the hot surface or ignition source, and the situation remains under control. With this reduction in the risk of fire from the hydraulic fluid, the result is a lower total cost of operation and a much safer work environment.

Making aluminum plants safer When considering how to reduce the fire risk from hydraulic fluids, there are several schools of thought. A factory might change design of the hydraulic unit to avoid mineral-oil leakages getting close to the hot surface. This means the company can keep the same oil technology, but it does not avoid using a straight hydraulic oil coming close to hot surfaces.

Others might prefer the installation of a fire-extinguisher system to avoid having to change the type of oil used, but this is not only expensive, it can be too little too late, as the main danger caused by oil-based lubricants is the initial explosive ignition and resulting fire balls.

Swapping a mineral-oil-based hydraulic fluid for an HFD-U type is one of the surest ways to improve safety. Factoring in its strong performance and good environmental credentials, HFD-U fire-resistant hydraulic fluids help factories run efficiently and safely.  JANUARY 2021

27

COMMON MISCONCEPTIONS ABOUT

By Buckley Brinkman, Executive Director/CEO of the Wisconsin Center for Manufacturing and Productivity

has been nearly six decades since the first industrial robots rolled onto a General Motors assembly line in Trenton, New Jersey. Today, a new generation of collaborative robots is changing how the manufacturing sector operates. These semi-intelligent machines are driving growth and improving efficiency not only for the GMs of the world, but also for small and medium-sized manufacturers (SMMs) as well.

According to the Robotics Industries Association, a collaborative robot, also known as a cobot, is specifically designed to work directly with humans, side by side, within a defined collaborative workspace. Most weigh under 80 pounds and take up mere inches of space. Cobots free employees from tedious, repetitive activities so they can focus on tasks that require more advanced skills.

Specifically, collaborative robots

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can be quickly programmed to streamline such tasks as: • quality inspections, • polishing, • machine tending, • screw driving, • injection molding, • assembly, and • pick and place.

Robotic technologies have never been more accessible. Collaborative robots are enabling SMMs to compete against their deeper-pocketed counterparts.

Increasingly, forward-thinking SMMs are using collaborative robotic technology as a formidable ally to help level the playing field.

According to Dan Ignasiak, president of South Erie Manufacturing Company (SEPCO), a small company with 35 employees that specializes in machined metal components for the transportation industry, “This kind of technology will attract more young people into manufacturing. And if our company

didn’t keep up with technology, I figure we’d be out of business in less than 10 years due to the advancing nature of the industry.”

For every SMM integrating robotic technologies into their

operations, I see many more missing an opportunity to accelerate business as they cling to common misconceptions about this new generation of automation. These myths include:

MYTH: Cobots are only for large manufacturers.

FACT: Cobots are ideal for SMMs. Unlike industrial robots, they are less expensive, take up little space, and do not require extensive training to operate.

When Dan and his team at SEPCO started working with Northwest Pennsylvania Industrial Resource Center, part of PA Manufacturing Extension Partnership (MEP) and the MEP National Network, they knew they needed to embrace new technologies to capitalize on new business and remain competitive.

The result: SEPCO eliminated the need to purchase another machine center, improved process flow, and made operators more effective. Today, Dan expects to increase sales by $60,000 and plans to add new jobs. Further, he estimates saving $75,000.

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MYTH: Cobots are dangerous.

FACT: Employee safety is an imperative for manufacturers seeking to integrate humans and machines on the factory floor. That is one reason that the manufacturing sector is increasingly embracing cobots. Their safety is what sets them apart from their industrial robot counterparts. Cobots are designed to mimic human actions.

They operate at lower payloads and speeds and are equipped with safety systems like automatic shutoff sensors. These safety systems respond to unsafe human proximity, which allow cobots to operate in the same work area as humans.

MYTH: Cobots destroy jobs.

FACT: Using Cobots in industrial settings may enable a company to create and retain jobs. Integrating cobots into the day-to-day operations can relieve workers from dangerous, strenuous, or repetitive tasks. It can also open the door for new jobs that require different skill sets, resulting in no net loss of jobs. No machine can replace the critical thinking, decision-making, and creativity of humans. Further, an increase in productivity from cobot integration can prompt additional hiring. RevMedx is the maker of XSTAT, a product that provides fast-acting hemorrhage control to stabilize a wounded patient for transport. RevMedx employees 25 people. When product demand required the company to expand production quickly, my colleagues at the Oregon MEP advised RevMedx on robotic solutions to dramatically increase product production.

By employing collaborative robots in the production process, RevMedx not only increased production yield by an estimated 10 times, but the company was able to add four new jobs – a 16% increase in staff.

MYTH: Cobots are too difficult to integrate into current processes and require a dedicated IT department to maintain.

FACT: Their ease of use is one of the key factors that make cobots so appealing to SMMs. They do not require factory renovations or costly installation projects. Further, they do not require advanced degrees or expertise in proprietary programming languages. Many cobots can be programmed through simple apps or by physically moving the unit to “teach” motion.

Beyond the myths, one thing is very clear – collaborative robots give SMMs an important competitive edge. They are good for business, good for manufacturing workers, and good for the U.S. economy.  For more information, visit www.nist.gov/mep or www.wicmp.org/.

This article was published previously on the Manufacturing Innovation Blog and is reprinted with permission of the author. For more information, visit www.nist.gov/blogs/ manufacturing-innovation-blog.

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JANUARY 2021

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Coval Introduces Vacuum Chamber for Gripping Masks

Winters’ WinAIR Gauge Available in a Compact Version A GLOBAL MANUFACTURER OF INDUSTRIAL INSTRUMENTATION

Winters Instruments, a manufacturer of pressure and temperature instrumentation, recently introduced the WinAIR Compact low-pressure differential gauge.

WinAIR Compact is a diaphragm-actuated, frictionless pressure gauge that can be used for measuring positive, negative, or differential pressure. Along with the original WinAIR and the WPS Series pressure switch, WinAIR Compact has been engineered to measure the pressure of air and noncorrosive gases.

With a full-scale 5% accuracy rating, WinAIR Compact has been specially designed for monitoring status on filters, ventilation and duct systems, clean rooms, fans and blowers, paint booths, dust collectors, and many other applications.

For more information, visit www.winters.com.

Ideal for robotics and cobotics, Coval’s CVGM series minivacuum chamber is designed to handle light and porous objects such as protective masks but also fabric or leather cut-outs.

The CVGM vacuum box was designed in response to the COVID-19 pandemic.

Weighing only 300 g (10.5 oz) and measuring only 130 x 60 mm, (5 x 2 in), the ultralight and compact Coval CVGM vacuum chamber easily integrates into an automated system. The chamber’s modular design and stainless steel gripping interface easily dismantles for frequent cleaning.

On request, COVAL develops customized solutions for automated applications in different sectors, such as packaging, food processing, or plastics processing. Coval’s experience as a supplier of components for vacuum automation and complete grippers enables it to assist manufacturers in defining technical solutions. Coval solutions are used all along the production chain, from the individual handling of objects to the palletization of complete layers at the end of the line.

For more information, visit www.coval-inc.com.

RAISING B E WUSIVE THE bar

L C X E

a new column by Dan Helgerson, FPJ technical editor.

IN G N I H C N U A L Y R A U JAN RN E R JOU W O P D UI ON F L

AL .CO

M

A fluid power professional for more than forty years, Dan holds several certifications from the International Fluid Power Society.

In Raising the bar, Dan addresses the fluid power community with an eye toward stirring conversation about the industry’s challenges in the 21st century.

Addressing assumptions …

Encouraging innovation …

Advocating efficiency …

Raising the bar

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