23050 Industrial Dr. E. St. Clair Shores, MI 48080
Phone: 586.778.7680
sales@yatesind.com
Yates Cylinders Ohio
550 Bellbrook Ave. Xenia, OH 45385
Phone: 513.217.6777
ohsales@yatesind.com
Yates Cylinders Alabama
55 Refreshment Place Decatur, AL 35601
Phone: 256.351.8081
alsales@yatesind.com
Yates Cylinders Georgia 7750 The Blu s Austell, GA 30168
Phone: 678.355.2240
gasales@yatesind.com
•Hydraulic and Pneumatic •1.5” up to 50” bore, with strokes exceeding 300”
•Hydraulic and Pneumatic
•1.5” up to 50” bore, with strokes exceeding 300”
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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.
Fostering Growth Mindset for Success
By Garrett Hoisington, Incoming IFPS President
»DEVELOPING A GROWTH mindset is crucial for enhancing your knowledge, skills, and mindset, regardless of your field. Whether you’re a student learning full-time, a professional in a technical field, or working to build stronger personal relationships, a commitment to continuous learning is essential for growth. How we choose to expand our knowledge and improve ourselves varies; many of us turn to resources like books, online platforms, and video tutorials. Over the past few years, these resources have proven invaluable as I’ve worked to expand a fluid power service business within the mining industry. However, while books and other media are helpful in providing foundational knowledge, the real challenge lies in applying that knowledge effectively. This is particularly true in specialized fields like fluid power, where technical resources are available but a clear pathway for personal and professional growth can be challenging to navigate.
In recent years, the International Fluid Power Society (IFPS) has made significant strides in providing accessible resources to support the growth of our members and the broader community. IFPS leadership, along with its dedicated staff and board members, has done an exceptional job updating certification materials, the organization’s website, technical manuals, and numerous other resources. Beyond these enhancements, IFPS has also introduced training programs and defined pathways to certification. This offers a structured approach for individuals aiming to deepen their knowledge of fluid power and validate their expertise through certification.
Reflecting on my own journey, I remember studying for my first IFPS certification test years ago and facing a considerable challenge. While a study manual was available to me, the responsibility to find mentors and resources for in-depth learning fell solely on my shoulders. The landscape of IFPS resources has transformed since then, making the certification journey much more supportive and comprehensive. Today, the IFPS provides a range of learning tools, from detailed study guides to instructional videos and live training sessions. This robust support system not only makes certification more attainable, but also fosters a sense of community by connecting learners with experts and peers.
In addition to these certification-focused resources, IFPS has committed to ongoing professional development and community engagement. Our organization offers continuing education webinars, comprehensive fluid power reference handbooks, discussion forums, and a variety of other resources aimed at empowering our members and the broader fluid power community. The focus is on sustained growth at both the organizational and individual levels,
creating pathways for both technical skill development and professional validation. For individuals interested in fluid power, IFPS aims to be a reliable resource for learning and growth, regardless of prior experience. Looking ahead, one of IFPS’s primary goals is to expand our reach internationally over the next five years. We are working to provide more accessible content, including free educational webinars, which will allow more people globally to engage with fluid power technology and grow their expertise. This goal reflects our commitment to fostering growth within our existing community while also encouraging a broader, international audience to discover the benefits of IFPS membership. By offering accessible learning resources and creating a welcoming environment for learners worldwide, we’re hoping to strengthen both individual members and the organization as a whole.
As I take on the role of IFPS President this coming year, I’m excited to lead our organization on this ongoing journey of growth and innovation. My focus will be on helping our members grow not only in their technical capabilities but also in their professional value within their respective industries. The resources and community support offered by IFPS represent a unique opportunity for anyone passionate about fluid power to advance in their career, gain recognition, and contribute to the field. I look forward to supporting each member in becoming a more knowledgeable, skilled, and valuable professional, and I am eager to see how our organization will continue to evolve and expand.
Through a collective commitment to growth, learning, and excellence, the IFPS is poised to make a meaningful impact in the fluid power industry.
Ethan Stuart, CFPS, CFPECS - Quadrogen Power Systems
Jon Rhodes, CFPAI, CFPS, CFPECS - CFC Industrial Training
Stephen Blazer, CFPE, CFPS - Altec Industries, Inc.
Wade Lowe, CFPS - Hydraquip Distribution, Inc.
Jeff Curlee, CFPE, Cross Mobile Systems Integration
Deepak Kadamanahalli, CFPS - CNH Industrial
Steven Downey, CFPAI/AJPP - Hydraulex John Juhasz, CFPS - Kraft Fluid Systems CHIEF EXECUTIVE OFFICER (EX-OFFICIO) Donna Pollander, ACA HONORARY DIRECTOR (EX-OFFICIO) Ernie Parker, Hydra Tech, Inc. CFPAI/AJPP IFPS STAFF
Chief Executive Officer: Donna Pollander, ACA Communications Coordinator: Stephanie Coleman
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.
NEW PROBLEM
The Tilting Table Will Not Fully Retract
By Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM, CFC Industrial Training
Tilting Table
» THE ATTACHED SCHEMATIC shows a condensed circuit of a steel mill's "Tilting Table" system. The proportional directional valve extends a 130 mm (5”) bore cylinder at varying speeds and stops when a linear transducer setting is reached. The cylinder that is labeled “Plate Balancing Cylinder” is attached to the same plate and adds lifting force pressure with the prop valve controlling extending speed.
When lowering the table plate, again with the prop valve controlling retracting speed, a retracting force is applied to the plate, helping to push the 8" bore cylinder down. The exiting oil from the 200 mm (8”) cylinder is pushed into an accumulator, which stops retracting when the 200 mm (8”) cylinder bottoms out.
Four (4) systems like this and three (3) work well while one keeps stopping short of full retraction. When this happens, slightly lowering the accumulator pre-charge lets it bottom out. This is followed by running another cycle 3-4 times a shift with no issue, and then it fails again.
For the solution, see page 31.
Robert Sheaf has more than 45 years troubleshooting, training, and consulting in the fluid power field. Email rjsheaf@cfc-solar.com or visit his website at www.cfcindustrialtraining.com. Visit fluidpowerjournal.com/figure-it-out to view previous problems.
Decentralized IO Modules
Revolutionizing Control Systems in Mobile Machinery
By Hartmut Rothweiler, Key Account Manager, Bucher Automation AG
IO Modules in Decentralized Architectures
The topologies in control systems are becoming increasingly complex, be it a construction machine, agricultural implement, or municipal carrier vehicle. A few years ago, only a central controller, a joystick, and potentially, a simple display were used. Since then, very complex architecture can be found even in simple machines due to the increased requirements for the degree of automation.
Decentralized topologies are trending, in which a head or display controller acts as the central controller. Small IO modules are placed where signals are generated and communicate with the head controller via the CAN. It is essential for these IO modules to have a flexible
IO configuration to be able to operate proportional and switching valves, electric actuators, and analog and digital input signals.
Thanks to increased CPU performance, IO modules are now able to process extensive functions independent of the main controller. Valve flow control, pre-processing measurement signals, or local monitoring is possible here. Different types of inputs and outputs, e.g. for hydraulic consumers, small electric drives, or precise measurement inputs, make it easier for an electrical engineer to design the system. When wiring the systems, various connection systems help us to find the optimum balance between flexibility and cost-effectiveness.
Automotive Cable Harnesses
In terms of expenditures, the automotive industry leads the way with large quantities and minimized unit costs. If the number of variants is low and the quantities are high, development work is essential to the engineering of the wiring harness. This, in turn, leads to a cost-optimized result along with mass-produced components from the automotive supplier industry. Automotive connector systems are the measure of all things in terms of size. Pertinent to packing density, connector systems such as Molex CMC are hard to beat. In addition to the increased level
of protection, a high current carrying capacity is also achieved with compact dimensions. These technologies are also used in commercial and special vehicle construction, as long as the installation situation is known and a certain number of similar cables are required. Assembly options are deliberately planned in; even if they are not connected, standardized cable harnesses provide a cost advantage that is negated by different variants.
The path from prototype to series wire harness runs longer because the optimization loops up to the final product release take time. With that being the case, a certain amount of documentation is required and large nailing boards have to be prepared for production. The small crimp contacts can only be reliably assembled by automatic machines. Subsequent changes to a wire harness are difficult in the pre-series due to the encapsulated design; repairs in the field are virtually impossible. It is also important to mention that an automotive wiring harness places high demands on the diagnostic implementation of the IO module. Due to the closed, encapsulated design, the electrical signals are barely accessible; typical faults such as cable breaks and short circuits must be detected and reported by the connected electronics. The quality of the diagnostics implementation is crucial for field serviceability.
Point-to-Point Wiring
The opposite of the automotive series wiring harness is the point-to-point connection. With this wiring, each signal of the IO module is provided with its connector, including the signal ground or any required sensor supply or reference voltage. Each consumer or sensor is connected directly via its cable. This principle offers maximum flexibility and enables special wiring variants down to a quantity of 1.
Individual cables may be pre-assembled in different lengths, cross-sections, and connector configurations. Deutsch DT has established itself as the connector technology of choice, combining robustness with a high IP protection rating. Deutsch contacts also allow manual assembly, so that special cables can be produced flexibly in small series.
A wide range of variants in the control software goes hand-in-hand with a lack of diagnostic depth via the IO module. To provide the user with optimum support, the IO modules have an LED matrix to display the switching status of all inputs and outputs. This means that diagnostics can be carried out in the field without additional measuring devices.
The module connection is made directly on the circuit board, using WAGO cage clamp connectors to which the individual strands are directly connected. Cable glands are also possible, e.g. for connecting consumers with higher currents. This indicates that DC motors can also be connected, such as those used in municipal or agricultural spreading applications.
In terms of service, this design provides direct electrical access to the signals. Of course, this requires perfectly trained service personnel and a willingness to take on a high level of responsibility when handling these systems.
On the material side, this type of solution does not generate the cost benefits of an automotive wiring harness. However, the complete elimination of drawing work and direct availability, with virtually no production times or approval processes, enables an unrivaled speed of assembly and maximum reliability.
Old-School with Special Advantages
Even when connectors are specified as IP6k9k, there are still scenarios in which they reach their limits. If the environmental requirements are extreme, e.g. when handling salts/fertilizers, performing daily cleaning with high-pressure lances, or operating in mechanically harsh environments. It’s advantageous to choose a classic route with robust die-cast housing and cable glands.
IO modules within this design pose decisive advantages, particularly in special vehicle construction with a wide range of variants. While individual wires are generally used in automotive cable harnesses, sheathed cables are used in conjunction with cable glands. Along with materials suitable for drag chains and metal cable glands, functional nodes can be placed in the direct working area of a machine.
The Future of Small IO Modules
IO modules are merely small controllers with a CANopen or CAN J1939 slave implementation, offering a portfolio of basic functions. Standards as defined by CiA or SAE enable users to use IO modules from different manufacturers with a high degree of functional compatibility. On the other hand, compatibility means that the lowest common denominator is sought when implementing functions and that complex functions are not included in the scope.
Specific to hydraulic control blocks or pneumatic valve terminals, it may be necessary to account for special design features of the valves. Configuring certain logical links between different actuators might also be essential. This extends the range of functions from a simple remote-controlled control box to a subsystem that can be integrated into complex architectures. The valve manufacturer's know-how can thus be easily transferred to a machine without the user having to possess this expertise.
The software for such modules is usually programmed in C/C++ and supplied by the valve block manufacturer. The valve manufacturer can then encapsulate any existing expertise while increasing the value of any sub-solutions. The machine or vehicle manufacturer benefits from the valve block’s higher performance and easy handling.•
Fluid Power Industry Growth Trend
» THE LATEST DATA published by the National Fluid Power Association shows September 2024 total fluid power shipments decreased -9.4% from the previous month and are -13.2% below September 2023’s index. 3/12 and 12/12 rates of change for total fluid power, hydraulic, and pneumatic shipments are negative and trending downward. The data and charts above are from NFPA’s Confidential Shipment Statistics (CSS) program where over 70 manufacturers of fluid power products report their monthly orders and shipments. More market information is available to NFPA members, allowing them to better understand trends and anticipate change in fluid power and the many customer markets it serves. Contact NFPA at 414-778-3344 for more info.
TOTAL FLUID POWER SHIPMENTS
INDEX DATA: 3 MONTH MOVING AVERAGE & 12 MONTH MOVING AVERAGE
This graph of index data is generated by the total dollar volume reported to NFPA by CSS participants. This graph uses moving averages to smooth out the data and clearly identify trends. (Base Year 2018 = 100).
SHIPMENTS: PNEUMATIC, MOBILE HYDRAULIC, AND INDUSTRIAL HYDRAULIC
INDEX DATA: 12/12 RATE OF CHANGE
Each point on this graph represents the most recent 12 months of shipments compared to the previous 12 months of shipments. For example, 7.3% (the August 2023 level of the pneumatic series) indicates that the value of pneumatic shipments from September 2022 to August 2023 were 7.3% higher than the value of pneumatic shipments from September 2021 to August 2022.
ORDERS: PNEUMATIC, MOBILE HYDRAULIC, AND INDUSTRIAL HYDRAULIC
INDEX DATA: 12/12 RATE OF CHANGE
Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. For example, 8.5% (the August 2023 level of the industrial hydraulic series) indicates that the value of industrial hydraulic orders received from September 2022 to August 2023 were 8.5% higher than the value of industrial hydraulic orders received from September 2021 to August 2022.
TOTAL SHIPMENTS: SEPTEMBER 2024*
This table shows various rates of change for the month of August 2023. Interpretation for each rate of change calculation:
M/M %: The percent change between the current month and the previous month.
Y/Y %: The percent change between the current month and the same month one year ago.
3/12 %: The percent change between the three most recent months and those same three months one year ago. 12/12 %: The percent change between the twelve most recent months and those same twelve months one year ago.
*Preliminary data subject to revision.
Pneumatic
26 UNIVERSITIES
GEAR UP FOR THE 2024-25 NFPA FLUID POWER VEHICLE CHALLENGE
» THIS SCHOOL YEAR, NFPA is thrilled to announce an unprecedented level of participation in its annual Fluid Power Vehicle Challenge (FPVC), with a record-breaking 26 university teams preparing to compete. Thanks to the ongoing support from NFPA members and the generous contributions of Pascal Society donors, the FPVC has expanded to feature three final competition sites for 2025. IMI plc will host the first event in Rockford, Illinois, from April 9-11; Danfoss Power Solutions will host the second competition in Ames, Iowa, on April 23-25; and IFP Motion Solutions Inc. will host the final event in Cedar Rapids, Iowa, from April 30 to May 2.
This year’s expansion comes as the FPVC’s influence continues to grow, bringing excitement and practical engineering experience to more students and universities nationwide. The challenge allows students to design and build their own fluid power-powered vehicles, offering them unparalleled hands-on exposure to fluid power technology, components, circuits, and systems.
Industry support remains integral to the success of the FPVC. NFPA members serve as mentors and judges throughout the program, sharing their expertise with students and shaping the future of the 21st-century fluid power workforce. NFPA is actively seeking industry professionals to volunteer as judges
for the 2024-25 Midway Reviews, which will take place via webinars in December and January. These reviews offer judges the chance to give direct feedback on students’ designs, technical drawings, and fluid power circuits as they progress in the competition. With the flexibility of recorded sessions, volunteers can participate at their convenience.
Whether as mentors, judges, or sponsors, NFPA members have a unique opportunity to connect with emerging engineering talent and foster innovation within the industry. Participation in the Midway Reviews is open to all NFPA members this year, creating an accessible pathway to engage with these students and witness the program’s impact firsthand.
UNIVERSITY TEAMS
• Cal Poly State University
• Cleveland State University
• Colorado School of Mines
• Florida A&M – Florida State School of Engineering
• Iowa State University
• Kennesaw State University
• Michigan Technological University
• Milwaukee School of Engineering
• Minnesota State University Mankato
• Murray State University
PROPORTIONAL CONTROL
A NEW LEVEL OF SIMPLICITY + PRECISION FOR HYDRAULIC CONTROLS
By Russ Schneidewind, Director, Business Development, and David Ruxton, Engineer II R&D, HydraForce
The mobile machinery market is experiencing a significant evolution in proportional hydraulic control, driven by the increasing implementation of automation. This shift, which has been underway for some time, is accelerating as machinery becomes smarter. Today, semi- and fully autonomous agricultural and construction machines are emerging, many of which still rely heavily on hydraulic actuation for key functions.
At the heart of this transformation is the widespread adoption of Controller Area Network (CAN) technology. This technology has enabled more efficient, distributed control architectures, allowing various components to communicate seamlessly. As a result, the precise control of proportional hydraulics is now managed by onboard electronics and sensors, offering greater accuracy and responsiveness.
flow-force compensation, reduced hysteresis, improved linearity, greater control simplicity with setpoint input via CAN, and energy savings specific to reduced parasitic losses compared to the mechanical compensator.
Closed-loop PID control is the industry standard for accurate process controls. Highly precise servo-control valves have been available in the industrial sector for some time, but there have been significant barriers to adoption in the mobile sector. This includes cost, size, and robustness. The new product offerings have been built from the ground up with a keen focus on these three key performance indicators.
CONTROLLING ACTUATOR SPEED OR POSITION
These advancements in hydraulic control are enhancing the performance, energy efficiency, and safety of mobile machinery. As automation continues to evolve, the integration of these smarter hydraulic systems will play a pivotal role in the future development of agricultural and construction equipment.
DIGITAL PROPORTIONAL CONTROL
There are many challenges to achieving digital proportional control. To that end, Bosch Rexroth and HydraForce have developed on-board closed-loop control products. HydraForce offers the Innercept® digital proportional control (patent-pending), and Bosch Rexroth has independently developed the EDG-OBE proportional compact directional valve with on-board electronics. Both products use closed-loop PID control with position sensing to form the feedback leg.
The benefits of digital proportional control go beyond improved precision. Closed-loop control with position feedback has the added benefits of improved step-response,
Digital proportional control product designs for the aforementioned offerings must conform to many rigorous ISO and SAE standards for off-road vehicles, heavy-duty trucks, and agricultural and forestry machinery specific to high-pressure operation, vibration, EMI immunity, environmental considerations, and ingress protection.
Size and space claim have always been at the heart of Bosch Rexroth’s product lines for mobile equipment. Compact cartridge valve manifolds, compact directional valves, and hybrid solutions are what the mobile marketplace has demanded for decades. With this in mind, Bosch Rexroth’s dedicated Compact Hydraulics business unit now includes HydraForce cartridge valve and control products. This offers the deepest bench of systems engineering, along with the broadest range of compact products meeting the specific performance needs of mobile hydraulic systems.
The cost barrier is the last significant challenge; servo control products can cost many thousands of dollars, and a typical mobile hydraulic system requires multiple independent closed-loop controls. Several innovative approaches to component design have reduced costs and helped make this technology applicable to mobile machinery.
Controlling the speed of an actuator using a proportional flow control poses many challenges versus the desire for a constant flow. The flow through an orifice depends primarily on the pressure drop across it. Fluid temperature, viscosity, changes in pressure downstream (load), or upstream (supply) can affect flow. In addition to these, mechanical variations from valve to valve such as actuator magnetics, coil resistance, temperature, spring variations, and friction also contribute to the chaos. Though all these variable factors may be small, they can have an additive effect that causes significant and undesirable performance variation. This can lead to unpredictable performance factors including high hysteresis. These factors require time-consuming factory adjustment and tuning.
INCREASED CONTROL PRECISION
Closed-loop control with position feedback allows for more precise control. Since the loop is closed with position feedback, the control can respond to the difference between the desired and actual positions. This is more precise because the control responds appropriately to correct the discrepancy, regardless of contributing factors such as manufacturing variation, friction, coil resistance, or load pressure, to name a few.
The Proportional, Integral, Derivative (PID) control checks the error condition and adjusts the actuator signal hundreds of times each second. A PID control algorithm can be tuned
to a desired response profile. It responds to three components of the system error. The proportional component applies a correction relative to the current error. The integral component gauges the error over time and contributes to the applied correction. The derivative component responds to the change in the error rate and anticipates future errors.
Tuning the PID loop is done in the factory and is optimized to immediately offer responsive control. Each LVDT and valve is calibrated against a flowmeter which ensures a given command results in the same flow, giving excellent valve-to-valve consistency. However, customers can perform custom tuning as required to adapt to the applied machinery’s performance characteristics.
IMPROVED HYSTERESIS
Hysteresis is an adverse characteristic of dynamic components that causes a difference in performance as the moving component travels in one direction, versus traveling in the opposite direction. This contributes to a degree of uncertainty in the output state. Dramatic improvements in hysteresis can be attributed primarily to the control’s ability to rapidly adapt the actuator signal to adverse factors like stiction. When tested at HydraForce, 3-5% hysteresis in open-loop operation was reduced to a negligible 1% or less when the same components were operated using the closed-loop control.
IMPROVED LINEARITY
Linearity is the degree to which a control can produce a linear output. It is the ability to produce a predictable result that is directly proportional to the input. Hydraulic valves have differing degrees of inherent nonlinearity due to actuator performance and other operating characteristics. This has been improved mechanically using features such as cross-holes and metering notches. Cartridge valves control metering using cross-holes. This produces a flow vs. spool position curve that's sinusoidal as the spool lands, uncovering a circular cross-section. Workarounds include controlling the size and position of cross-holes. However, with spool position feedback, we can modulate the actuator to correct the output flow, straightening the curve. This makes it much easier to apply this valve and control a larger system.
IMPROVED STEP RESPONSE
Step response is the speed at which a valve responds to a rapid change in command. It is the milliseconds that fall between the command and the valve reaching 90% of its desired
position. When running an open loop, we must limit actuator force because we can only make assumptions guided by our knowledge of how the valve will respond to avoid overshoot. When operating a closed-loop control with spool position feedback, the controller can overdrive the valve and push the spool into position much faster than it can use a fixed current value. This greatly improves step response, and with optimized tuning, overshoot can be limited as well.
COMPENSATING FOR FLOW FORCES
Hydrodynamics, or Bernoulli forces, are the effects of fluid flowing through a valve; they tend to counteract actuator forces. For example, a rapid flow across the metering orifice can induce a contrary force on the spool. When driving the valve open loop, it is often essential to compromise, applying larger valves or mechanical compensators to reduce fluid velocity. The closed-loop control drives the spool to a position and maintains that position using feedback. This strategy effectively compensates for flow forces and valve-to-valve variation, eliminating the need to tune every machine coming off the production line.
THE PROMISE OF ENERGY SAVINGS
Proportional valves require some form of pressure compensation to overcome load and supply variation. Mechanical compensation controls the pressure differential across the throttling orifice, opening and closing as the differential changes. The controlled differential ensures controlled flow. The compromise
comes as a parasitic loss that converts to heat and erodes the margin pressure available to drive load-sensing hydraulic pumps. Digital proportional control can enable an alternative method of pressure compensation known as electronic load sensing. The mechanical compensator is an additional element that relies on a parasitic margin to operate. Electronic load sensing uses transducers to sense load pressure in any control leg of a hydraulic circuit, forming the load-sensing network. The control software can then modulate the control valve position to compensate for load dynamics in any part of the system or operate a pressure control to pilot the load-sensing pump. Parasitic compensator losses can add up to a few percent of the overall power consumption. However, for a large excavator operating 8 to 10 hours daily, this can add up to significant fuel savings and a reduction in carbon emissions.
The Rexroth SPM spool position monitoring sensor can be used with multiple compact directional valve products.
THE PRODUCTS
HydraForce offers the Innercept® line of digital proportional controls consisting of a Linear Variable Differential Transformer (LVDT) position sensor with on-board controls that return a 0 to 5v signal proportional to valve spool position. This sensor is accurate to +/- 0.1 mm. A coil-mounted ESDR-0201A, two-output, one-input closed-loop Electronic Servovalve Driver performs the control function. The LVDT is a modular design that allows easy application to any of HydraForce’s proportionally actuated flow and proportional directional control valves.
Bosch Rexroth offers the EDG-OBE pre-compensated compact directional valve for flow rates up to 40 lpm and maximum operating pressure of 350 bar. The EDG line has many options for inlets and directional elements, including the EDG-OBE with on-board electronics and contactless Hall-effect spool position sensing element.
All of these digital proportional control products are highly modular and can be used in any mobile application requiring precision actuator control. Digital proportional control is perfect for applications where precision and response are key. With fast-acting, repeatable directional flow control, one can achieve more stable autonomous functions like automatic steering or precise placement of cargo in a narrow storage bay. More control-by-wire applications can open the use of rental machines to a broader range of less experienced operators. New possibilities are emerging every day.•
HydraForce Innercept° digital proportional controls closed-loop proportional cartridge valves (US and international patents pending).
Rexroth EDG-OBE proportional directional control with on-board electronics.
HOW TO
PROTECT PNEUMATIC ROTARY ACTUATORS
By Michelle Anastasio-Festi, Marketing Director, Rotomation
Pneumatic rotary actuators are crucial in modern industrial applications, offering reliable and precise movement that drives automation across various sectors. From manufacturing to mining, these devices are indispensable for tasks requiring rotational motion. However, the environments in which these actuators operate can present significant challenges, such as extreme temperatures, corrosive substances, and elevated levels of dust and debris. Protecting pneumatic rotary actuators from these conditions is essential to maintain their performance and longevity. This article explores the common challenges these actuators face in harsh environments and provides protection strategies.
Common Challenges Faced in Harsh Environments
Introduction to Pneumatic Rotary Actuators and Their Applications
Pneumatic rotary actuators convert compressed air into rotational motion, making them an essential component in various industrial processes. They are commonly used in applications requiring precise rotary motion, such as valve automation, material handling, and assembly line operations. These actuators offer several advantages, including high torque output, quick response times, and simple integration with existing pneumatic systems.
Key Applications
Pneumatic rotary actuators are widely used to automate valve operation in industries such as oil and gas, chemical processing, and water treatment. They provide the necessary torque to open and close valves quickly and accurately. In manufacturing and warehouse environments, these actuators are used to drive conveyor diverters, box erectors, pick and place operations, and other material handling equipment. Pneumatic rotary actuators are essential in assembly line operations to position components for welding, inspection, or fastening.
While pneumatic rotary actuators are designed to withstand various operating conditions, harsh environments pose significant challenges that affect their performance and durability. Understanding these challenges is the first step in developing effective protection strategies.
Extreme Temperatures
Pneumatic rotary actuators often operate in environments with extreme temperatures, ranging from cold to scorching heat. These temperature variations can affect the materials and components within the actuator, leading to issues. This includes elevated temperatures causing seals to expand and lose their effectiveness, while low temperatures can make them brittle and prone to cracking. Additionally, extreme heat can cause lubricants to break down, decreasing their ability to reduce friction and wear.
Corrosive Substances
In industries such as food processing, actuators are exposed to caustic cleaning material to wash down the equipment that can damage their components. Corrosion can lead to pitting, rusting, and weakening of the actuator's components, compromising its performance. Corrosive chemicals can attack the lubricants, metal surfaces, and seals of
the actuator, leading to premature failure. In marine environments, saltwater can cause rapid corrosion of metal components, if they are not adequately protected.
Dust and Debris
Dust and debris are common in many industrial environments, and they can infiltrate the internal components of pneumatic rotary actuators. Dust interferes with the lubricants inside the actuator, reducing the life of seals and sliding components. Particles can block the airflow and impede the actuator's movement, affecting its performance by causing blockages.
Vibration and Shock: STRATEGIES FOR PROTECTING PNEUMATIC ROTARY ACTUATORS
Heavy machinery and equipment often generate significant levels of vibration and shock, which can impact the performance of pneumatic rotary actuators. Excessive shock loads can fracture even high-strength alloy components such as gear teeth. Continuous overload or vibration can lead to fatigue failures. Shock and vibration can loosen connections and fittings, leading to air leaks and reduced efficiency. To ensure the reliable performance and longevity of pneumatic rotary actuators in harsh environments, it is essential to implement effective protection measures. The strategies detailed below can help mitigate the challenges discussed above.
Selecting the Right Materials
It is crucial to choose actuators made with materials that can withstand the specific conditions of the operating environment. To ensure an adequate lifetime, use materials such as stainless steel, anodized aluminum, or specially treated metals that resist corrosion and chemical exposure. It’s recommended to configure the actuator to include materials and components that can withstand extreme temperatures without degrading, such as high-temperature seals and lubricants. Some manufacturers offer actuators with features that allow for thorough cleaning without compromising their integrity. Washdown-protected actuators incorporate highly effective shaft seals, sealed housing, and corrosion-resistant materials.
Implementing Protective Coatings
Applying protective treatments to the actuator's external and internal components
can provide an additional layer of defense against harsh conditions. Leveraging nickel, chrome, or zinc plating, epoxy, or ceramic can protect metal surfaces from corrosion caused by chemicals and saltwater. Use of metal surface treatments is also useful; this includes black nitride, hard anodizing, salt bath treatments, or PEO.
Using Sealed Enclosures
If the actuator cannot be made to withstand the extreme environment, it may be possible to house it in a sealed enclosure to protect it from dust, debris, contaminants, and moisture. Ensure that the enclosure is adequately vented to prevent pressure build-up. The enclosure must also incorporate a rotary seal to allow the actuator shaft to project without allowing the entrance of contaminants.
Regular Maintenance and Inspection
Avoiding Damage from Shock Loading Damage Prevention
Avoiding damage from shock loading is a multi-step process that starts during the project's design stages. Utilizing weight-saving measures including lightweight materials and efficient design involves the following:
Consistent maintenance and inspection are essential to identify and address potential issues before they lead to actuator failure. Implement a preventive maintenance program inclusive of regular visual inspections to check for signs of wear, corrosion, and damage with attention to seals, fittings, and connections. It’s vital to ensure that the actuator is adequately lubricated to reduce friction and wear. Use lubricants that are suitable for operating conditions. Furthermore, the actuator must be clean and free from dust and debris. Use appropriate cleaning methods and solutions to avoid damaging the components.
continued on page 14
Custom Material Actuator in Stainless Steel
Compact Valve Actuator Made with Hard-anodized Aluminum and 316 Stainless Steel components
Cutaway of A2 Actuator with Washdown Protection Option
Washdown Protection
continued from page 13
Keep the mass of rotating elements as close to the center of rotation as possible. Remove unnecessary structural mass, such as tables.
Select an actuator of adequate displacement, proportional to the inertia and speed of the load.
Configure the actuator with shock-reducing features, e.g. pneumatic cushions, bumpers, or shock absorbers.
Carefully set up and tune the system. Use meter-out flow control valves to control the speed of the actuator, making it go only as fast as necessary to achieve target production.
Apply full-system air pressure to maximize acceleration.
Installing external shock absorbers is essential, as these act directly on the load rather than being incorporated into the actuator. This allows higher speed and lower force shocks, which are more efficient. It also puts the shocks where they can be observed and replaced at the end of life.
Monitoring and Diagnostics
Implementing monitoring and diagnostic tools can help identify potential issues before they lead to actuator failure. Consider utilizing sensors to monitor the condition of the actuator, such as temperature, pressure, and vibration levels. Implement a system to alert maintenance personnel of any abnormal conditions. Call on observation and/or PLC monitoring measures to ensure that the target velocity is being maintained. Flow control and pressure settings may require periodic checking and adjustment. In addition, predictive maintenance techniques may be used to analyze data from condition monitoring sensors and predict when maintenance is required. This approach can help prevent unexpected failures and reduce downtime. •
Adjuster and Cushion Combined adjuster and cushion for single rack actuators or steppers. Installed separately, cushion on top rack, in dual rack units. Stroke reduction also reduces cushion action.
Cushion A reversed U-cup on the auxilary piston closes the free passage to the port, forces exhaust through the control needle valve over last 30° of roation. For return, pressure folds U-cup down, allows full pressure and flow to piston
REAL-WORLD EXAMPLE & CASE STUDY
VALVE ACTUATOR SOLUTION FOR DEEP-SEA OIL RIG:
To illustrate the effectiveness of these protection strategies, let’s explore a real-world example and case study of a pneumatic rotary actuator operating in harsh environments.
CHALLENGE:
A leading supplier of control systems for the energy industry was tasked with modernizing a deep-sea oil rig's hydraulic well safety equipment. The existing manual control system needed to be replaced with an automated system that could operate valves remotely and efficiently. The primary challenge was finding a compact, reliable, and corrosion-resistant valve actuator that could interface with specialized, high-pressure hydraulic valves.
SOLUTION:
Rotomation, a leading manufacturer of pneumatic rotary actuators, was approached to provide a solution. By utilizing one of its three-position pneumatic rotary actuators, Rotomation was able to create a custom-engineered solution that met the specific requirements of the control system.
Compact Design: The actuator was designed so the valve could be attached directly to it, eliminating bulky couplings and brackets.
Corrosion Resistance: To ensure long-term reliability in the harsh marine environment, the actuator was constructed using hard-anodized aluminum and 316 stainless steel components.
Manual Override: A robust handle and visual indicator were included to allow for manual operation in case of power failure or emergency.
BENEFITS:
Improved Efficiency: The automated system, powered by Rotomation's valve actuators, significantly enhanced the efficiency of the oil rig's operations.
Enhanced Safety: The reliable and corrosion-resistant actuators contributed to improved safety by ensuring the proper functioning of the hydraulic well safety systems in case of emergency.
Part Reduction: The number of valves was cut in half by going from pairs of two-position valves to single, three-position valves
CASE STUDY CLOSING SUMMARY:
Rotomation's valve actuator solution provided a critical component in the modernization of the deep-sea oil rig's hydraulic well safety equipment. The actuator's compact design, corrosion resistance, and manual override feature made it an ideal choice for this demanding application.
CONCLUSION:
Businesses can learn how to operate pneumatic rotary actuators successfully in harsh environments by carefully selecting and configuring the actuator to match the load and including appropriate materials and features. Additional protective measures, along with careful setup, monitoring, and maintenance will ensure long life and alleviate the risk of unexpected failures.
UNDERSTANDING THE FUNCTION & APPLICATIONS OF AN FRL
FRLs (Filter, regulator, lubricator) are common in and specific to pneumatic systems. FRL, just as the acronym indicates, is a combination of 3 smaller components assembled as a larger unit, consisting of a filter, a regulator, and a lubricator (see Fig. 3.54). The main function is to condition and prepare the compressed air for use within an entire pneumatic system or a branch circuit at a specific tool location. The FRL filters particulate contaminants from the air, removes moisture, regulates the pressure, and supplies oil/lubrication to the system or tool downstream of the FRL. Pneumatic applications with properly conditioned air will operate longer, cost less, and improve system efficiency.•
TEST YOUR SKILLS
1What is the purpose of an FRL?
A. Filter contaminants.
B. Regulate air pressure.
C. Lubricate the system/tool.
D. Lubricate downstream of the compressor.
E. All of the above.
See page 31 for the solution.
HYDR AULIC FL ANGES D COMPONENTS
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Air Compressors
Clean Dry Air Improves Performance...
Clean, Dry Compressed Air Starts with The Extractor/Dryer® Manufactured by LA-MAn Corporation
• Point of Use Compressed Air Filter to Improve and Extend Equipment Life
• Removes Moisture and Contaminates to a 5-Micron Rating: Lower Micron Ratings are Available
• Models with Flow Ranges of 15 SCFM to 500 SCFM Rated Up To 250psi are Standard
• Differential Pressure Gauge Built in
• Mounting Hardware Included for Easy Installation
• Weep Drain is Standard; Float Drain or Electronic Drain Valves Optional
machines effective, helping them avoid the use of carcinogenic chemicals.
Since no two waterways are the same, Weedoo has developed a range of products and accessories. Their TC-Series workboats are compact and powerful, with a unique hull design that allows for maximum payload and balance. The TC-3012 can clear 500 pounds of weeds per minute, transforming a whole lake in an afternoon. A range of quick-change hydraulic attachments saves valuable time and includes a marine bucket, root rake, silt sucker, skimmer bucket, sediment remover, and pole saw. The Weedoo AmphiKing 6450 carries out water maintenance, construction, and even disaster cleanup tasks in the harshest, most inaccessible environments. A front-mounted, articulating boom features convenient quick-connect hydraulics. It brings well-known power to the front collecting rake, mowing and collecting basket, small auger dredge, weed grapple, and T-cutting bar. With no ramp required and a shallow draft for easy access to problem areas, the Weedoo workboats are multifunctional, powerful, and extremely maneuverable.
HEALTHY waterways
By Jim Wahl, Wahl Marketing and Ben Garmier, Renewable Lubricants, Inc.
Clearing the world’s waterways of invasive vegetation, algae, refuse, and other pollutants is essential work with enormous impact. Healthy marine environments are a lifeline for so many things. This includes jobs such as farming, fishing, and shipping. It’s essential to clean water and wildlife habitats, as well as property values, tourism, and recreational opportunities. Regular herbicide use, chemical runoff, and basic evolution have caused numerous plant species to develop resistance, leading to clogged waterways and other hazards. Removing the offensive materials mechanically is ideal, but that method poses different challenges. Fortunately, Weedoo Greenboat, Inc. discovered an environmentally friendly solution that is also cost-effective from Renewable Lubricants.
UNIQUE WORKBOATS OFFER MECHANICAL CLEARING AND REMOVAL
When John Grimes and his father Phil wanted a machine to clear weeds from their lake in an environmentally conscious manner, they took matters into their own hands by inventing one. 20 years later, Weedoo has grown to make several lines of environmental workboats and amphibious work equipment that can take on the toughest jobs in extreme and challenging aquatic conditions. Their advanced, environmentally friendly shoreline equipment provides a cost-effective way to clean waterways of invasive vegetation, algae, refuse, and other pollutants. Customers ranging from individuals to large companies actively seeking to preserve nature and protect natural resources have found these
The mechanical removal of weeds and debris eliminates the need for using threatening substances, but working in the water with hydraulic equipment poses new challenges. These machines require essential fluids for transmitting power, lubricating the system, and dissipating heat. While there are many options available, most are not suitable for use in water. Mineral-based options are not biodegradable, cause long-term pollution and exposing aquatic life to toxicity. Even a small leak, much less a blown hydraulic hose, can have disastrous effects on the environment. Plus, there’s a potential to incur high fines for these accidental discharges. Water-based fluids are a logical consideration, but they are only moderately biodegradable, must be replaced frequently, and tend to wash away. They’re better suited for low-pressure systems and environments that are not sensitive. To complicate matters further, regulations for chemical use in waterways become more stringent with each year. In 2024, the Environmental Protection Agency (EPA) introduced the strictest clean water legislation to date, including stiff penalties for violators.
Weedoo realized that use of an environmentally friendly hydraulic fluid was a necessity. While researching the options, they found that not all eco-conscious choices are the same. Even though they have an identical ISO weight,
there are significant differences in the oxidation process. This yields critical performance variances. Oxidation is a complex series of chain reactions common to most hydraulic fluids and consists of three stages: initiation, propagation, and termination. During the initiation phase, hydrocarbon molecules react with catalysts such as heat, pressure, or contaminants. This leads to the formation of free radicals, highly reactive molecules that combine to create new products. In propagation, the radicals fuel the process by reacting with oxygen, creating peroxides and other reactive species. The byproducts from these reactions sometimes act as propagators, further expediting the process. Many factors including high temperatures, moisture, metal contaminants, and agitation can accelerate the oxidation process as well, leading to rapid degradation. Consequences of oxidation include increased oil viscosity and organic acids, along with the formation of sludge, varnish, and deposits. Additive depletion can occur as well, including anti-wear additives, dispersants, and corrosion inhibitors, along with the loss of other vital performance properties. The termination phase occurs when stable, non-reactive products have formed, and oxidation has ended.
HYDRAULIC FLUIDS THAT EXCEED EXPECTATIONS
Companies and government agencies that buy biobased anti-wear (AW) hydraulic fluids at the lowest bidding cost are assuming all biobased fluids (in the required ISO viscosity) perform the same, which is false. Fortunately, Renewable Lubricants solves the problem with its patented, fully biodegradable options. A recent study conducted on seven brands of biobased hydraulic fluids demonstrated Renewable Lubricants' remarkable performance in resisting oxidation.
polyol ester-based AW hydraulic fluids. The longer the time in minutes, the greater the stability of the fluid. The US Steel requirement for anti-wear hydraulic fluid is greater than 120 minutes, which equates to 1,800 hours of service life. While many brands do not achieve that minimum, every Renewable Lubricants formulation exceeds the requirement by more than double. Some products, such as the Bio-Ultimax 2000, deliver an impressive 650 minutes of product life, more than five times the requirement.
Bio-Fleet is particularly suitable for the demanding conditions encountered by Weedoo’s workboats, which operate in heat and water. Superior fluid performance ensures reliable operation, maintaining hydraulic systems' performance while minimizing environmental impact. Bio-Fleet Hydraulic Fluids are environmentally accepted lubricants (EALs) that are formulated from renewable biobased resources. Ideal for both high-pressure and low-pressure hydraulic applications, they meet the Environmental Protection Agency (EPA) 2013 Vessel General Permit (VGP) guidelines for Environmentally Acceptable Lubricants (EALs). A direct replacement for mineral oil-based hydraulic fluids, they should be
fluids pass both A and B Sequences of the ASTM D-665 Turbine Oil Rust Test, and they provide excellent water separation as shown in ASTM D-1401 Demulsibility Test. With a higher viscosity index than synthetics, they feature improved thermal shear stability and increased load capacity, which translates to enhanced performance and longer equipment life.
GREEN ALTERNATIVES ARE THE FUTURE
Intense OSHA monitoring and new regulations for water supply safety add increased urgency to eco-friendly business efforts. Transitioning to environmentally safe hydraulic fluids ahead of regulatory requirements benefits many companies. In addition to ensuring compliance, companies can reduce the risk of operational disruptions or expensive fines. Minimizing environmental liabilities is a sound operational policy and demonstrates a commitment to sustainability. There are also financial incentives available, such as grants and tax breaks. By adopting these greener technologies, companies can future-proof their operations, align functions with global sustainability goals, and gain a competitive edge in an increasingly eco-conscious market.
The ASTM D-2272 Rotary Pressure Vessel Oxidation Test (RPVOT) is a standardized method of comparing the oxidation life of lubricants in similar formulations. In the accelerated life-cycle testing format, all Renewable Lubricants lines significantly outperformed the other biobased and synthetic
used when low toxicity, biodegradability, and non-bioaccumulation properties are required. They exceed the acute toxicity (LC-50/EC-50 >1000 ppm) criteria adopted by the US Fish and Wildlife Service and the EPA. Since they meet the environmental requirements, they can also be used where ISO 15380 (HEES/HETG) Hydraulic Fluids are specified.
Highly inhibited against moisture and rusting in both fresh and seawater, Bio-Fleet
Bio-Fleet formulations show excellent performance in both test and real-world applications, ensuring reliable operation even in harsh conditions. Available in various ISO weights, including 22, 32, 46, and 68, the fluids offer antiwear, anti-rust, anti-oxidation, anti-foam, and demulsibility properties, making them suitable for high-pressure systems, and ideal for marine applications like winches, capstans, dredges, and other workboat applications.•
Kickstart the New Year with IFPS Training and Certifications
» NOW IS THE perfect time to prioritize training and certification for your fluid power workforce. A skilled team not only drives operational efficiency but also ensures adherence to the latest safety standards and technical practices essential for today’s fast-evolving industry. The International Fluid Power Society (IFPS) offers a flexible approach to training, designed to meet the unique needs of organizations and individuals alike. Whether you’re preparing your team for certification exams or refreshing their technical knowledge, IFPS is here to support your journey.
IFPS provides tailored training solutions, allowing you to build a program that directly aligns with your goals. From core topics like hydraulics, pneumatics, and fluid power math to specialized technical practices, our expert trainers are equipped to offer in-depth guidance that meets the highest industry standards. With options for in-person, online, or hybrid training, IFPS ensures that each organization can choose the format that best fits their operations, workforce location, and scheduling needs.
For professionals aiming for certification, IFPS provides a pathway to expand skills and demonstrate advanced expertise in roles like Hydraulic Specialist and Pneumatic Specialist. Certification not only enhances individual knowledge but also strengthens your entire organization, affirming that your team is qualified and up-to-date.
Make this year the one where your workforce excels. Trust IFPS as your training partner for customized programs that elevate skills, enhance safety, and keep your team at the cutting edge of the fluid power industry.
Become a Webinar Presenter for IFPS
LEAD, EDUCATE, AND CONNECT WITH THE FLUID POWER INDUSTRY
» ARE YOU AN expert in fluid power systems? As a presenter, you'll educate both up-and-coming and experienced professionals, sharing insights that enhance efficiency and safety in the field. Your recorded webinar will be featured in our Web Seminar Library, extending your reach beyond the live event. You'll also have the chance to interact with attendees, providing valuable networking opportunities.
Presenting a webinar with the International Fluid Power Society (IFPS) offers great exposure for you and your company. Your webinar will be promoted through various marketing channels, reaching a diverse audience and positioning your company as an industry authority that values correct application and safety of fluid power equipment.
Presenters earn three recertification points for their participation. By sharing your knowledge, you and your company will be appreciated for educating the industry on best practices. Don't miss this chance to shape the industry and connect with a community dedicated to fluid power excellence.
Unlock Your Potential IFPS’s Comprehensive Digital Learning Tools
» THE IFPS OFFERS a wide range of digital learning tools tailored to both newcomers and seasoned professionals in the fluid power industry. From interactive digital handbooks to downloadable study manuals, IFPS’s resources provide on-demand access to essential fluid power knowledge. The Digital Fluid Power Reference Handbook, with its interactive table of contents and search tools, allows users to quickly locate vital information on the go, making it an invaluable tool for study or on-the-job reference.
IFPS’s online training modules bring learning to life with animations, interactive review questions, and modules covering topics like Fluid Power System Design and Hydraulic and Pneumatic best practices. For those looking for practical experience, Hybrid Certification Programs combine online sessions with hands-on labs, offering a blend of theory and realworld application through instructor-led classes and specialized training kits.
Safety is paramount in fluid power, and IFPS emphasizes this with comprehensive Hydraulic Safety Training courses. These online courses cover essential safety protocols, particularly for high-risk maintenance tasks. Alongside this, animated circuit resources provide visual insight into hydraulic and pneumatic systems, clarifying complex concepts for a deeper understanding. Explore the range of IFPS digital tools at IFPS Training to build your expertise and advance in the field.
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 Kyle Pollander at Kpollander@ifps.org if you do not see a location near you. Every effort will be made to accommodate your needs.
Written Certification Test Locations
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
TENTATIVE TESTING DATES FOR ALL LOCATIONS
JANUARY 2025
Tuesday 1/7 • Thursday 1/23
FEBRUARY 2025
Tuesday 2/4 • Thursday 2/20
MARCH 2025
Tuesday 3/4 • Thursday 3/27
APRIL 2025
Tuesday 4/8 • Thursday 4/24
JOB PERFORMANCE TEST LOCATIONS
Arizona California
Colorado Florida
Georgia
Maine Michigan Minnesota Montana New Jersey Nova Scotia Pennsylvania Texas Washington Wyoming Western Australia
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
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Fort Pierce, FL Ft. Myers, FL Gainesville, FL Jacksonville, FL
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Albany, GA
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Kansas
Kansas City, KS
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Kentucky
Ashland, KY
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Highland Heights, KY
Louisville, KY
Morehead, KY
Louisiana
Bossier City, LA
Lafayette, LA
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Natchitoches, LA
New Orleans, LA
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Maryland
Arnold, MD
Bel Air, MD
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Massachusetts
Boston, MA
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Michigan
Ann Arbor, MI
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Branchburg, NJ
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Pennsylvania Bloomsburg, PA Blue Bell, PA
Gettysburg, PA
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Newtown, PA Philadelphia, PA Pittsburgh, PA
Wilkes-Barre, PA York, PA
South Carolina
Beaufort, SC
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Greenville, SC Greenwood, SC Orangeburg, SC
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Tennessee Blountville, TN
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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
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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
West Palm Beach, FL
Wildwood, FL Winter Haven, FL
Spartanburg, SC
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
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
Tentative Certification Review Training
IFPS offers onsite review training for small groups of at least 10 persons. An IFPS accredited instructor visits your company to conduct the review. Contact kpollander@ifps.org for details of the scheduled onsite reviews listed below.
HYDRAULIC SPECIALIST
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org)
ELECTRONIC CONTROLS SPECIALIST
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
PNEUMATIC SPECIALIST
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org)
CONNECTOR & CONDUCTOR
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
MOBILE HYDRAULIC MECHANIC
For custom training IFPS inquiries, please contact Bj Wagner (bwagner@ifps.org)
Online Mobile Hydraulic Mechanic certification review for written test is offered through CFC Industrial Training. This course surveys the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written test. Members may e-mail for a 20% coupon code off the list price. Test fees are not included.
INDUSTRIAL HYDRAULIC MECHANIC
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
INDUSTRIAL HYDRAULIC TECHNICIAN
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
MOBILE HYDRAULIC TECHNICIAN
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
PNEUMATIC TECHNICIAN & PNEUMATIC MECHANIC
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
The Enduring Benefits of Electro-Hydraulic Linear Actuators in an ELECTRIFIED WORLD
By Erik Larson, Business Development Manager, Parker Hannifin
OEMs are increasingly interested in adapting their products to a more electrified world. New technologies have flooded the market claiming they are the best fit in the up-and-coming electrified world. One prime example is the electromechanical actuator, also known as an EMA. EMAs offer numerous advantages and are well-positioned for certain linear applications. In many instances though, they are not the best solution. An existing technology, the electro-hydraulic linear actuator (EHA), continues to have a very important role in the market and the new electrified world.
Definition of a Linear Actuator and the Most Common Forms
A linear actuator is a device designed to move a load between two points in a straight line. There are many combinations available to meet a wide range of speed, power, and load requirements. These actuators come with multiple standard features and numerous add-on options, including limit switches, position feedback, and other features to ensure
they can fit a variety of applications. Linear actuators function via a variety of technologies. Electromechanical and electro-hydraulic are most used technologies in applications that reduce environmental impact, compact envelopes, and minimal assembly costs.
An EHA is a fully self-contained system that uses an electric motor to drive a hydraulic pump to extend or retract a hydraulic cylinder. Electrical wiring, compared to an external hydraulic supply, provides power and EHA commands. In contrast, an EMA does not use hydraulics. It is powered exclusively by motors using a toothed belt or a ball, lead, or planetary roller screw to convert the rotational force of a rotary electric motor into linear movement.
Key Differences Between EHAs & EMAs
Pros and Cons
EHAs
Designed for maximum reliability and minimal maintenance, EHAs feature a closed
housing that prevents contamination, moisture, and air infiltration. Linear bearings provide extra support during rod extension. Pressure relief valves provide safety to hydraulic components. EHAs are preferred in a number of applications due to their ability to handle heavy loads with their compact envelopes.
Known as the most powerful type of actuator on the market, EHAs are very easy to command even from a far distance from the application. They can be controlled both wired and wirelessly. Due to their incompressible fluid and check valves, EHAs can hold constant loads without the motor in operation.
The most significant obstacle with an EHA is that it contains hydraulic fluid, which can leak. This causes the contamination of nearby equipment, products, and the environment. However, EHA leaks are a rare occurrence due to advances in EHA seal technology and overall design resilience. Most hydraulic systems leak from hose and fitting connections which EHAs do not have. Depending on the application, another consideration when deciding between an EHA and an EMA is the
EHA's level of accuracy. EHAs are less precise than EMAs, so applications requiring a high level of accuracy are not ideal for an EHA.
EMAs
The most advantageous feature of an EMA is its leak-free quality. This means no product, equipment, or environmental contamination, as well as less maintenance. This yields reduced costs and greater productivity. Precise operations are another key benefit, leading to repeatable actions with easy, automatic operation controls. Simple wiring leads to quick and easy installations. Additionally, there is no need for external pumps or motors since EMAs are smaller, thus taking up less space.
Having said that, there are several limitations to consider. Since EMAs are less durable than EHAs, they do not perform optimally in outdoor applications. A corrosive environment and uneven terrain that is common in many off-road applications can create problems for EMAs, which do not handle moisture, shock, or vibration as well as EHAs. As a result, EMAs are primarily utilized for in-plant settings where they are housed in a climate-controlled environment. Additional limitations to consider are an application’s extend and retract forces. If the force required in an application is relatively higher, both the speed and life expectancy of an EMA decrease significantly.
Past Performance & Future Opportunities
Hydraulic technology has been used effectively in off-road machinery for decades. This is due to its proven performance in rugged environments with robust potential for shock, vibration, dust, water, corrosive chemicals, and other potential hazards. Hydraulic actuators have historically enjoyed a lead in power density over EMAs, which enhances their performance in the most demanding applications.
Recent advancements in EMA design have captured headlines and interest in recent years. Key to their popularity is an increased market focus on zero-leak initiatives that are vital in industries such as food manufacturing where contamination is a concern. There are also other industries concerned about the environmental impact of hydraulic fluid. Improvements in longevity, control, stroke length, and force capacity have also increased their popularity.
Despite their popularity, EMAs are not suited for all applications. They are ideal for plant settings where their tight tolerance for position sensing and precision operation are more critical. EMAs have faced roadblocks to gaining market share in the off-road industry
because of their inherent design, which makes them less durable than EHAs. They are more susceptible to shock loads and vibration; such damage may cause side loading and possible shearing of the rod screw. That rules out applications requiring movement over uneven surfaces such as stumps, rocks, and other hazards that could cause possible shock loads on the EMA.
Some manufacturers address this concern by adding dampeners to the EMAs to improve shock absorption. Despite these enhancements, EMAs remain inferior to EHAs for many applications. This is why EHAs are often the product of choice in mobile equipment industries including construction and agriculture. These areas are known for their harsh environments including uneven/rugged terrain, rain, and humidity, all environmental factors that compromise an EMA’s performance. Finally, there have been instances in which the specifier has been attracted by positive press to install an EMA, only to learn that it breaks quickly. This happens due to the duty cycle of the application being greater than it was initially designed for, or greater than the environment in which the application is in.
Considerations When Choosing the Right Actuator
Not all EHAs and EMAs perform in the same manner. It’s important to evaluate multiple considerations when choosing the right EHA or EMA for an application. Considerations such as force, speed, power, envelope size, etc. should all be factored in to help size an actuator so that it draws the lowest electrical current while providing optimal performance.
As previously mentioned, determining the level of potential vibration and shock loads in a particular application also helps determine what type of linear actuator to choose. Other environmental factors such as the potential ambient temperature of the application, a possible corrosive environment, or the potential for the actuator to be pressure washed or submerged under water are all factors that should be considered.
Force is a critical consideration in choosing the right actuator for an application. For low-force applications, especially under 2000 lbf, ball screw EMAs are preferable due to their ability to extend and retract quickly with a long life expectancy. As the extending and retracting force
Digital Documents reverse-engineer systems cross/type components
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ELECTROMECHANICAL ACTUATOR VS.
Description
Uses an electric motor to convert electric energy into a mechanical force most commonly by way of a ball or roller screw
ACTUATOR
Advantages Disadvantages Maintenance Applications
Zero leak
High precision and accuracy
Quick and easy installation
Less durable in outdoor environments
Harder ability to absorb shock and vibration loads
Minimal
Factory automation
In-plant material handlers
Mobility transportation
a CT ua TO r
Self-contained hydraulic power unit featuring a built-in actuator operated by an electric motor.
continued from page 23
required in an application increases, EMAs' performance degrades. Both the EMA speed and life expectancy decrease greatly. EHAs, in comparison, are advantageous at higher force requirements because of their inherent higher-power density due to hydraulic fluid power. It is always important to review catalog information to determine which factors are most critical to the application.
Evolution of EHAs
In recent years, EHAs have benefitted from numerous improvements that make them more competitive and attractive. A noticeable change is the incorporation of Controller Area Network (CAN) bus into EHAs, making them smarter, more efficient, and more user interactive. It is now possible to not only control actuation speed, but determine actuator position using advancing and existing technologies such as LVDTs and non-contact sensors. This offers users the ability to fully command every aspect of the EHA from basic on/off inputs
Power density to lift heavy loads
Durable to operate in the most extreme environments
Absorbs application pressure spikes
Easy installation
Potential hydraulic fluid leak
Less precision
to complete absolute positioning PID loops. EHAs can also have multiple built-in sensors to monitor motor winding temperature, motor RPM, and amp draw to offer users complete visibility and key diagnostic data.
These controllers can be assembled directly onto the motor, which has begun to transition from brushed motors to much more efficient and longer-lasting brushless motors. The greater control, life expectancy, and efficiency is a significant boost to potential productivity, which means longer work uptime. This is especially critical in the push towards electrification where higher efficiency and lower power options are vital to keep battery-operated machines running.
Choosing the Right Supplier
There are many manufacturers of both EHAs and EMAs. Any chosen partner must have sufficient technical knowledge of multiple solutions and alternatives. For example, if neither option is the optimal solution for a potential application, it is important to consider working with a partner that can offer other solutions that
Minimal Off-highway, agriculture, and construction
Marine Mining
are designed for the up-and-coming electrified world. An example might be an ePTO or ePump, which may be a better fit for a particular application. Parker, for example, uses special algorithms to calculate the tradeoff between power consumption and speed to help identify the best solution for your application.
Conclusion
The market is experiencing a shift in thinking. Those who recently favored EMAs are reconsidering the benefits of improved, power-dense, and intelligent EHAs. Owners and operators are prioritizing power, speed, and durability which leads them to ultimately choose an EHA, thus helping to cement their place in hybrid environments.
Among their other attributes, EHAs are easy to install using a plug & play design. Technology advancements have enabled EHAs to meet current and future market needs, including the need to adhere to SAE J939, CANOpen, and other industry requirements. This positions EHAs well for both the hybrid and the future electrified world.•
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For further information on the Cordis Pressure Controls or any of Clippard’s line of precision fluid control product, visit www.clippard.com. Proudly made in the USA.
No integral bleed required
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The Importance of in Construction Cranes
CBy SUCO ESI North America
Essential Tools for Industrythe
ranes are fundamental instruments in the construction sector, allowing for efficient and precise movement of heavy materials. Pressure sensors are crucial to ensure these machines operate safely and effectively.
How Pressure sensors Measure Oil Pressure in Hydraulic Cranes
Most modern construction cranes are powered by hydraulic systems. The cranes’ movements are powered by pressurized oil. These hydraulic systems are dependent on pressure sensors, which provide real-time data concerning system pressure.
Pressure sensors in Mobile Cranes
Pressure sensors are used in mobile cranes to measure the pressure of the hydraulic fluid. This is important when controlling the crane’s movement. Pressure sensors, also called pressure transmitters or transducers, convert
this hydraulic pressure into an electric signal. Operators use this to monitor pressure and make necessary adjustments. This ensures the crane is operating within safe limits and prevents overloading or mechanical failures.
Sensors are built to withstand harsh construction site conditions. Not only are they durable, but they also provide precise measurements to help maintain the integrity and performance of the crane's hydraulic system. Cranes are large and potentially dangerous pieces of equipment that require meticulous monitoring. The use of pressure switches and transducers help in ensuring the safety of crane operation.
Improve safety with Pressure sensors
Essential for Load Monitoring
Pressure sensors measure critical parameters, such as brake and steering pressure. These sensors provide real-time feedback to help
prevent accidents caused by hydraulic failures and system overloads. The pressure sensor can alert the operator when hydraulic pressure falls below or exceeds the safe threshold.
Load monitoring ensures that cranes are operating within their safe working loads. Pressure sensors are important to this process. They measure the hydraulic pressure needed to lift the load, providing data that can be used to calculate the weight of the load being lifted.
AcCuracy of Load Monitoring systems
Pressure sensors deliver precise and dependable information in load monitoring systems. Operators use this key data to make informed load management decisions, helping to ensure that cranes do not exceed their load rating. By preventing overloads, pressure sensors contribute to the longevity of cranes and reduce the risk of accidents. Pressure sensors from SUCO ESI North America feature advanced digital signal processing technology and SOS sensing. These features offer high precision and reliability, which is essential for effective load monitoring.
OptimIzing Performance Using Pressure sensors
Integrating pressure sensors enables imme diate issue detection by swiftly identifying leaks or blockages, avoiding costly downtime while providing data-driven insights that help operators analyze performance trends and refine processes for improved productivity. Ultimately, operators achieve higher perfor mance standards while enhancing safety and reliability in construction operations.
Improving Crane Performance
critical information concerning the hydraulic system, used for lifting, lowering, and rotating heavy loads.
Ensuring safe Operations
Pressure sensors are used to detect system failures which could cause accidents or equipment damage. Sensors provide alerts, e.g. if hydraulic system pressure is outside of the safe range. This allows immediate action to be taken. It’s also essential in alerting to situations such as leaks or a burst hose, that can compromise the stability and safety of the crane. Pressure sensors help to avoid overloading, a major risk in crane operation. These sensors monitor the amount of pressure needed to lift a weight, helping the operator determine if the load is within the safe working limits for the crane. This is also done to avoid structural strains and possible tipping incidents, which could pose a threat to workers and passersby.
Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime cutting the overall cost of hydraulics. No Kinks No Hose
Durable & Versatile Pressure sensors
One of the goals of pressure sensors is to minimize electromagnetic interference (EMI) in crane operations. The pressure transducers or sensors from SUCO ESI North America are specifically designed to resist EMI. This ensures that crane control systems function smoothly, even in environments with high electromagnetic activity. Pressure sensors help maintain safe, efficient, and reliable construction crane operations. They provide
Pressure sensors are built to last and tested in tough conditions, like salt chamber tests, to make sure they perform over time. They come in different IP ratings, so they can work in various environments and climates. SUCO ESI North America’s sensors are field-adjustable, which means you can make quick changes on-site when machinery is down, helping to reduce downtime and make installation easier. These important features are essential for ensuring safe and efficient operation of construction cranes.•
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Stocks FM Series Motors: Ready for Your Application Needs
FluiDyne Fluid Power is excited to announce the newest addition to their motor product line: the FM4 Series Motor! Now available in stock alongside their FM1, FM3, and FM50/51 models.
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Diamond Hydraulics Inc.
Diamond Hydraulics is a veteran owned small business that manufactures, rebuilds, and repairs hydraulic equipment including cylinders, pumps, motors, valves, power units, and much more. We were established in 1999, and have over five decades of experience in hydraulic equipment repair.
Diamond Hydraulics provides quality workmanship, extensive industry knowledge, and fast turnaround time on repairs and replacements. All repairs are brought back up to OEM standards and tested with state-of-the-art test equipment.
Protection for All Things Hydraulic, Pneumatic and Fluid Power
MOCAP manufactures an extensive range of protective closures to guard pipes, hoses, and hydraulic fittings from dirt, moisture, and damage to help maintain equipment reliability. Included are a variety of sizes and styles of Threaded and Non-Threaded plastic Caps and Plugs for Metric, NPT, BSP, JIC and SAE Threaded Connections, Ports and Fittings. These are in addition to MOCAP’s already extensive lines of lowcost Caps, Plugs, Grips, Netting, Tubing and Tapes for general Product Protection, Finishing and Masking. All of our stocked items are ready for immediate shipment and available in Box, Mini-Pack and Micro-Pack quantities. Free Samples are always available for testing purposes.
sales@mocap.com www.mocap.com
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800.521.7918
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Check Valve Carriers
Inserta® Check Valve Carriers provide a convenient and effective way to install an Inserta® ICS or IGS
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The flow path through the valve is axial as opposed to the 90 degree flow path in a typical hydraulic cartridge valve, which can provide design flexibility in certain applications. ICS and IGS check valves, ordered separately, are available with fixed restrictive orifices for flow control options.
Inserta® Products
Blue Bell, PA | www.inserta.com | 215.643.0192
Hydraulic Noise and Shock Suppressor
Wilkes and McLean manufactures an In Line Noise and Shock Suppressor for hydraulics and is a stocking distributor of Nacol Accumulators. Our suppressors eliminate pulsations, which greatly reduces noise and vibration from applications from a few gallons up to 200 gallons. We stock all of our suppressor sizes as well as Nacol Accumulators and parts from 1/5 of a pint up to 15 gallons, in our Schaumburg, Illinois facility.
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A full time position is available for a Fluid Power Application Engineer at Fluid Power, Inc. Positional responsibilities include design, development, and testing of hydraulic and pneumatic systems, component research and selection, 3D modeling, and proposal generation. Some customer interfacing is required.
This is a stimulating position that allows the successful candidate to participate in interesting projects involving a global customer base, across a variety of industries and applications. There is also an opportunity to participate in the design, development, and application of the company’s own proprietary components, in addition to application of third party components.
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CLASSIFIED BULLETIN
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This problem arose when one of our instructors was teaching the basics of the hydraulic systems he used. He asked if a wet coating was present on the tool that depressed the nitrogen stem on the Schrader nitrogen valve. The instructor indicated that releasing some of the nitrogen would fix the problem. He said that there was a small amount of oil indicating that the accumulator piston was leaking oil into the gas side. Replacing the accumulator fixed the problem.
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Our experienced team is always available to help customers identify the best product for their project specifications, quality requirements and bottom line. We’ll even work with you to set forecasts for JIT delivery management!
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