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Design for Maintenance
A CALL TO ACTION FOR INDUSTRIAL EQUIPMENT ENGINEERS
By Garrett Hoisington, President CEO, Open Loop Energy
» IN MANY PARTS of the world, we enjoy modern conveniences that make our lives safe, comfortable and enjoyable. Some of these are easy to take for granted. Late model appliances, automobiles and other equipment offer specific design features that make life easier for maintenance. Your refrigerator filter is easily changed from the front without having to move the appliance to access the rear. Your automobile has sensors and an accessible diagnostic port to help determine why the check engine light is on. Things haven’t always been this way, and while access and ease of maintenance is designed into some machinery, there’s room for improvement in others.
My career has been spent supporting the mining industry. The progression and focus on safety has been tremendous. OSHA was
established in 1971 and the Mine Safety and Health Administration was established in 1977. That wasn’t very long ago, and yet a comparison of workplaces then vs now is a stark difference. I can remember operators having to climb ladders to access a piece of equipment the size of a two-story house. Today, there are hydraulic access stairs with handrails. What's great is that it's the imprpoved industry standard. Looking back, it’s easy to see the incredible progress that has been made since the establishment of these regulatory agencies and the beginning of a focus on workplace safety and the long-term health of workers.
Owners and operators of large industrial equipment are held accountable for how machinery is operated and maintained. Unfortunately, many of the industrial equipment designers and manufacturers aren’t doing enough to improve the challenges their customers face after the equipment is put into service. There are a few designs I’ve seen recently where our customers struggle with changing hydraulic pumps or cylinders for example. The pumps are mounted inside a tank, or the cylinders are mounted on the equipment with no designed lifting points. Many times there are structures above that block access to a crane and the pre-designed solutions are missing. The end user is then responsible for figuring out how to perform these component changes themselves. They often have to hire engineers to design special tooling or lifting points, and then hire companies to manufacture these tools. In the meantime, the maintenance personnel are faced with decisions on how to get the machinery back online the safest way available at the time. Sometimes it’s not safe, which can lead to injury or death, and many times
a difficult changeout isn’t clean which can lead to additional and unnecessary downtime.
This is where a designer has the opportunity to save a life, or at least reduce the risk of injury while maintaining their equipment. I’m sure there are engineers and designers that do this already, and if you are one of them I applaud you for designing safety and maintenance ergonomics into the machinery. If you don’t currently consider the maintenance tasks and major components that need to be changed most frequently, it’s time to start. This includes access, considering how components will be removed as well as considerations that will improve technicians’ ability to troubleshoot the system. If you’re not someone who has ever participated in maintenance tasks, I would encourage you to find people who have. Ask their opinion on designs and what they would recommend for making troubleshooting and service easier. Your customers will love you for it.
Many times engineers and designers get to visit the location where the equipment will be used. Take this opportunity to speak with maintenance crews that will be responsible for taking care of the equipment. Share your designs and get as much feedback as you can. Use it to help make their lives easier and safer. In the end, this could be the competitive edge you have over the competition!
I believe there is always room for improvement in everything we do. All our customers take safety and reliability seriously, and the technicians that are performing the work can use all the help we can give them. There are people all over the world working long hours struggling with things that proper machine design can prevent. Don’t forget those people, and use your design powers to save someone’s life, sanity, or time.
Bruce Bowe, CFPAI/AJPP - Altec Industries, Inc. Cary Boozer, PE, CFPE - Motion Industries, Inc. 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
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 Evaluating a Customer’s Circuit Before Trouble Shooting
By Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM, CFC Industrial Training
» I HAVE BEEN teaching hydraulics since 1980 and found that many good maintenance technicians cannot determine what pressures should be on the attached circuit. How well will you do?
Note: The actual drawing shown does not show the counterbalance bypass check that was built into the valve used. (Errors and omissions like this are common with drawings we are given to trouble shoot a problem.)
First: What would you expect the approximate pressure to be on gage “A,” if only the electric motor and Sol. 1B were energized?
Second: If the system were turned off with the ram fully retracted, would the ram drift down?
Third: If the ram were held in the fully retracted up position with the motor running and Solenoid 2B energized, what would gage “E” read?
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. For the solution, see page 25.
Gage D
Gage B
Gage C
Gage E
Gage A Sol. 2B
2A
Pilot pressure pump piggy backed on main pump
Sol. 3B
FOR MAXIMIZING THE LIFESPAN OF PROPORTIONAL VALVES STRATEGIES 6
By Steve Warnock, Director of Engineering & Technical Support, Bailey International
Proportional valves are sophisticated electromechanical devices that control the flow rate and pressure of fluid within a hydraulic system. Unlike conventional valves, which can be switched either on or off, proportional valves provide precise control over fluid flow by adjusting the size of the valve opening in response to input signals. In this article, we’ll analyze proportional valves, highlighting their functionality, design considerations, and performance characteristics.
Like any mechanical device, proportional valves are subject to wear and tear over time, which can lead to decreased equipment performance and costly downtime. For this reason, we will also address practical concerns surrounding the longevity and reliability of these valves, offering valuable guidance on maintenance best practices, troubleshooting techniques, and optimization strategies. By equipping yourself with the knowledge and tools needed to prolong
and cost-effectiveness of your hydraulic systems.
Understanding Proportional Valves: A Technical Overview
Proportional valves enable fine-tuning of flow rates and pressure levels, making proportional valves ideal for industries that require dynamic and precise fluid control, such as forestry, material handling, construction, and farming, to name a few.
The basic components of a proportional valve include a spool or poppet mechanism, an actuator (such as a solenoid or servo motor), and sometimes a feedback mechanism (such as a position sensor). When an electrical signal is applied to the actuator, it moves the spool or poppet to adjust the size of the valve opening, thereby regulating the flow of fluid. A position sensor, if included, provides feedback on the actual position of the valve, allowing for closed-loop control and precise adjustment of flow rates.
Factors Affecting Proportional Valve Lifespan
Several variable factors impact the lifespan and performance of proportional valves, including:
Fluid Contamination: Contaminants such as dirt, debris, and moisture can degrade the internal components of a proportional valve, leading to increased friction and corrosion. Implementing effective filtration and fluid cleanliness practices is essential for maintaining optimal valve performance and longevity.
Overpressure: Excessive pressure levels can cause damage to the internal seals, springs, and other components of a proportional valve. For this reason, operating the valve within its specified pressure range and implementing appropriate pressure relief measures is highly encouraged to prevent overpressure conditions.
Temperature Extremes: Extreme temperatures can affect the performance and reliability of proportional valves, causing thermal expansion, contraction, and degradation of materials. Maintaining proper temperature control within the hydraulic system is critical for ensuring optimal valve operation and longevity.
Mechanical Wear: Continuous operation and repetitive cycling can cause mechanical wear and fatigue in the moving components of a proportional valve, leading to decreased performance and eventual failure, which is why implementing regular inspection, lubrication, and maintenance procedures can
continued on page 08
MH300 Series Telescopic Cylinder
A Brief History of Proportional Valves
The origins of propor tional control can be traced back to the mid20th century, with early experiments and research efforts focused on achieving variable control of hydraulic and pneumatic actuators. One of the pioneering developments in this was the introduction of servo-valves in the 1950s, which utilized electrical or mechanical feedback mechanisms to modulate the flow of fluid in propor tion to an input signal. These early servo-valves laid the groundwork for more sophisticated proportional control systems, enabling finer control motion and force in industrial applications such as metalworking, automotive manufacturing, and aerospace.
Throughout the 1960s and 1970s, advancements in electronics and materials science led to significant improvements in proportional valve technology. The introduction of solid-state electronics and microprocessor-based control systems enabled more precise and responsive control of proportional valves, while advancements in materials and manufacturing techniques allowed for the development of smaller, lighter, and more durable valve designs. These innovations expanded the range of applications for proportional valves, allowing for their widespread adoption.
The late 20th century witnessed further refinements in proportional valve design and performance, driven by the growing demand for higher accuracy, reliability, and efficiency in fluid power systems. Manufacturers began incorporating advanced features such as onboard diagnostics, digital communication protocols, and integrated feedback sensors into their proportional valve designs, enhancing their functionality and ease of integration into complex control systems. Additionally, the adoption of standardized interfaces and protocols, such as CAN bus, facilitated seamless interoperability between proportional valves and other components within modern mobile equipment.
In more recent years, the ongoing trend towards automation and digitization of manufacturing processes has fueled further innovation in proportional valve technology. Proportional valves can now be equipped with sensors that provide real-time monitoring of performance metrics such as pressure, flow rate, and temperature. This data can be collected and analyzed to optimize the operation of hydraulic systems, improve efficiency, and prevent potential failures. These advancements are enabling unprecedented levels of efficiency, flexibility, and productivity in fluid power applications across a wide range of industries, from heavy equipment to elevated work platforms and more.
So regardless of the type of proportional valve you select, or even which industry you are a part of, one thing remains certain - the growing demand for automation and efficiency within hydraulic systems (and proportional valves specifically) will continue to evolve from here, which means innovation around enhancing the capabilities of fluid power across sectors is almost always right around the corner.
continued from page 07
help mitigate mechanical wear and prolong valve lifespan.
Electrical Issues: Electrical faults such as short circuits, voltage spikes, and electromagnetic interference can damage the electronic components of a proportional valve, affecting its control and feedback mechanisms. By implementing proper electrical protection measures, ensuring a stable power supply becomes easier.
To maximize the lifespan of proportional valves, follow these best practices:
1
2
3
Use Effective Filtration: Install high-quality filters to remove contaminants from the hydraulic fluid. This will go a long way in preventing damage to the internal components of the proportional valve.
Maintain Proper Fluid Condition: Monitor fluid condition regularly and replace or replenish fluid as needed. Use compatible fluids that meet the specifications of the appropriate proportional valve manufacturer.
Operate Within Specified Limits: Operate the proportional valve within its specified pressure, temperature, and flow rate limits to prevent overloading and causing damage to internal components. Using the right pressure relief and incorporating cooling systems such as heat exchangers or fans to dissipate excess heat generated during operation helps maintain safe operating conditions.
4
5
Conduct Regular Inspections: Perform visual inspections and functional tests of the proportional valve at regular intervals to detect any signs of wear, damage, or malfunction. Replace worn or damaged components promptly to prevent further degradation and ensure reliable operation.
Lubricate Moving Parts: Consistently apply lubricants to the moving parts of the proportional valve to reduce friction, wear, and corrosion. Remember to only use lubricants compatible with the materials and operating conditions of the valve to ensure longevity. If you are unsure how to determine which lubricant is best for your valve, its technical documentation, including the user manual or datasheet, is a good place to start. Manufacturers often specify recommended lubricants based on valve type, materials of construction, and operating conditions in these materials.
6
Calibrate and Tune Control Systems:
Periodically calibrate and tune the control systems of the proportional valve to maintain accurate and responsive operation. Verify the accuracy of feedback signals from position sensors and adjust control parameters as needed. One approach for accomplishing this is leveraging diagnostic software. These tools provide valuable insights into the behavior of proportional valves and help identify any deviations or anomalies in feedback signals. This information can then be used to make informed decisions regarding control parameter adjustments and system optimization.
Common Types of Proportional Valves
Proportional valves come in various configurations to suit different applications and performance requirements. Some of the most common types include:
Proportional Directional Control Valves:
These valves regulate the direction of fluid flow in hydraulic systems, allowing for precise control of actuator motion. They are commonly used in applications like machine tools, mobile equipment, and industrial automation.
Proportional Pressure Control Valves:
These valves regulate the pressure of fluid within a hydraulic system, maintaining a desired pressure setpoint regardless of load variations. They are used in the injection molding and metal forming applications we mentioned earlier.
Proportional Flow Control Valves: These valves regulate the flow rate of fluid within a hydraulic system, allowing for precise control of speed and motion. They are used in applications such as hydraulic presses and aerospace systems. •
Optimize productivity, CO2 reduction, and energy savings through enhanced monitoring. Learn how the design and implementation of smart devices at the machine level can help to achieve production goals, reduce downtime, and cut costs by making data-driven decisions. This paper will explore the ramifications of adding significant monitoring and communication to the standard modular air preparation system in the industrial automation workspace. Such a system can reduce compressed air use while digitally finger-printing the machine's current performance. Let us use a case packer as an example: Typically, these machines have pneumatic actuators that operate at a remarkably high cycle rate. If the case packer is outfitted with sufficient monitoring, communication, and control, the end user can very quickly realize deep energy savings (25-40%) by “semi-automatically” switching the machine into one of two possible “eco modes” when the machine is idle. The end user can also take full advantage of the monitoring (via an OPC UA interface) to collect and analyze machine performance and establish condition-based maintenance (CBM) algorithms, thus minimizing breakdowns due to pneumatic component failure.The data stream could bypass the traditional methods of PLC mining and go directly to the end user’s Supervisory Control and Data Acquisition (SCADA) system to minimize integration effort, particularly on legacy machines.
Smart & Sust ainable Monitoring Solutions for Pneumatically-Driven Machines
Revolutionizing Compressed Air Management
By Jon Jensen, Industry Projects Manager, Energy, and Nathan Eisel, National Product Development Manager, and Sahith Raaghav Sanike, Energy Engineer, SMC Corporation of America, CA
Pneumatics is the discipline that describes compressed air flow and how to use the properties of compressed air to transmit energy or convert the same into force and motion. Pneumatic applications use the most widely available resource — air. Pneumatic systems are integral to industrial automation and are especially useful when machines need linear motion or elastic behavior. They also offer a functional way to store energy for subsequent uses. Pneumatic systems are clean, dependable, and simple to operate, and thus are widely used in the food & packaging, beverage & brewing, automotive, and pharmaceutical industries, to name a few. Pneumatic systems have good power density, low initial cost, and significant reliability. The only significant drawback is their low energy efficiency.Because of this inherent inefficiency, compressed air is typically one of the most expensive forms of power transmission used in industry, so much so that it is often considered a “third utility.” When viewed as an expensive utility, or process variable, proper management is required to minimize the environmental impact. The duty cycle of any pneumatic machine includes the
supply of the compressed air, the mechanical work done by actuators/drives, and air expansion that generates noise. Air expansion – treated as energy loss – has the following sources: leakage through holes and breaks in pneumatic lines, leakage through damaged or mismatched connectors, and internal leakage in directional control valves, linear and rotary actuators, etc. Measuring leaks and other forms of compressed air waste from pneumatically-driven machines is difficult due to the geometry of the leaking components, safety barriers around the machinery, and scheduling enough planned downtime on the machine to perform a leak survey, since planned production always takes precedence. Therefore, calculating the system efficiency is quite challenging, necessitating the use of measuring equipment, trained and skilled professionals, and calculations. The main objective of this paper is to propose a userfriendly method for determining, optimizing, and eventually eliminating compressed air waste, using an affordable and simple monitoring system, hereafter referred to as an Air Management System, or AMS. It is a widely accepted truth in the pneumatic industry that
most pneumatic component failures can be predicted by a leak. A byproduct of monitoring the key performance indicators (KPI’s) of pneumatic system performance, namely pressure and flow, will result in improved reliability. Having the data available will assist a production facility in implementing a condition-based maintenance program. Condition-based maintenance (CBM) is a widely followed industrial management philosophy that aims to minimize the total cost of inspection, repairs, and replacements. This is achieved only by continuous monitoring of the operational condition of a critical component or asset.
Continuously monitoring and optimizing compressed air to pneumatic-driven machinery is now possible using the approach proposed in this paper. As a result, energy losses are more easily identified and mitigated, the opportunity to produce cleaner and more sustainable products is provided, machine digitalization is achieved, costly downtime is avoided, and excessive maintenance-related expenditures are reduced. In 2022, SMC Corporation performed a six-month study at a key client’s facility, installing an Air Management System (AMS) on a bottle-filling production line with 10 machines. Results were extrapolated to 8760 hours of operation (24 X 365). The main objectives were to: Demonstrate the use of an AMS to conserve energy on production machines during their idle time.
Demonstrate secure wireless Data Acquisition from IO-Link sensors on the machine using OPC UA protocol without the use of an edge device.
Make the data available for future integration into the client’s existing SCADA system for purposes of condition-based maintenance and digitalization.
Air Management System (AMS)
The Air Management System evaluated was an assembly of components, consisting of the following:
• Electro-pneumatic pressure regulators
• Manual pressure regulators
• Multiple communications units (HUB):
• 2AMS base units
• 8 remote units
• Residual pressure relief valves
The AMS system was designed to easily and semi- automatically reduce or remove (isolate) the air pressure supplied to a machine while idle. The primary sustainability benefit comes from using the compressed air when it is needed to run the production process and reducing or removing the pressure when the machine has paused, no matter how briefly. Consequently, leakage and other non-productive uses of compressed air on the machine are reduced or removed. Consider, as an analogy, that most modern automobiles set the engine to idle when the vehicle is coasting and turn off the engine completely when the vehicle is stopped, thus reducing, or removing the need for fuel.
The AMS base unit had an integrated OPC UA server to facilitate data transfer. Compressed air pressure, flow, and temperature values were stored at 10Hz in an internal buffer and published to the supervisory control system at 1Hz via the integral OPC UA client. Data was simultaneously published to the machine’s controller (PLC), using an industrial fieldbus protocol (the device used supports PROFINET, EtherNet/IP, and EtherCAT). The eight wireless remote units (maximum of ten remote units possible within 100-meter radius), were paired with the AMS base units. This enabled a hybrid system wherein the PLC takes control of the realtime processes, and the data is communicated to the data cloud for analysis. The wireless remote units communicated with the base unit using a proprietary wireless protocol at the 2.4 GHz ISM (Industrial, Scientific & Medical) frequency band. The data generated by the AMS is high resolution, so fine details of a machine’s operation can be observed. With analytics software packages, high-resolution data can be used to detect air leakage, predict pneumatic component failures, build digital twins, and understand the machine’s efficiency more deeply.
The AMS configurations used were as follows:
• AMS-A (see Figure 1)
• Electro-pneumatic pressure regulator
• AMS HUB - BASE
• AMS HUB - REMOTE
• Residual pressure relief valve
• AMS-B (see Figure 2)
• Manual pressure regulator
• AMS HUB - BASE
• AMS HUB - REMOTE
• Residual pressure relief valve with soft start
1
2
The AMS unit’s sustainability features include management of the machine’s operational mode, standby mode, and isolation mode. When the measured flow rate drops below a user-defined value, for longer than
3
the user-defined time, and the machine’s digital input signal (24V DC) is ON (provided to the AMS HUB), the AMS reduces the output pressure (operating pressure setpoint) to the secondary, or stand-by, pressure setting (lowest
continued on page 12
Figure
Figure
PSI, MPa, Bar
CFM, L/Min, M3/Min
etc.
Figure
feasible pressure setting on the machine). If the standby mode continues until a user-defined time, the isolation valve closes to exhaust the output pressure. From standby mode or isolation mode, the AMS’s output pressure is set to increase to the operational pressure mode when the standby input signal goes OFF (0 VDC), thus putting the machine back into Operation Mode. The AMS installed for our test was designed to replace the traditional filter/ regulator unit for easy installation and maintenance. Its compact size took little additional space in the facility or on the machine, making it an attractive solution for users looking to improve their environmental performance without incurring significant installation costs.
AMS & IO-Link
Connected devices are gaining importance for their increased capability, easy configuration, and the ability to change parameters while the system is running, providing higher resolution data for enhanced operations. The AMS was developed to simplify and standardize device wiring and installation. IO-Link compressed air pressure, flow, and temperature sensors were built into the AMS HUB. In addition, the AMS included a web-based configuration tool to set the parameters of the AMS unit. Although not used in the initial case study, the AMS unit was able to support an additional IO-Link sensor (such as dewpoint or vibration) that could be connected to the AMS HUB. Figure 3 shows a Digital Ecosystem where IO-Link devices are connected and monitored using an Air Management System (AMS) in a star topology network.
AMS & OPC UA
Manufacturers across the world are prioritizing the need to digitize factory data. The advent of Industry 4.0 has driven the manufacturing environment towards machine-to-machine communication or machine-to-cloud communication to make improved production decisions. This makes OPC UA the world’s most popular standard for open automation data connectivity, since it is manufacturer, platform, and programming language independent. With built-in security mechanisms, OPC UA avoids the use of Distributed Component Object Model (DCOM) and eliminates translation middleware. The AMS does not require the use of an “Edge Computing” device but will work with architectures that utilize them. Innovative technologies and methodologies such as new transport protocols, security algorithms, encoding standards,
or application services can be incorporated into OPC UA while maintaining backward compatibility for existing products. OPC UA products built today will work with future products. The Air Management System in our test had an embedded OPC UA server which provided secure data connectivity to directly integrate into the client’s enterprise network.
Case Study | Baseline Conditions
Production line
Ten machines were configured in the bottle filling line. The machines were numbered from 1-10 in the order of the production process; the functions of the machines were:
• Machine 1 – Bottle tipping
• Machine 2 - Bottle unscrambling
• Machine 3 - Labeling
• Machine 4 - Filling
• Machine 5 - Capping
• Machine 6 – Cap sorting
• Machine 7 – Shrink-wrapping
• Machine 8 – Cardboard box erecting
• Machine 9 – Box weighing
• Machine 10 - Palletizing
The annual operational hours of the facility were 8,760:
• 60 % - Production mode
• Product made
• 38% - Idle mode
• No product made
• Machines at full pressure
• 2% - Isolation mode
• Machines at no pressure
Operation
In the typical production process, bottles are unloaded and tipped into a drum. A conveyor carries the bottles from the drum and drops them into an unscrambler. The bottles are set upright, loaded into pockets on a conveyor, and moved toward the filling machine. The product is dispensed and caps from the cap sorting machine are indexed in the capping machine using air nozzles. The capping machine applies the caps and seals the bottles. The bottles move toward the labeling machine wherein labels are applied, and a group of bottles is then shrinkwrapped before being transferred to boxing. Simultaneously, cardboard boxes are erected at the respective machine and the wrapped bottles are placed in the boxes. A box-weighing machine compares the box’s weight to the standard and pneumatically rejects those that are out of compliance. The box then moves to the palletizing station where a group of boxes are shrink-wrapped on a pallet.
Every action on every machine is pneumatically driven and involves the use of a plethora of pneumatic components. Any mishap in
the process or a machine waiting (idle mode) for the product to arrive still consumes compressed air in terms of leaks or blow- offs. To estimate energy savings and carbon emission reduction for any given system, it is important to consider:
• The specific power consumption of the compressors (kW/CFM)
• The compressed air energy costs ($/kWh)
• The CO2 emission factor (kgCO2/kWh) The annual hours of operation (see Table 1)
The target for compressed air cost reduction is typically the “Idle-mode air consumption,” which includes the machine’s internal leakage, air used for blow-offs, air used to cool electric motors and electrical cabinets, and other pneumatic functions. Also of concern are the machine’s pressure set points, average, maximum and minimum flow rates, and any fluctuations.
Instrumentation
The activity began with selecting and installing the instrumentation required to measure the compressed air pressure and flow to understand the machine’s air consumption.
Pressure and flow measurements
Each machine had a 1-inch air inlet pipe to the machine. Compressed air flowed from left to right through an appropriately sized air preparation unit with a manual residual pressure relief valve. In-line flow meters and pressure sensors were installed at the air inlet of all 10 machines. The air flow and pressure data was obtained using proprietary data loggers. Table 2 shows the pressure readings on the machines when in production mode and in idle mode. Table 3 shows the flow readings on the machines when in production mode and in idle mode.
AMS installation
The AMS units evaluated had an Ingress Protection (IP) rating of 65, which eliminated the need for a protective enclosure. They were installed as shown in Table 4.
Other installation considerations included:
• Digital integration of the AMS units
• Communication cable (M12 -RJ45 Ethernet cable) to connect the AMS base unit to a network switch and assign an IP address.
• Supplying 24V DC power to the AMS units
Table 1
Table 3
Compressed Air Pressure
Table 4
Machine 1 Tipping AMS-B, Remote
Machine 2 Unscrambling AMS-B, Base
Machine 3 Labeling AMS-B, Remote
Machine 4 Filling AMS-B, Remote
Machine 5 Capping AMS-B, Remote
Machine 6 Cap Sorting AMS-A, Base
Machine 7 Shrink-wrapping AMS-A, Remote
Machine 8 Cardboard Box Erecting AMS-A, Remote
Machine 9 Box Weighing AMS-A, Remote
Machine 10 Palletizing AMS-A, Remote
from the host machines
• Machine input signals for activating standby and isolation modes. In this case, a digital signal that provided the machine state was used to activate standby mode and isolation mode. IIoT architecture, as shown in Figure 4
• Embedded OPC UA server
• IoT gateway – with OPC UA client
• Data cloud – for data processing
• Data visualization software
• Creation of OPC UA tags, so that the OPC UA clients can access the pressure and flow data
Results and Discussion
Reducing energy consumption during idle mode to first establish the baseline performance, we measured the compressed air pressure and consumption on all ten machines in the production line. As expected, there was no significant reduction in pressure or air consumption by the machines during idle mode. The average pressure reduction between the production mode and idle mode in the entire line, as observed in Figure 5, was 2%.
After the installation of the AMS units on the machines, the data was thoroughly analyzed by the client’s proprietary data visualization software. The AMS units semi-automatically reduced the pressure supply on the machine during the traditional machine idle mode by activating the standby mode. The user defined the secondary pressure (or the standby mode pressure) and the threshold flow on the AMS web configurator after understanding the basic pressure and flow
Table 2
Figure 5
continued from page 13
requirements, and pneumatic functions of the machine. It is evident in Figure 6 that the average pressure reduction for the production line, because of standby mode, was 63%.
There were no changes to productivity, and no changes made to the machine’s normal operation when in production mode. The machines benefit from standby and isolation mode functionalities only when production is stopped. The significant pressure reduction contributes to the significant decrease in air consumption. The activation of the standby function during the machine’s idle mode significantly reduced the artificial demand that
existed otherwise. As the machines switched into isolation mode, there was no consumption, as shown in Figure 7
Table 5 and Table 6 (below) show a 26% decrease in annual power consumption (from 230,570 to 170,719 kWh) in the entire production line, realized by installing an AMS and taking full advantage of the standby mode and isolation mode functionalities. The savings were realized by switching the production line into isolation mode 36% of the year, as compared to the previous state in idle mode (paused under full pressure) 38% of the year. The cost-saving calculation (see Table
7 below) subtracts the annual cost of air after the installation of the Air Management System from the annual cost of compressed air before the installation of the AMS.
• $ = (annual consumption [ft3]) × (USD/ft3)
• ROI = (total investment) / (annual cost savings)
• kWh = [(kW/CFM) × 60] × (ft3)
• Emission reduction = (kgCO2/kWh) × (kWh)
• $ = annual cost
• Ft3 = annual air consumption
• USD/ft3 = cost / cubic foot
• kW/CFM = specific power
• kWh = annual energy savings
• kgCO2/kWh = emission factor
Figure 7
Figure 6
Value proposition
It can be seen from Table 7 and Table 8 below that the value of the Air Management System (AMS), just based on the energy savings proposition, generated a return on investment (ROI) of just over one year. Of course, the savings will be specific to each application, and can vary widely due to the flow rate of each individual machine. Gathering baseline data and prioritizing those machines or production lines that have the potential to generate a good return on investment is always a sound strategy.
Table 5 - Financial Case Cost [USD]
Table 6 - Sustainability Case Energy Savings (kWH) 59,851 Energy Savings (MWh) 59.85 CO2 Reduction (kgCO2e) 46,501.36
Conclusion
Although alluded to above, it is beyond the scope of this paper to quantify the additional cost savings and efficiency gains to be realized
by utilizing the data generated by a sophisticated monitoring system (AMS).
Consider, however, that an AMS can provide real-time pressure and flow data on each machine. That data can be used to identify future maintenance needs before machine or line stoppage occurs. At minimum, a data collection system can be set to provide an alarm when the average flow or pressure increases beyond an established baseline level, signaling the need for inspection of the machine during the next scheduled maintenance window.
An improvement to the above scenario would employ a Supervisory Control and Data Acquisition (SCADA) system to “watch for outliers” and compare those to the baseline data, again signaling the need for maintenance (data analytics). Even more granularity could be achieved by employing artificial intelligence (AI) to map the pressure and flow data against a machine’s motion profile. In such an instance, an increase in flow at a particular timestamp could be used not only to identify that a leak was developing, but to specify which portion of the circuit was beginning to fail. Then the repair parts could be ordered in advance, and the maintenance scheduled when convenient.
Each of the possibilities outlined above can provide the data necessary to perform predictive maintenance, with the end goal being little or no unscheduled downtime. Unfortunately, the cost avoidance of unscheduled production delays is difficult to calculate from the outside. It is certain that every manufacturing facility has an internal “cost of lost production” for every hour that production is halted. These costs are often significant.
From an enterprise perspective, there is also value in “digitalization.” Comparing like machines in separate locations and getting a sense of productivity at an enterprise level also has significant value.•
ADDITIONAL takeaways
Significant energy savings in pneumatic systems can be realized by monitoring and semi- automatically regulating and isolating compressed air.
An Air Management System (AMS) can reduce the artificial demand for compressed air during periods of non-production.
A controlled pressure ramp function avoids sudden “pneumatic jerks” when restoring the compressed air supply to the machine.
Potential problems due to electrical control issues will not affect the pneumatic system since an AMS that operates “Normally Open (NO)” can be Selected.
Flow Consumption by the machines in the production line can be converted to energy (kWh), and energy cost ($) and be correlated to production metrics, viz., understanding the energy consumption per item produced, the cost of defective product, the cost per shift due to waste, and thereby optimize production processes.
The extra IO-Link port on the AMS can be utilized for vibration sensors, vision sensors, dewpoint sensors, etc., to gather data on critical process variables.
Pressure, flow, temperature, and other process variables can be monitored to establish baseline conditions for machines and other consumers of compressed air. If operation conditions change, preventative action can be taken by the now informed user.
The high-resolution data provided by an AMS can enable the benchmarking of machines and factories. Users can compare machines to learn from them and implement best practices company- wide.
Installing an AMS (Figure 8) on a machine’s pneumatic system and evaluating the air consumption on the machine leads to optimized air consumption, increased life of pneumatic components, and improved production process- related decision-making.
Figure 8
quality matters. every
Fluid Power Challenge Introduces Middle School Students To Engineering
MCC GROWS TRAINING PROGRAM FOR FLUID POWER INDUSTRY
By Susan Smiley, ssmiley@medianewsgroup.com, Macomb Daily
More than 110 middle school students competed in the eighth annual Fluid Power Challenge April 11 at Macomb Community College’s South Campus.
All participants attend the Butcher Center Middle School Science and Technology Center, a half-day STEM program that draws from four middle schools in the district. Fluid power encompasses hydraulics and pneumatics technologies. Both use liquid or gas to transmit power from one location to another.
Each team was given materials including wood, glue, and hydraulic apparatus to build a small crane-like machine that uses fluid power to move. Each team was given the same materials and the same amount of time to construct their crane, but the specific design was left up to the team members.
Once the cranes were completed, the teams participated in a final competition where they showed how effective their creations were at picking up small barrel-like pieces and moving them.
“They get two minutes to move these wooden barrels and score as many points as they can, but they are getting points all along the way,” said Chadwick Conte of Peninsular Cylinder in Roseville, sponsor of this year’s event. “The teams can get up to 90 points for things like teamwork, design, operation and their portfolio, which is like their overall plan for the project.”
The event is meant to introduce students to fluid power and engineering while teaching them about teamwork, communication, problem solving and project management.
“There are two open positions for every one person looking for a job in this field so there is a big void of talent in the industry,” said Conte. “Manufacturing is on the decline as far as being where younger people want to be so we are hoping to show the kids some of the fun things about fluid power while highlighting all of the different jobs that could be encompassed by the industry.”
With less than 20 minutes left to complete their cranes, the fluid power teams were in various stages of their build outs. Confidence levels
More than 110 Warren Consolidated Schools middle school students participated in the Fluid Power Challenge at Macomb Community College April 11. (PHOTO BY SUSAN SMILEY)
ranged from “we are going to do awesome” to “we’re worried.” Everyone was intent on getting their crane built to perfection by the deadline.
“With events like this, we want to build an awareness of fluid power and hope that it will resonate with some students,” said Haley Nemeth, Workforce Program Manager for the National Fluid Power Association.
“Doing the design and build, maybe someone will remember it in high school engineering class or will have an industry expert visit their physics class and they will remember doing this and consider exploring a fluid power career option.”
So many things that students see and use everyday use fluid power, which is something else events like the fluid power challenge emphasizes.
“Doors, adjustable chairs, garbage trucks, the brake system in a car, construction equipment like a jackhammer, spaceships, rockets, and agricultural equipment all use fluid power,” said Conte. “The one that usually draws kids in is rides at the amusement park; they all use fluid power.”
MCC Associate Dean of Engineering and Technology Laura Thero said while the college has not had a stand alone fluid power program in the past, one will be in place beginning with the fall 2024 semester. Events like the middle school fluid power challenge, she added, help to spark interest in budding engineers.
“The engineering concept of designing and building something is going to transfer into something more math and science heavy later in life, but just the idea of exposure to a very hands-on experience in a field they may not even realize exists as a career option down the line is exciting,” said Thero.
Even for students who choose a different pathway, Thero said the teambuilding and problem solving skills developed through an event like the challenge can be translated to many careers.
“Regardless of if they end up in fluid power or in some aspect of manufacturing, the skills they are going to learn are transferable skills that will take them throughout their life,” Thero said. “There is just so much excitement from the kids.” •
Fluid Power Challenge participants were given materials and a specific amount of time to construct a crane to use in the official competition.
(PHOTO BY SUSAN SMILEY)
INSPECTING FLARELESS FITTING ASSEMBLIES
Assembly instructions
1. Use a tube cutter on the tubing to cut to length and ensure a clean, straight cut.
2. Prepare the end of the tube with a deburring tool to ensure a surface free of burrs.
3. Slide the nut and then the ferrule/ sleeve onto the tube. The threaded end of the nut must face out.
4. Insert tubing into the fitting body, making sure the tube is bottomed out on the fitting shoulder.
5. Assemble the nut to the body, hand-tight.
6. Tighten the nut to the body using a wrench to the number of turns indicated in the table above.
Inspecting the ferrule/sleeve set
Preset inspection for:
• Ridge raised to at least 50% of ferrule/sleeve thickness (A).
• Leading edge coined flat (B).
• Slight bow to remaining part of ferrule (C).
• Back end snug against tube (D).
• Slight indent around end of tube (E).
and larger 2 1/4"
The following illustrations show incorrect presets and their causes:
TEST YOUR SKILLS
1.
What are the three causes for an incorrect ferrule set?
A. Tube incorrectly inserted, under torque, too much force.
B. Incorrect wrench size, bad ferrule, too much force.
C. Wrong ferrule size, mismatched nut, wall thickness.
Shallow bit too close to end tube not bottomed Overset ferrule inadequate force
Overset ferrule too much force
Uneven bite ferrule cocked on tube
Leakage at flareless fitting can be caused by:
• Shallow bite.
• Overset ferrule/sleeve.
• Ferrule/sleeve cocked on tube.
• No bite.
D. Incorrect tube size, incorrect material, shallow bite.
E. Incorrect wall thickness, too much torque, shallow bite.
2 What are the three parts of a flareless fitting?
A. Tube, nut, and sleeve.
B. Nut, ferrule(s), and fitting body.
C. Ferrule bite, tube, and fitting body.
D. Tube, nut, and fitting body.
E. Ferrule, sleeve, and fitting body.
See page 25 for the solutions.
Figure 52 Tube Size Additional turns from hand tight
Figure 53 Correct Preset.
Since 1968, Essentra Components, formerly known as Alliance Plastics, has been dedicated to safeguarding hydraulic hose fittings.
Our extensive range of Plastic Plugs and Caps, manufactured in Erie, PA, has played a pivotal role in this endeavor. However, over the past two decades, our focus has expanded to protecting our customers' complete Hydraulic Hose Assembly. To achieve this, we have introduced ranges of new and improved engineered products, including Spiral Wrap, Textile Sleeve, and Point of Contact Protectors.
At Essentra Components, our commitment is to deliver innovative products that meet the evolving needs of our customers, ensuring their Hydraulic Hose Fittings and Hose Assemblies remain protected and secure. We
understand that each customer may encounter different challenges in their daily work, so we have an extensive stock of off-the-shelf components ready for immediate shipment complemented by custom engineering capabilities.
To discover how Essentra's products can extend the lifespan of your hydraulic hose assemblies, request a copy of our Solutions to Protect Hydraulic Hose & Fittings mini log at https://www.essentracomponents. com/en-us/catalogs. Many companies, like yours, have already chosen the right parts for their applications and are benefiting from improved longevity.
Yates MANUFACTURES and REPAIRS Cylinders for over 50 years!
Yates Industries is a manufacturer and rebuilder of hydraulic and pneumatic cylinders of world-class value. Established by William H. Yates II in 1972, Yates has evolved into a state-of-the-art family-owned company with over 365,000 + sq. ft. of manufacturing and repair space.
Yates Industries repairs all brands and designs including Telescoping. In addition to being a highly reputable cylinder repair company, we manufacture both pneumatic and hydraulic Tie Rod, Welded, and Mill-type cylinders for all demanding applications.
This pit cylinder was repaired at our state-of-the-art Decatur, AL facility. The cylinder measures 24” Bore x 270” Stroke x 21” Rod. You name the size; we can make or repair it!
Going strong for over 50 years; Yates proudly serves all industries from Steel, Aluminum, Oil & Gas, Paper & Wood, Food, Defense and many more. The viable demand for Yates quality products and services continued to grow, prompting several expansions in Georgia, Alabama, and Ohio. Adding these facilities gave Yates greater capacity for our welded and mill duty cylinder lines; enabling us to provide faster turnaround times and increase our service area throughout the southern U.S. Yates strives to maintain our reputation as one of the largest most complete cylinder manufacturing companies in the country.
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Flexible design for the future of energy
The F4800E is based on Fundex Equipment’s diesel-powered F4800 foundation rig, which has a 500 kNm (368,761 lbf.ft) full-length drilling torque and a daily energy consumption of up to 2,000 kWh (1,490 hph). With a leader length of 48 meters (157 feet), the electrification of foundation machines of this size is unprecedented, making the powering of the machine the primary challenge.
BUILDING THE WORLD’S FIRST FULLY ELECTRIC PIONEERING SUSTAINABILITY IN CONSTRUCTION
By Stefan Eichler, Senior Manager Editron Sales EMEA, Danfoss Power Solutions
Construction machines worldwide emit a staggering 400 MT of carbon dioxide annually, equivalent to the yearly emissions generated by international aviation. For construction sites to decarbonize and reach emissions reduction targets, construction machines must evolve.
When Hydrauvision, a leader in hydraulic and electrical drive and control solutions and parent company of foundation rig specialist Fundex Equipment, decided it wanted to help drive the construction industry’s sustainable transition, it decided to electrify a foundation rig in a world-first project.
While some construction equipment is fairly easy to electrify due to the relatively
To make the machine compatible with most construction sites, Fundex decided to prioritize flexible design and give the new F4800E the ability to switch between different energy sources. As a result, the basic machine, including winches and hydraulic pump units, is entirely electrically driven by permanent magnet machines and drive converters supplied by Danfoss. The F4800E also features a 150 kWh (112 hph) integrated battery pack for peak shaving during regular operation. In addition, the battery is used to store regenerated energy from the winches. This means the machine can operate totally emissions-free when connected to a power source.
However, power sources are not yet available on every construction site. Therefore, Hydrauvision developed a new DC-generator set with a diesel engine to supplement the battery pack on the basic F4800E machine and prevent inefficient peak loads, with peak shaving as a power backup. This configuration maintains the machine’s sustainability bene-
low energy required, building a large, fully electric foundation rig had yet to be achieved until Hydrauvision took up this challenge. The company needed to develop an innovative approach to power supply to ensure a large foundation machine stayed running throughout the working day.
fits by reducing energy consumption by 25% to 40%, depending on the foundation process.
Another issue currently facing the construction industry is uncertainty around what the primary energy source for producing and storing electricity will be in the future. To account for this, the generator set can easily
be disconnected and replaced with various energy sources, such as hydrogen, formic acid, or e-methanol. The system can also be connected directly to the electric grid. Therefore, as soon as other energy sources become available, Hydrauvision can respond to them very quickly due to the flexible design of the F4800E. This gives customers a high return on investment.
High performance to match conventional foundation rigs
Aside from the substantial sustainability benefits, Hydrauvision also prioritized high performance in the design of the F4800E. By basing the design on the conventional machine, though replacing the diesel powertrain with a fully electric system, they were able to maintain and, in places, enhance performance.
The F4800E is specially designed for both drilling and pile driving techniques. Production performance is also equal to that of conventional machines, including a high drill torque of 500 kNm (368,761 lbf.ft) along the entire leader length and a maximum 1333 kN (150-ton) pull-up force and 356 kN (40-ton) tool weight.
The F4800E’s controls are identical to the conventional machine’s, meaning operators can easily transition to the electric rig. Due to its electric motor, the machine also provides a 90% noise
reduction during operation compared to a diesel-driven rig, which is a valuable advantage when working in urban environments.
One step closer to a more sustainable construction industry
The result of Danfoss Editron’s collaboration with Hydrauvision and Fundex Equipment is the first fully electric large foundation rig on the market. The rig’s performance was tested in September 2023 when it successfully completed its first commercial project in Rotterdam for the real estate and construction services business Heijmans.
While operating on the Canvas Living residential building project in Rotterdam, the F4800E successfully installed over 250 foundation piles. A conventional F3500 foundation rig was used on the same project as a point of comparison for the electric rig. Powered by Hydrauvision’s electric powertrain system and DC-generator set with a diesel engine, the F4800E proved to be a strong, robust, and reliable machine that can match the performance of conventional rigs. •
Digital Documents reverse-engineer systems cross/type components
Photo Navigation drilling down to individual components & parts
Interactive Prints illustrate machine operations & functions Video Troubleshoot capture tribal knowledge & train on-the-job
Work Offline on any device browser
PRODUCT SPOTLIGHT
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.
Diamond Hydraulics Inc. 409-986-3957 (Office) 409-986-7437 (Fax) sales@diamondhydraulicsinc.com
MP Filtri MYclean filter series is a market innovation breakthrough for mobile and industrial equipment OEM’s. Our patented polygon endcap interface feature ensures only original filter elements are used guaranteeing maximum performance and safety throughout the machine's design lifespan.
MP Filtri USA, Inc. 1181 Richland Commerce Drive Quakertown, PA 18951 Toll free: 888-263-0090 sales@mpfiltriusa.com www.mpfiltriusa.com
Beach Specialty Filters
Beach’s model F-GGC and F-40C are effective, low cost, point-of-use desiccant type filters rated from 5 to 15 scfm and a maximum working pressure of 250 psi. Ideally suited for instrument air, air to fluid controls and many other applications requiring a low volume of pure air.
BEACH FILTER PRODUCTS, INC.
555 Centennial Ave. PO Box 505
Hanover, PA 17331
Phone: (717) 698-1403 • Fax: (717) 698-1610
1-800-BEACH-85 • www.beachfilters.com
Coxreels® Extreme Duty XTM Dual Hydraulic Reel!
XTM-DMP-450 is the most robust reel with triple axel support, twin-line fully bonded hose, and stainless-steel hose guide rollers. As with all Coxreels reels, it features heavy gauge steel construction, durable CPC powder coat, rolled and ribbed discs, and USA made. www.coxreels.com
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. 877.534.6445 | info@wilkesandmclean.com | www.wilkesandmclean.com
Think Yates Cylinders for ALL of your cylinder needs!
Custom Welded Cylinders:
• 1.5” up to 50” bore, with strokes exceeding 300”
Heavy Duty Mill Cylinders:
• 1.5” up to 50” bore, with strokes exceeding 300”
NFPA/JIC Tie Rod Cylinders:
• 1.5” up to 24” bore; interchangeable with all brands
Yates Industries (HQ)
586.778.7680
Yates Cylinders Alabama
256.351.8081
Yates Cylinders Georgia
678.355.2240
Yates Cylinders Ohio
513.217.6777
Max Machinery, Inc.
Skip counting teeth and join the revolution. By measuring the gear’s rotation, we can double your resolution and accuracy across all your process flows. From 1 cc/min to 240 liters/ min, Max Gear Meters provide 0.3% accuracy and data up to 500 pulses/cc. See what flow you’re missing and how to improve your process by using a Max Precision Gear Meter.
Precision Flow Meters
Max Machinery, Inc. 33A Healdsburg Ave. Healdsburg, CA 95448 707-433-2662 www.maxmachinery.com
» HERE IS THE SOLUTION TO FIGURE IT OUT ON PAGE 05
The first question: gage “A” would be somewhere around 0.35 to 0.7 MPa (50 to 100 PSI). The pilot operated relief’s pilot flow through an orifice is vented back to tank allowing the valve to unload at the bias spring pressure.
The second question: Will the ram drift down from the fully retracted up position? Yes, it will. Most Counterbalance valves use sliding spools that require clearances in the bore of the valve. Sun hydraulics show their valves leak several drops per minute at 21 MPa (3000 PSI). The directional valve spool leaks more. Over a weekend this press drifted three feet.
The third question: Everyone seems to say, it would be 10.3 MPa (1500 PSI). It would be system pressure at 17.2 MPa (2500 PSI). Any pressure in the drain line of the pressure reducing valve is additive to the spring setting. In this case, the valve would only reduce extension pressure and have no control on retraction pressure.
SOLUTIONS
The correct answers to Test Your Skills on page 18 are 1A and 2B.
Hydraulic and Pneumatic Industry Trends With NFPA
» THE LATEST DATA published by the National Fluid Power Association shows March 2024 total fluid power shipments rising slightly to -0.3% month over month compared to February 2024’s -0.7% month over month change. Shipments across all three major categories are below March 2023 levels. 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 2023
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
Newly Certified Professionals
MARCH 2024
CONNECTOR AND CONDUCTOR (CC)
Clancy Vaughn, Coastal Hydraulics
Aaron Alston, Coastal Hydraulics Inc
Christopher Williams, Coastal Hydraulics Inc
Quest Duperron, Coastal Hydraulics, Inc.
Adam Moreland, Coastal Hydraulics, Inc.
Mark Rippy, Coastal Hydraulics, Inc.
Nathan Nelson, Open Loop Energy
Ashton Bright, The Boeing Company
Walter Carr, The Boeing Company
Steven Fierst, The Boeing Company
Duane Gray, The Boeing Company
Jesse James, The Boeing Company
Zackary Kogle, The Boeing Company
Timofey Kuyarov, The Boeing Company
Blayne Massey, The Boeing Company
Shawn McNaught, The Boeing Company
Chad Murrow, The Boeing Company
Brennon Nelson, The Boeing Company
Nicole Pennington, The Boeing Company
Christian Whalen, The Boeing Company
Rory Williams, The Boeing Company
Jesse Winterburn, The Boeing Company
HYDRAULIC SPECIALIST (HS)
Michael Davis, EOH
Justin Haley, Hydraquip
Sarah Turney, OneHydraulics, Inc.
Paramjeet Chopra, Proall Manufacturing
Jackson Kalahiki, SIT
Jonathan Matthysen, SIT
Dillon Phamdo, SIT
Logan Sullivan, SIT
Jacob Vincent, SIT
Liam Evans, Supreme Integrated Technology Inc.
INDUSTRIAL HYDRAULIC TECHNICIAN (IHT)
Christopher Lane, Hydradyne LLC.
MOBILE HYDRAULIC MECHANIC (MHM)
Patrick Farmer, AEP
Gavin Foster, AEP
Billy Franklin, AEP
David King, AEP
Jay Morris, AEP
Tyler Schmitt, AEP
Darrell Toler, AEP
Peter Alexander, Altec Industries, Inc.
Louis Driver, Altec Industries, Inc.
Joe Gabler, Altec Industries, Inc.
Jeremiah Jussen, Altec Industries, Inc.
Seth Merical, Altec Industries, Inc.
Daniel Ritchie, Altec Industries, Inc.
Darcy Scally, Altec Industries, Inc.
Davin Sullivan, Altec Industries, Inc.
Jonathan Weatherby, Altec Industries, Inc.
Ryan Woodall, Altec Industries, Inc.
Jensen Ballinger, Ballinger Industries, LLC.
LaMar Ballinger, Ballinger Industries, LLC.
Nick Ballinger, Ballinger Industries, LLC.
Bryan Boyd, Ballinger Industries, LLC.
PNEUMATIC MECHANIC (PM)
Logan Furnish
PNEUMATIC SPECIALIST (PS)
Kylie Rasinski, Air Engineering and Supply
Jordan Reisinger, Bergkamp Incorporated
Ethan Taylor, Force America
Jacob Cavner, Parker
Matthew Bagley, Parker Hannifin
Andrew Balla, Parker Hannifin
James Bock, Parker Hannifin
Daniel Ferretti, Parker Hannifin
Sarah Maglosky, Parker Hannifin
Charley Shin, The Boeing Company
Jacob Lenss
Andrew Luce
Nolan Pust
Tim Rahja
Trevor Reierson
Jason Velez Pico
SPECIALIST (S)
Kylie Rasinski, Air Engineering and Supply
Jordan Reisinger, Bergkamp Incorporated
Ethan Taylor, Force America
Jacob Cavner, Parker
Matthew Bagley, Parker Hannifin
Daniel Ferretti, Parker Hannifin
Sarah Maglosky, Parker Hannifin
Charley Shin, The Boeing Company
Jacob Lenss
Andrew Luce
Nolan Pust
Tim Rahja
Trevor Reierson
Jason Velez Pico
Fluid Power Reference Handbook
» ACCESSING YOUR REFERENCE handbook digitally offers a range of benefits that enhance your learning and reference experience:
Convenience and Portability: With digital access to the Fluid Power Reference Handbook, you can carry your handbook with you wherever you go without the need to lug around the heavy book. Whether you're studying at home, in a café, or on the go, having digital access to your handbook means you always have your reference materials at your fingertips. Plus, you can instantly access any updates made to the handbook, ensuring you have the most current information available.
Interactive Table of Contents: Digital access features an interactive table of contents that makes it easy to navigate through chapters. This feature allows you to jump to specific sections quickly, saving you valuable time that would otherwise be spent flipping through pages.
Efficient Search Tools: Digital access comes equipped with search tools that allow you to find the information you need with just a few keystrokes. Instead of manually scanning through pages, you can simply enter a keyword or phrase and be taken directly to the relevant section. This not only saves time but also enhances your overall learning experience by enabling you to find information quickly and easily.
UPCOMING TRAINING & EVENTS
ITW: Accredited Instructor Workshop
WHAT IS AN IFPS ACCREDITED INSTRUCTOR? An Accredited instructor (AI’s) are certified professionals who train and can prepare candidates for IFPS Certification Programs. AI’s have extensive backgrounds and instructional experience in the fluid power industry.
If you hold an IFPS certification and have a knack for training, plan to attend!
WHEN: August 27 - 28, 2024
WHERE: IFPS Headquarters - Cherry Hill NJ Mark Your Calendar For more information, visit ifps.org/web-seminars.
Customizable Reading Experience: Digital access offers a customizable reading experience that allows you to tailor the text to your preferences. You can adjust the font size, style, and color to suit your needs, making it easier to read and understand the material.
Enhanced Visuals: Digital access includes high-quality visuals, such as charts, graphs, and illustrations, that can be zoomed in on for closer inspection. This feature eliminates the need for a magnifying glass or reading glasses, ensuring that you can clearly see and understand the information presented.
NEW! Fluid Power Support Associate Certification
» FLUID POWER SUPPORT ASSOCIATE CERTIFICATION STUDY MANUAL: Begin your preparation for the Fluid Power Support Associate Certification exam with our newly released, comprehensive study manual. Assess your readiness for the certification exam with available pretests. Our comprehensive pre-tests, available online and in the back of each study manual, are designed to test your understanding of the material covered, allowing you to identify areas that require further attention before taking the real test. IFPS members receive FREE access to these study materials – join now to take advantage of this exclusive benefit!
» FLUID POWER SUPPORT ASSOCIATE CERTIFICATION ONLINE TRAINING
MODULES: This online training module features full-color and animated graphics, enhancing the learning experience. Interactive chapter review questions provide immediate feedback, helping learners assess their understanding. Voice-over text caters to auditory learners, making the content more accessible. Three additional online pre-tests offer more opportunities for practice and self-assessment. Safety and energy tips are interspersed throughout the module, reinforcing key concepts. Additionally, the module contains additional explanations not covered in the printed manual, providing a more comprehensive learning experience.
» FLUID POWER SUPPORT ASSOCIATE CERTIFICATION REVIEW TRAINING POWERPOINT: The PowerPoint Presentation for Support Associate Certification Review Training is designed to enhance the learning experience by incorporating every illustration from the Study Manual. The presentation includes detailed instructor notes to guide you through each slide and facilitate a comprehensive review session. With this resource, you can effectively reinforce key concepts, clarify complex topics, and prepare participants for success in their certification exams.
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
JULY 2024
Tuesday 7/9 • Thursday 7/25
AUGUST 2024
Tuesday 8/5 • Thursday 8/22
SEPTEMBER 2024
Tuesday 9/10 • Thursday 9/26
OCTOBER 2024
Tuesday 10/8 • Thursday 10/24
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» CFC Industrial Training – Cincinnati, Ohio – December 2-6, 2024
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» CFC Industrial Training – Cincinnati, Ohio – August 5-9, 2024
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» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
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Manifold and valve finishing command the highest scrutiny.
By Bruno Boutantin, Director of Market & Business Development, Extrude Hone Group.
Hydraulic functions are critical in scenarios where failure is not an option, such as in jet fighter flaps, moving tails, or missile launch systems. Any hydraulic failure in these situations would be unacceptable.
As hydraulic systems become more complex, the tolerances for components have become stricter, leading to numerous intersecting holes and edges that can be potential failure points. To mitigate human error, selecting the best finishing method for critical components is essential.
Some finishing methods stand out due to their numerous benefits and reliability. These methods include Electrochemical Machining (ECM), Thermal Energy Method (TEM), and Abrasive
Flow
Machining (AFM).
ECM uses electrical and chemical processes to remove material, TEM uses thermal energy for deburring and cleaning, and AFM uses a pressurized abrasive medium to smooth surfaces and edges.
After reading this article, you will understand the capabilities of these methods, where they are most effective, and their advantages
and disadvantages. Before delving into the three technologies, it's important to address the risks associated with burrs.
What does Burr mean?
Nobody wants burrs. Even with tremendous efforts into design, process planning, and manufacturing, it is hard to ensure that finished parts are completely free from burrs consistently.
Burrs can compromise the design integrity of a part, necessitate additional processes to fix, create safety hazards, and lead to product malfunctions. This results in extra costs, re-manufacturing, warranty claims, service issues, and recalls, not to mention
potential damage to the company's reputation. It is crucial to remove or secure burrs to prevent them from detaching from the part. The characterization of a burr depends on how strongly it is attached to the workpiece material, with the sharpness of the burr being a critical criterion for safety concerns.
Burrs Impact in Fluidic Systems
It starts with the assembly of components. The hydraulic function involves the smooth motion of elements like the spool in the bushes (sleeve) and sealing. Mounting seals in intricate bores is a critical operation. Typically, specific tooling helps position the seals correctly, but if a seal encounters a sharp edge or a burr, it can be damaged. Such damage might go unnoticed until a leak occurs, which could happen long after the testing phase, such as when an aircraft is in flight or a rocket is supposed to fire.
Today, fluid power is at the heart of many critical areas. It's present in some of the most challenging tasks – trigger, control, maneuver, lift, brake, steer, adjust, and many more. At the same time, the demand for higher power, faster response, finer control, and compact sizes has driven modern-day fluid power toward higher operating pressures, intricate designs, and compact dimensions.
Aerospace is at the forefront of this trend because weight is a critical factor. The industry is driven by the need to pack as much functionality as possible into the minimum space and weight. A hydraulic failure could be devastating and potentially life-threatening in most aerospace and defense applications.
of anodic metal dissolution via an external DC power source.
One of the critical features of ECM is that there's no contact between the tool (-) and the workpiece (+). The shape of the tool cathode determines the shape of the material removal. ECM is an imaging method. Extrude Hone uses insulating material where no work is needed, leaving the conductive material visible in areas where the material removal process occurs. Due to the use of a cathode, the electrochemical process comes without physical contact, applying zero stress to the components. The geometry is perfectly under control and the tool experiences minor electrical wear, but none mechanically. The cathode is consumable.
The final shape accuracy depends on the cathode design and the machining precision. An electrolyte solution (NaCl or NaNO3) handles charge transfer in the working gap to allow the dissolution. The resulting electron current releases metal ions from the workpiece. The removed material comes as hydroxide and is rinsed out of the gap by the electrolyte flow. Then, it must be removed from the electrolyte by an appropriate separating device. Extrude Hone's process uses a large chamber filter press to ensure a clean electrolyte returns to the machine.
locations simultaneously. When the cycle is over, the cathode recesses to the standby position to enable the part to be released.
In the Dynamic ECM, the current applies while the cathode is moving. Usually, the cathode is attached to a single or dual NC-controlled axis to allow sophisticated, exact motion. This method is use in EC Rifling to create a twisted groove inside a gun barrel or to drill a hole behind a wall that direct conventional drilling could not reach.
ECM is the Selective Deburring Method Under a Minute
ECM is ideally suited for Aerospace's hydraulic aluminum manifolds. It's a selective process, meaning you can decide which areas to process. In addition, you can process several regions in different locations at once and choose what kind of machining, deburring, edge shaping, polishing, or structuring you would like to apply to these targeted areas.
Electrolytic machining (ECM) is a subtractive method operating on the principle
The ECM process provides quality and productivity, surpassing conventional capabilities.
ECM Variations
The most common iteration is Static ECM, in which the cathode moves once from its standby position to the working position before the current is applied while the cathode does not move. A single cathode can include multiple areas of different geometries to process several
Finally, we come to the process of micro-structuring ECM. Suppose you need to machine various internal or external patterns, like radial and axial structures. In that case, you must do it with high accuracy and repeatability— micro structuring benefits compressors, heat pumps, refrigeration, air bearings, or clean gas applications. ECM offers a solution to deliver productivity gains and an attractive cost per part for all these variations.
ECM Process steps
1. The components are loaded into the ECM open fixture. The top side of the fixture is then closed on the bottom one, surrounding the part.
2. The electrolyte starts to flow; The short circuit test takes place before applying the total current.
3. Full current runs, controlled by cathode or cathode groups.
4. Burrs are dissolved, edges are rounded, shaped, and structure applied.
5. The cycle finishes, and the fixture opens.
6. The component is unloaded
continued on page 34
Workpiece (+)
Cathode (-)
Insulation
Hydroxide
The workpiece
The hole to be machined
The dynamic ECM cathode assembly
ECM Applications Sweet Spot
As previously mentioned, ECM is ideal for conductive materials, including those that are hard to machine. It excels in processing targeted areas, even those that are difficult to reach, with precise control and high productivity. Many hydraulic components meet these criteria. The average cycle time for ECM is usually under a minute, and for simple applications, multiple parts can be processed simultaneously in a multi-fold fixture.
A Few Words about Post-Treatment
A two-post-process step operation, including electrolyte rinsing and passivation, usually follows ECM machining. Simple dunking stations are the most common, but it goes up to multiple automated stations with advanced cleaning features like ultrasonic.
Electrochemical Machining benefits
• Design accuracy.
• Stress riser removal.
• Enhanced component longevity.
• Process efficiency.
• Deburring precision.
• Increased productivity.
• Quality and repeatability.
ECM Case Studies:
An Aerospace Manifold
Let's focus on an Aerospace manifold, precisely one from Dassault Aviation, that goes in a Falcon jet. That's 248 (yes, no typo, two hundred forty eight) areas processed in 5 minutes in a 3-step process. The ECM technology allows the design of complex fixtures; in that case, one advanced fixture per step. The machine can be a single, dual, or triple station, depending on how you want to organize the production. The limit will be the current available, which depends on the total surface to be processed. Remember, for example, that an intersected hole surface is an oval ring that contributes to limiting the surface.
Deburring oval intersection plus specific radius
Polishing multiple edges at once to protect seal introduction during assembly
Thread extremities deburring and radiusing/recess intersection radiusing
Remove burrs in the blink of an eye with Thermal Deburring
TEM can accommodate one of Aerospace's most common hydraulic manifold materials, aluminum. Thermal Deburring can take away burrs by generating a super heat wave, reaching 3,300°C (6,000°F) in just a few milliseconds. TEM is suitable for that material because it is that fast, and the pressure is much lower with aluminum. Imagine TEM at shallow pressure can remove burrs from plastics.
Nevertheless, with aluminum, some critical points must be assessed when dealing with aluminum components. Do you have some
walls, structure, or specific areas of your components, like small lips that are very thin? If this is the case, there is a need to pay some special attention.
As in thermal deburring, we deal with a combination of hot temperature and the force of a heat wave. If the part is fragile by nature, the fixturing will ensure the best part orientation and maintain it firmly to take the best out of the heat wave, avoiding potential deformation. Your part includes some tricky designs with thin material; if the orientation and fixture leave too much energy, some inserts can physically protect the most fragile regions.
That could sound overwhelming to those unfamiliar with the process, but it's the best way to avoid deformation and damage and make the most of a deburring cycle that will last less than a minute.
TEM Process steps
A few words about post-treatment
Aluminum loses its brilliance during the TEM process. A suitable post-cleaning agent can restore its shiny appearance.
For other materials, no worries too. A cleaning operation will remove the TEM oxide by-product. Chemical market leaders in cleaning and degreasing offer a range of post-cleaning products designed to address the different materials.
The third benefit of that technology is low cost per part. For more insights about the thermal deburring process and how it compares to the other technologies, we recommend reading the Fluid Power article: Small Burrs Create Significant Problems from the May 2024 edition.
1. Loading of the components into the TEM chamber. The chamber is closed.
2. The chamber is filled with a pressurized mixture of gases.
3. Gas is ignited
4. Burrs are oxidized, and the component deburred.
5. The chamber is vented to de-pressurize
6. The chamber opens, and the component is unloaded
TEM applications sweet spot
Because a gas envelops the part and goes deeply into it, the circular deburring requirement with no specific edge tolerances is perfect for the TEM process capability. When you need to remove all burrs and particles, TEM can ensure quality and productivity. Please note that fixture design comes into play, allowing multiple parts to be processed simultaneously to increase productivity drastically.
These products are utilized in post-treat ment stations typically used for cleaning and passivation. The equipment starts with straightforward dunking stations and goes up to multiple automated stations with advanced cleaning features like ultrasonic.
Thermal Deburring benefits
The first benefit of that technology is speed. Because the burrs or flashings are much smaller than the component, they reach their auto-ignition point instantly. The burrs oxidize in the oxygen-rich chamber without any harmful impact on the element.
The second benefit of that technology is integrity. Compared to manual deburring, you have the insurance that the deburring operation will run without further inspection. That's reliability. In addition, you remove the burden of finding skilled labor by relying on a machine. You are a perfectionist; the machine can be automatically loaded and unloaded.
TEM Case Studies: Spools
Let's focus on one critical component that plays a massive role in hydraulic systems: a high-precision turned part, the spool. Spool manufacturing means high volume with tight tolerances that match stringent standards of quality. It comes with plenty of areas with burrs; manual deburring would be tedious and risky, and other finishing processes usually take too long. One solution is to use TEM to deliver 100% accuracy in burr removal by removing all burrs from all edges, threads, breakthroughs, and inner intersected holes. continued on page 36
continued from page 35
AFM - The Abrasive Media flow for surface enhancement, deburring, and flow tuning
AFM (Abrasive Flow Machining) was born to address the need to polish flow paths. A viscous-elastic, non-Newtonian media loaded with abrasive grits is pushed back and forth through the passages. Under pressure, the grits will naturally be forced on the external surface, which means that higher pressure means better cutting impact. A passage can be a natural channel (e.g., a manifold) or artificially created by enclosing a part in a fixture (e.g., an impeller). A hole in a manifold is a natural geometry, while for open impellers,
the fixture will create a gap between the part surface and the wall fixture.
The fixture's purpose is also to handle the part or multiple parts and to guide the media toward the working areas.
In addition to this, multiple parameters come into play. For the fixture design, you must decide on the gap dimension, control the restriction, and the cutting impact. Regarding the media itself, the media recipe encompasses the polymer type and viscosity, the nature of the abrasive grits (aluminum carbide, boron carbide, and diamond being the most common), the grit size, and the density of the abrasive in the mix. But that's not all; the process parameters, the extruded volume of media, the media flow rate, pressure, and the media temperature range will have to be decided and controlled. Each application is unique, and knowledge plays a huge role. It's essential to work with experts who, in addition to building
equipment, designing and mixing their media, and running parts in contract shops, have decades of experience and a massive knowledge base.
AFM immediately found its markets in extrusion die polishing, complex automotive intakes and exhausts, and aerospace components that require polishing in the final fluid flow direction.
Hydraulics came rapidly after entering the picture, first with closed impellers, valve bodies, and manifolds made of exotic materials. Today, in hydraulic systems and especially with AM (Additive Manufacturing) components full of organic channels, the AFM thrives in delivering its process edge by nature. But that's not all about surface improvement. When flowing along a surface, any restriction will see more intense cutting action, so change in the direction, edges will be the target of choice for the media, delivering deburring (up to 0.2mm or 0.08 inches) and edge radiusing.
The AFM process will clean up the edge from the burrs, even micro-burrs, remove stress risers, and eventually create specific shapes. A good illustration is using AFM for turbine disk blade slot edge rounding. Another excellent application is the deburring and radiusing of intersected holes in a titanium manifold.
The AFM process provides quality and productivity, surpassing some conventional capabilities.
AFM Variations
The most common is Two Ways Flow AFM, in which a machine includes two opposite media cylinders that actuate a volume of media, pushing it through the tooling that handles the part and guiding it toward the working areas. In the One-Way flow AFM, the media is continuously pushed in the same direction through the part before falling on a table and then within a replenishment media cylinder; this configuration fits applications where a massive volume of media is needed, like in hot runners' blocks or large pump impellers. Finally, MICROFLOW. If you want the AFM benefit for small holes, MICROFLOW
is one solution to address flow tuning down to 40µm (1,575 micro inches) orifices, way below what we find in Aerospace. Think about nozzles, spray holes, and any flow restriction calibrated holes. MICROFLOW is capable of micro-deburring and polishing the surface without damaging the geometry pattern while applying controlled flow calibration.
AFM Process steps
1. The component (s) are (are) loaded into the AFM fixture when required or connected to the media system with hoses for some manifolds. When using a tooling, the fixture's top side is closed while the machine clamps on it.
2. The media starts to flow, filling the empty volumes.
3. The process runs with all the HMI monitoring of all parameters.
4. Surfaces and edges are polished, rounded, and shaped.
5. The cycle finishes, the machine is unclamped, and the fixture opens.
6. The component(s) is (are) unloaded
AFM applications sweet spot
With AFM, you decide which surface, channels, and passages to process. Applications requiring flow path surface enhancement for flow rate improvement are good candidates. Components needing flow calibration, such as air, gas, oil, or any other fluid, are suitable applications.
Parts with out-of-reach areas and intricate passages with no line of sight are usually predisposed to benefit from AFM. AFM can also process components made of exotic, hard-tomachine materials. AUTOFLOW is the most advanced control of the media flow, measuring various process parameters in a close loop system to precisely handle the media flow from both cylinders. It’s ahead of the backpressure feature, the most common first step in improving control over the process.
A few words about post-treatment
Customers' main question, especially regarding manifolds processed with AFM, is how to ensure the complete removal of the media. First, we conduct a blowing operation after processing that provides 99% media removal. A cleaning operation will then top the process. Depending on the cleanliness requirement, it goes from simple rinsing and cleaning, which is usually good enough, to advanced cleaning operations, including an ultrasonic phase when stringent requirements apply, such as high purity, semiconductor, medical, or injection applications.
Abrasive Flow Machining benefits
• Surface finishes even for out-of-reach areas.
• Enhanced component longevity.
• Process efficiency is under control.
• Extended media life and better cutting force control with AUTOFLOW.
• Increased productivity.
• Quality and repeatability.
AFM MICROFLOW sweet spot: Calibrated Orifices in Aerospace
As said, MICROFLOW is a variation of the AFM process. To better illustrate how it is, consider a nearly liquid polymer media compared to the stiff media from the traditional AFM. Calibrated orifices precisely control fluid flow to accurately guarantee flow rates, pressure spikes, or the amount of fluid in an injection system. In Aerospace, devices with calibrated orifices allow better control of hydraulic movements, providing a smoother and more well-controlled motion, an exact measure of the fuel delivered to an engine. In injection systems, the geometry of the orifices is critical in some cases as it contributes to the quality of the spray pattern. The orifice entrance radius, the absence of deformation within the orifice in addition to the geometry of the orifice, conical or not, will impact the
can deliver the perfect orifice finish with a nicely rounded entrance and a nicely polished passage while preserving the exit orifice sharpness. The absence of cavitation with MICROFLOW drastically improves the post-processing outcome.
In Aerospace, for hydraulic applications, the average diameters to calibrate range between 0.5mm (0.02 inches) and 1.5mm (0.06 inches).
AFM Case Studies:
Servo valve bushes in Aerospace
Advanced motion control is critical to some aerospace functions. Since the introduction of servo valves in 1951, they have been tremendously improved and continue to be enhanced.
A servo valve must fulfill critical features such as high accuracy, repeatability, and high-frequency response. A closed-loop control is established thanks to the feedback wire attached to the flapper and connected to the spool. While electronics drive the system, hydraulics provide the force. Such a high-quality level also requires a spool/ bushes assembly, which is not the weak point. That's where AFM comes into play to ensure a perfect finish of the bushes (Sleeve). In a previous section of this article, we saw how spool can benefit from TEM deburring.
Multiple bushes are usually processed simultaneously within an AFM fixture, and the media is flowed through according to the two-way flow principle. As the intersected holes of the bushes/ sleeves are the restrictions, they will benefit the most from the media-cutting impact, first removing any left micro-burrs and then generating a nice micro radius (dimensions directly depend on the cycle time) on both sides of each hole. While the media also flows through the central bore, it will provide a slight cleaning effect without impacting the tolerances.
Wrapping up
at the
holes and flow-tune the orifices. If you want to optimize productivity, specific fixtures can process multiple sets of holes simultaneously and eventually different sets with different flow targets within the same part. For flow tuning applications, especially the ones requiring a high flow lift, MICROFLOW
The three technologies described in that article, ECM, TEM, and AFM, greatly benefit hydraulic system manufacturing. They enhance finishing capabilities, quality, repeatability, and productivity while removing the human factor. You get the best cost per part while guaranteeing and securing the system's function into which your components are integrated. On top of that, you do not have to worry about human mistakes and the search for super-skilled labor.
These three technologies satisfy many customers in various industries; what about you? •
MICROFLOW will remove micro burrs
intersected
ES Series 2-Way & 3-Way Electronic Valves
The compact footprint coupled with the long life, and exceptional leak resistance make the ES line suited to improve reliability in a wide range of applications including biomedical, dental, test equipment, oxygen control, textile, packaging, pressure control, automation and portable systems.
• Over 1 billion cycles (under ideal conditions)
• 0.01 atm sccm leak rate
• No threads in flow path
• Fast response - 5 to 10 ms (nominal)
• Close mounting - 7/8” on center. Overall height less than 1”
• Ideal for ultra-low leak applications
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