Fluid Power Journal March 2022

MARCH 2022

Replace or Restore?

RETROFIT THAT AGING PRESS

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SMART PNEUMATICS SAVES COSTS AND HELPS THE PLANET P. 8

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IN THIS ISSUE

MARCH 2022

VOLUME 29 • ISSUE 3

Features

6

6 Cover Story Replace or Restore? Why You Should Retrofit that Aging Press Saving inefficient and unreliable extrusion presses by replacing their outdated working systems.

8 On the Air: How Smart Pneumatics Saves Costs and Helps the Planet As the pressure to decarbonize ratchets up, IIoT-based options can help manufacturers.

10 Case Study: Building an Industrial Hydraulic System Designing for a new facility required more than a typical HPU for a typical OEM. 22 Test Your Skills

Gas-Charged Hydraulic Accumulators 26 Drive-Through: Hydraulic AWD Takes It on the Road An energy-efficient alternative to mechanical all-wheel drive for trucks.

10

Departments

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

CELEBRATING 60 YEARS

4

Notable Words

5

Figure It Out

13

NFPA Update

14

IFPS Update

20

Component Showcase

24

Product Spotlight

28

Literature Review

31

Classifieds

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Make Hydraulex your first call when you need replacement hydraulic components for your work truck.

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N OTA B L E WO R D S

Heavy Equipment Relies on Hydraulics

By Alan L. Hitchcox, Freelance Technical Editor

»

NO MATTER WHEN we first learned the fundamentals of hydraulics, our training covered variable displacement pumps and how they offer much higher efficiency over systems using fixed displacement pumps.

I remember asking an instructor why hydraulic systems didn’t use variable speed electric drives powering a fixed displacement pump to regulate hydraulic output. He said some systems did, such as small drives powered by a DC motor or circuits powered by an internal combustion engine. But at that time – the late 1970s – a variable speed drive powering a fixed displacement pump just couldn’t offer nearly as fast a response with a high-inertia load as that of a variable displacement pump running at a fixed speed. Plus, variable speed electric drives of that era were not as efficient as they are today. Furthermore, variable speed electrical drives were almost unheard of in mobile equipment, except for huge drives powering locomotives and mining equipment. These machines use an onboard, high-power electric generator to power their electric motors.

Today, however, more and more heavy equipment manufacturers are coming out with machines powered by electric drives instead of internal combustion engines. These machines use electric drives to power most rotary functions (such as wheel drives and swing drives) and a second variable speed drive to power their hydraulic system.

These electric drives are powered by high-capacity lithium-ion battery packs. Machine manufacturers claim that these rechargeable battery packs offer enough energy output to power a machine through a typical work shift. If a project is running a single shift, the machine could be connected to a charging station to re-energize its battery pack for the next day's shift. If the battery was needed for two consecutive shifts, the battery pack could be swapped with a freshly charged one in minutes.

From a design standpoint, though, driving a hydraulic pump at variable speed raises some important considerations. For example, a pump’s volumetric efficiency generally decreases with rotational speed, meaning that at slower speeds, case-drain flow consumes a larger portion of total flow.

Another concern of running a pump at a wide range of speeds is pressure pulsation. A variable displacement pump may run at a constant speed, say, 1,800 rpm. If half the flow is needed, the pump’s displacement reduces 50%, but the drive speed remains 1,800 rpm. With a variable speed drive, reducing pump speed to 900 rpm means the pump’s pressure pulsation frequency is half of what it was at 1,800 rpm. This lowerfrequency pressure ripple could cause erratic operation, and it becomes more pronounced at lower speeds.

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MARCH 2022

This all means the hydraulic pump must be selected and sized carefully to optimize performance when driven by the variable speed motor.

Several equipment manufacturers have apparently conquered these challenges and offer a limited range of machines powered by battery packs and electric motors. For example, Mack Trucks introduced a refuse truck prototype that uses variable speed motors for wheel drives and to power the hydraulic pump. Mack later announced that production on its LR electric refuse trucks would begin in 2021. Caterpillar is working with a major equipment dealer in Europe to provide excavators with electric drives for motion and to power the machines’ hydraulic systems. Mecalac, a French manufacturer, introduced its e-12 electric excavator, a modified version of its 12 MTX model that is powered by lithium-iron phosphate battery pack.

On the other hand, Volvo Construction Equipment took a different approach and presented an all-electromechanical mini-excavator in 2018 – with no hydraulics. Dubbed the EX2, it featured electric wheel drives and electromechanical actuators in place of hydraulic cylinders. Even though Volvo reported that the EX2 performed comparably to its hydraulic counterpart, I was skeptical. It might look equivalent on paper, but I doubted that delicate linear actuators could stand up to the frequent heavy shock, hostile working conditions, and operator abuse typically found in construction applications.

This appears to have been the case. Volvo’s website has not had any new information on the EX2 since 2019. Instead, the company is promoting its ECR 25 electric compact excavator and L25 electric compact wheel loader. Both machines use lithium-ion batteries and electric motors for ground drives and to power hydraulic systems.

More recently, Bobcat introduced an ell-electric, compact wheel loader with no hydraulics. It will be interesting to learn if this latest entry can compete with the heavy-duty performance and long life of mobile equipment powered and controlled by hydraulics. Electric wheel drives should be able to succeed, but time will tell if electromechanical linear actuators can stand up to the voluminous duty cycles, rapid and repeated reversing motion under load, and heavy shock and impacts encountered in rugged work environments.

•

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FIGURE IT OUT

New Problem PUBLISHER Innovative Designs & Publishing, Inc. 3245 Freemansburg Avenue, Palmer, PA 18045-7118 Tel: 800-730-5904 or 610-923-0380 Fax: 610-923-0390 • Email: Art@FluidPowerJournal.com www.FluidPowerJournal.com Founders: Associate Publisher: Editor: Technical Editor:

Director of Creative Services: Account Executive: Accounting: Circulation Manager:

Paul and Lisa Prass Bob McKinney Michael Degan Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Erica Montes Kristy O'Brien Donna Bachman, Sarah Varano Andrea Karges

INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org 2020 BOARD OF DIRECTORS President: Denis Poirier Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC Danfoss Power Solutions Immediate Past President: Rocky Phoenix, CFPMMH Open Loop Energy First Vice President: Scott Sardina, PE, CFPAI, CFPHS Waterclock Engineering Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries Vice President Certification: James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM - The Boeing Company Vice President Marketing: Chauntelle Baughman, CFPHSOneHydraulics Vice President Education: Randy Bobbitt, CFPAI, CFPHS Danfoss Power Solutions Vice President Membership: Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM - Open Loop Energy DIRECTORS-AT-LARGE Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT - Altec Industries Steve Bogush, CFPAI/AJPP, CFPHS, CFPIHM - Poclain Hydraulics Cary Boozer, PE, CFPE - Motion Industries Lisa DeBenedetto, CFPS - GS Global Resources Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics Brian Kenoyer, CFPHS - CemenTech Jon Rhodes, CFPAI, CFPS, CFPECS - CFC Industrial Training Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPHS - Northrop Grumman Ethan Stuart, CFPS, CFPECS - Wainbee Limited Brian Wheeler, CFPAI/AJPP, CFPMM, CFPMIP The Boeing Company HONORARY DIRECTORS-AT-LARGE AND EX OFFICIO Donna Pollander, ACA Paul Prass, Fluid Power Journal Liz Rehfus, CFPE, CFPS Robert Sheaf, CFPAI/AJPP - CFC Industrial Training IFPS STAFF Executive Director: Donna Pollander, ACA Communications Director: Adele Kayser Technical Director: Thomas Blansett, CFPS, CFPAI Assistant Director: Stephanie Coleman Certification Coordinator: Kyle Pollander Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk Layout/Design Assistant: Susan Rulon 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.

Shaft Seal Failed on New Pump

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

»

IN THE BASEMENT of a paper mill, a hydraulic power unit supplies all the flow and pressure needed to run one section of the mill. This section applies pressure to one rotating I roll that presses down on a rotating P bottom roll. At each end, hydraulic TOP ROLL pressure applied to the top roll presses DRIVEN EM BOTTOM ROLL it against the bottom roll. They refer to this pressure as the NIP pressure.

This section squeezes the paper to a required thickness and finish.

The mill had a problem with their main pump “grenading.” The internals were broken into multiple small pieces. They determined the problem was caused by a rag that plugged the pump inlet line. Apparantly, several rags were left behind 3800 PSI the baffle when the tank was drained and cleaned after they mistakenly added a water-based fluid instead of the mineral-based fluid for which the system was designed.

EM They replaced the pump and 3500 PSI changed the pressure and return-line filter elements. They also drained the oil, cleaned the tank, and installed new filtered oil. The pump had a flooded intake line with a ball valve shut off, safety relief, and filters. It was a simple design that worked well. They filled the pump case with new oil and started up the system.

After the pump noise settled down and compensated at 500 psi (34 bar), they increased the compensator setting on the piston pump to 3,400 psi (234 bar) and the shaft seal blew out. Since the new pump looked great internally, they installed a new shaft seal, and the same problem happened again.

What caused the problem?

Solution to the January 2022 problem:

Emergency System Fails to Close Safety Doors

The safety door emergency system accumulator piston was leaking oil to the nitrogen side, reducing the oil volume the accumulator could deliver. A replacement cured the problem.

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.

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MARCH 2022

5

COVER STORY

Upgrade solutions can be integrated into a press in a weekend.

Replace or Restore?

Why You Should Retrofit that Aging Press

By Mike Kramer, Press Application Engineer, Bosch Rexroth

O

ne of the most productive and hardworking machines in the industry today is the extrusion press. With proper maintenance and life-cycle management, many extrusion presses operate productively for decades, often with their original hydraulic pumps, control valves, and other components. However, this longevity leads to persistent complications; many extrusion presses are using outdated, inefficient, and unreliable hydraulic pumps.

Rather than replacing the entire press, there are strategic cost savings and performance advantages that can be realized by retrofitting legacy hydraulic systems on many of today’s presses. These include significant reductions in energy consumption and measurable improvements in press throughput. Replacing outdated working systems can dramatically reduce downtime, maintenance, and repair costs, especially when replacing hard-to-obtain components such as older hydraulic pumps and valves.

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MARCH 2022

A retrofit increases performance and decreases maintenance frequency.

Equally important, the newest generation of high-pressure variable displacement pumps and pump control systems incorporate smart technologies and connectivity that make it easier to implement Industry 4.0 capabilities such as advanced diagnostics, predictive maintenance, and real-time production data collection.

Risk factors of aging press hydraulics As they age, even the best-maintained presses hit a point where retrofitting or replacement of critical components starts to make both operational and economic sense. The initial symptoms may simply be more frequent downtimes to replace or service malfunctioning equipment.

There is also loss of press performance due to hydraulic fluid leaks, which lead to safety and environmental hazards that take time to remedy.

At one Midwest extrusion press, hydraulic pump oil leaks caused an estimated 65 to 70 hours of downtime every year to repair. From constant welding to fabricating new pipes and connections for a fifty-year-old pump when parts were no longer available, the cost and downtime of trying to keep the legacy equipment alive became prohibitive.

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As technology advances, a 1960s-era press may not be able to produce newer parts that meet current requirements. Modern automotive parts are an excellent example: metal used in today’s cars and trucks is significantly different from that used several decades ago, and it now includes a growing percentage of aluminum extrusions. These new alloys bring unique requirements for processing and forming to automotive standards that presses of an older era cannot accommodate, including accurate control of extrusion velocity and force.

Based on the current age and performance of presses with legacy hydraulics, manufacturers should analyze all available data to identify pain points and determine the value of a retrofit for their operations.

Weighing these factors, here are key reasons why a retrofit may be the right path forward.

Upgrading technology can quickly improve performance. In certain cases, switching from older technology may be the best move for machine performance. For example, upgrading the hydraulics in an existing machine from traditional hydraulics to servo-hydraulics, or a “hybrid” system, can bring a substantial upgrade in machine capability.

Speed control, force control, torque control, and other enhancements all come from upgrading to a servo system. Adding a servomotor to a pump to create a hybrid system can yield similar benefits.

The current generation of high-pressure variable displacement pumps from leading manufacturers provide critical performance advantages and can be easily configured to replace older press pumps. This generation of pumps has been proven to operate virtually trouble free for over 60,000 hours in extrusion applications. Productivity increases greater than 10% have been demonstrated under real production conditions, and they have been designed to operate with low noise to improve operating environment conditions.

In addition, high-speed variable displacement pumps, such as Bosch Rexroth’s AA4VSO system, provide short control response times and excellent suction characteristics, enabling increased parts production while reducing energy requirements.

Real-time data and analytics can transform press control. A key factor in production efficiency is minimizing unnecessary downtime, thus increasing overall usage. Implementing analytics is vital to understanding what is going on with machines in production. Several leading press technology providers now offer online digital condition monitoring systems that more effectively support predictive maintenance on large industrial equipment.

Today’s electrohydraulic pump and control technologies now offer self-diagnostic and connectivity capabilities that can help manufacturers implement true Industry 4.0 capabilities in press operations. By adding sensors to key functional components and connecting back to simple hardware with a web-based interface, it’s possible to gain real value from data you didn’t think you could get.

With real-time data, operators have instant visibility to equipment problems or deviations. Sensors can be calibrated to monitor machine part wear or temperature and keep operators informed on individual press operations and other key production processes.

With increased transparency of the system’s status, there is more assurance that the machine is being properly maintained and operated. In the connected world of Industry 4.0, actionable data can drive lean manufacturing and continuous improvement efforts. Integrated sensors can even predict production issues before they occur and alert machine operators to take action before production is affected.

Modular ‘drop-in’ retrofit solutions deliver results fast. One concern that many press operators have about retrofits is the cost and disruption they assume automatically comes with retrofits. After all, when a press WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Retrofitting an older machine can add a decade or more to its service life.

isn’t producing parts, no one is making money. It can take a week or more to remove old piping, valves, fluid reservoirs, and pumps, then integrate new pumps with digital controls into the press’s controls platform, then test and bring the press back online. Some press operators prefer to just keep doing the repairs and kick the retrofit plans down the road.

In the past, this concern might have been legitimate. However, leading electrohydraulic controls and pump providers like Bosch Rexroth have developed modular, turnkey replacement programs that can remove a legacy pump and control valves and complete the replacement in a weekend – in some cases, in just one shift. These drop-in solutions feature a unique system to directly replace the old, expensive, and inefficient pumps by designing and engineering a pump/manifold/controls solution.

With rapid advances in connectivity and performance in both electromechanical and hydraulic systems, press operators should consider upgrading presses via retrofit. Optimized machine functionality and additional safety features can increase throughput and press productivity.

In fact, hydraulics upgrades using the modular drop-in solution often demonstrate productivity increases exceeding 10%.

Adding improved sensors and digital controls can quickly convert a decades-old workhorse press into a cutting-edge, Industry 4.0 system that is more energy-efficient and equipped to deliver many more years of high-quality parts production.

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MARCH 2022

7

ON THE AIR

The AVENTICS Smart Pneumatic Analyzer.

(Courtesy of Emerson)

How Smart Pneumatics Saves Costs and Helps the Planet

By Robert Brezni, Global Account Manager, Fluid Control & Pneumatics, Emerson

A

t a time when the need to decarbonize economies is at its greatest, manufacturers are better positioned than ever to take meaningful action. The digital transformation of industrial facilities makes it possible for manufacturers of every size to access real-time process data, insights, and diagnostics that can help improve energy efficiency and sustainability across the plant floor. The key is integrating smart technologies and using the data they collect to make decisions that reduce energy use and related emissions.

Many smart technologies are scalable, so facilities can focus their attention in one area and expand from there. For example, compressed air systems are responsible for about 10% of a typical industrial facility’s electricity use, which makes them significant opportunities for savings. By integrating smart pneumatic technologies, operators can collect system data, including airflow, pressure, and temperature, to identify whether and where they are wasting compressed air. With this data, operators determine corrective actions.

Wasted energy in pneumatic systems can be staggering. To put a number on it, manufacturing plants typically lose about 30% of compressed air due to leakage alone. This wasted energy leads to machine downtime and, of course, increased energy costs.

Compressed air helps operate machinery and processes throughout industrial facilities, so its prevalence makes it pivotal to lower year-over-year energy costs. In fact, improvements in the airflow of a plant’s machinery of even just a few percentage points can mean tens of thousands of dollars in saved energy costs each month, depending on the size and nature of the equipment. That translates to hundreds of thousands of pounds of carbon dioxide (CO2) emissions saved. With smart pneumatics like software monitoring and notification solutions to detect leakage, manufacturers often reduce their compressed air energy spending 10% to 20% and reduce their CO2 footprint by 10%.

However, for many manufacturers, this transformation remains a goal rather than a reality.

While they may acknowledge the benefits, over 70% of manufacturers lack a data analytics plan and a clear blueprint for success. These companies consider the Industrial Internet of Things and other enabling technologies too complex, costly, and time consuming to implement.

But that doesn’t have to be the case. Manufacturers can invest in plug-and-play smart pneumatic solutions that keep installation time and costs to a minimum. They can take the first step toward digital transformation with a closer look at how smart pneumatics saves energy in areas where leaks and losses occur.

Plants improve compressed energy savings through digital transformation in two primary ways: addressing leaks and leveraging the ratio between air pressure and airflow.

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MARCH 2022

The AVENTICS AF2 Series airflow sensor.

(Courtesy of Emerson)

The PACSystems RXi2-BP Edge Computing Device.

(Courtesy of Emerson)

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Case Study: Saving Energy in a Brownfield Setting Live data captured by flow sensors using the AVENTICS Smart Pneumatics Analyzer.

(Courtesy of Emerson)

Addressing leaks The most obvious way manufacturing plants lose energy in pneumatic systems is through leakage. When pneumatic system components are subject to wear, leakage can occur and grow over time. The larger the leak, the more significant the energy loss, resulting in wasted energy, a bigger carbon footprint, and higher operating costs. Some operators lose more than $50,000 a year per machine!

In addition to energy loss, a compressed air leak causes a machine’s system pressure to fluctuate, affecting equipment efficiency and even production. As a result, a machine must work harder to compensate. This unnecessary cycling and increased run time raises energy costs, decreases equipment service life, and increases maintenance.

To detect and locate compressed air leaks, companies bring in technicians with ultrasonic equipment to test for them. But leaks often appear, persist, and grow between those periodic, stopgap visits.

On the other hand, smart pneumatics continuously monitors airflow. Some sensors collect and provide real-time insights on flow while also capturing pressure and temperature data in the feed line, enabling advanced diagnoses of the operating parameters. These solutions often easily retrofit to existing machines with the use of edge gateways. Around-the-clock software monitoring detects leaks in near-real time. The software identifies the machine in question and sends notification alerts directly to maintenance staff to investigate further.

Addressing compressed air leaks early also reduces both unplanned and planned (to test for leaks on each machine) downtime, and it improves overall equipment efficiency.

Air pressure and airflow Some manufacturers may not have the full picture when it comes to the relationship between air pressure and airflow. This means they don’t know the optimal consumption point of compressed air for their manufacturing process. The air pressure in their industrial machines may be higher than it needs to be. When equipment consumes more compressed air than necessary, it consumes more energy, which raises energy costs and CO2 emissions.

Smart sensors and an edge computing device collect data about air pressure and airflow.

By analyzing the edge analytics of the pneumatic system, plants gain a clearer picture of the relationship between air pressure and flow. By lowering the overall pressure of their pneumatic system, they reduce airflow to a certain point while maintaining the same cylinder cycle time.

Finding the optimal ratio between pressure and flow reduces compressed air consumption, energy costs, and CO2 emissions without affecting production.

Manufacturers understand that sustainability is not just a trend. It’s their responsibility to reduce energy use and greenhouse gas emissions however they can. Monitoring compressed air in pneumatic systems is one place to start. When companies monitor and record machine performance, they can be confident they are using energy as it’s intended, and they are stopping losses before they can grow.

The flexibility offered by today’s smart pneumatic devices makes it possible for manufacturers to tailor their digital transformation in ways that work for them. Partnering with an automation expert with a proven history in smart pneumatics and fluid power applications can help a company of any size recognize its specific circumstances, set sustainability goals, and identify solutions. With the right solutions in place, manufacturers can take meaningful action to make meaningful change.

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A global producer serving the automotive industry recently took steps in its digital transformation by focusing on the energy lost through compressed air leakage and air consumption. The company partnered with Emerson to monitor and measure the amount of energy the line used.

Like most brownfield applications, this production line included legacy equipment that came from different suppliers. A power supply, Ethernet bus coupler, power meter (one per circuit), and IO-Link, which included eight available ports for sensors, made up each meter box. Current transformers were located either inside or outside the meter box, and these modules all had to be installed upright to allow air circulation. Making the setup even more complex, there were a limited number of Ethernet access points to work with. Expanding would require considerable investment.

To meet the needs of this complex setup, Emerson recommended its AVENTICS Series AF2 Sensor, an easy-to-use airflow sensor that measures flow, pressure, and temperature and monitors air consumption in pneumatic systems.

The AF2 is ideal for a collection of legacy machines like this for a couple of reasons. First, the compact sensor is easy to assemble and install on existing machines and pneumatic systems. Second, the AF2 has IO-Link and Ethernet communication options. The sensor is easy to integrate into air preparation units and gives manufacturers the option to operate as a stand-alone version. With a colored rotatable LED display that provides clear feedback, the AF2 sends notification alerts to users when it detects a leak so they can take action. This simple IIoT-enabled device allowed the company to invest in energy savings while keeping installation time and costs to a minimum.

After choosing a sensor, Emerson helped the company monitor and measure the amount of energy the line used by temporarily connecting the AVENTICS Smart Pneumatic Analyzer to one machine. The SPA, which provides pneumatic system analysis at a glance, recorded, analyzed, and visualized the line’s air consumption during the production process. The team was able to read the real-time air consumption, which the SPA displays in norm liters per minute, alongside average and maximum values to quickly identify trends and anomalies.

The data collected from the SPA helped the company decide whether Emerson’s PACSystems RXi2-BP Edge Computing Device was worth investing in. In simple terms, the device interprets and displays incoming AF2 sensor data. The information is recorded and displayed on a live web-based dashboard and gives users even more energy insights without additional software. The SPA data revealed that the PACSystems RXi2-BP Edge Computing Device helped the company save energy and associated cost.

Emerson supplied approximately 180 AF2 flow sensors to meet the production line’s needs, along with the PACSystems RXi2-BP Edge Computing Device.

This system monitors pneumatic air consumption and generates and interprets machine data, giving the automotive producer actionable insights. As a result, the company found areas for improvement, including reducing peak power consumption, optimizing maintenance costs, and avoiding downtime. It plans to continue optimizing its machines to use less energy.

NOVEMBER MARCH 2022 2021

9

Case Study Building

By Steve Misiakowski, Engineering Director, Exotic Automation & Supply

an Industrial Hydraulic System Eight of the sixteen pump/motor groups.

Recirculation skid for kidney loop filtration.

D

esigning a large central hydraulic system to support a new 138,000-square-foot industrial facility presents many unique challenges compared to the more common practice of designing hydraulic power units for OEM machine builder’s equipment. As this article shows, such a significant project for one of our customers presented similar key design challenges and considerations.

The customer’s new greenfield facility is a test lab responsible for structural advanced life-cycle testing. There are dozens of individual test locations throughout the building, each presenting unique hydraulic actuation requirements to facilitate the necessary tests. The customer’s goal was to partner with a turnkey supplier to design, construct, install, and commission a large central hydraulic system capable of providing stable hydraulic oil pressure at variable volumes.

The problem The customer’s existing central hydraulic system had been designed and installed 35 years ago. That installation included fixed displacement gear pumps to provide flow and pressure throughout the facility.

A great amount of energy was continuously wasted in the form of heat 10

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generated by oil flow over relief valves at the pump units. Most of the test rigs throughout the facility included high-precision, high-speed servo valves that were sensitive to fluid contamination. Since the hydraulic system wasn’t airtight, the company couldn’t control the ingress of contaminants into the hydraulic fluid. The contaminated oil resulted in expensive, weekly repairs to maintain the servo valves. After 35 years, the customer knew what it wanted for its new building: an energy-efficient system that reduced component repairs and increased overall system uptime.

The requirements of this new central hydraulic system were very detailed and, in many instances, much more stringent than typically seen in general industrial hydraulic applications. The specs included: • Precise control of a large volume of fluid (over 18,000 gallons) • Flow variation up to 250 gpm in as little as 200 milliseconds • Stable system pressure (3,000 psi, + 0 psi/-100 psi) at variable volumes of 0-2,200 gpm • Engineered (nonwelded) piping • Maintain oil temperature between 112°F and 130°F during operation • Oil cleanliness of ISO 12/10/7 • Water content in the oil below 10 ppm • 24/7 year-round operation with a life expectancy 30-plus years Other than known limited space constraints in the design for the pump room, concepting the hydraulic portion of the project began with a blank sheet of paper. We presented multiple concepts and detailed proposals that included 3D CAD models over the course of 12 months before the project was finally awarded. It took 4 1/2 years from initial inquiry to final customer acceptance.

The project involved many stakeholders. Countless design review meetings with the facility’s general contractor, design architects, structural engineers, representatives of other building trades, and the end user resulted in a system with the following major components: • Reservoir (11,000-gallon capacity) with closed loop air exchange • Pump/motor groups with duplex pressure filtration manifolds (360 cc pumps coupled to 16 300-hp motors) • Recirculation and cooling skid • Roof-top heat exchanger (6 million BTUs) • Vacuum dehydrator and particle counter • Return filter skid • 20 accumulator stands, including 104 15-gallon bladder accumulators WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

• About 10,000 feet of engineered piping • Controls architecture, including soft-starter panels, variable frequency drive panels, programmable logic controller panel, operator interface, I/O handling, sensors, and alarms

Design challenges There were a number of unique characteristics and design challenges for each of the system’s major components.

Reservoir. The highly engineered reservoir had to be large enough to support the variability of worst-case operating and emergency-stop scenarios. The final dimensions of the reservoir were 7 feet high by 7 feet wide by 35 feet long.

The real challenge to designing this large 304-stainless steel reservoir was handling the velocity of return oil flow. We installed a custom 8-inch schedule 40 pipe with hundreds of 1-inch holes as a diffuser down the center of the tank.

This effectively “calmed” the return fluid while minimizing aeration as it mixed with the tank’s volume. We incorporated numerous baffles to separate the return oil coming into the center of the tank from the pump inlet supply fluid outlets on either side.

This was truly a unique hydraulic reservoir that required a structural 3D CAD model, finite element load analysis of the reservoir lid segment, accommodations for pressure testing, and multiple locations for level and temperature sensors. Once built, it required exterior sugar blasting followed by a clear-coat application.

Pump/motor groups. We were challenged to design a system that eliminated the user’s ability to perform manual tweaking of the components.

The pump solution for the new central hydraulic system included pressure-compensated pump technology with load sense control for 24/7 year-round operation. Partnering with Parker Hannifin, we delivered a custom pump control scheme. Parker’s experience with large system applications and its load-sharing expertise led to a solution that included 16 360-cc displacement Parker PVplus Series pumps with load sensing control and electrical unloading.

While piston pumps were more expensive than the gear pumps in the customer’s existing hydraulic system, they provide longer life operating at higher pressure and longer continuous duty cycles. The load sensing system generates fewer power losses because the pump reduces both flow and pressure to match the load requirements of the system.

Each of the 16 pumps was coupled to a 300-hp inverter-duty-rated motor. These pump/motor groups were each incorporated into free-standing drip trays that supported a custom pressure filter manifold that held two WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

duplex filter assembles rated to 5,000 psi with 3µ filter elements. We placed eight pump/motor groups on each side of the large main reservoir.

Recirculation and cooling skid. Another significant challenge was meeting the stringent oil cleanliness requirement of 12/10/7 per ISO 4406:99. An oil recirculation skid, or kidney loop filtration system, was needed. This recirculation skid provided a continuous flow of oil filtered at 2µ separate from the main supply pressure filters, and directed the filtered oil up to the 6 million BTU heat exchanger (cooler) located on the roof of the new building.

Roof-top heat exchanger. The large heat exchanger on the roof was exposed to weather conditions typical of the Midwestern U.S. – from subzero winter temperatures to 125°F in summer. With oil returning to the reservoir at 140°F, the challenge was to maintain the oil temperature between (Continued on page 12)

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The engineered piping trench.

(Continued from page 11) 112°F and 130°F during operation, regardless of weather conditions outside.

The solution was to have the recirculation skid’s pumps individually cycle on or off as needed to keep the hydraulic system’s temperature regulated. We accomplished this by having each of the four screw pumps on the recirculation skid controlled with a variable frequency drive. The VFDs provided precise speed control (flow control) and energy efficiency. Since the fluid temperature was being monitored in numerous places throughout the hydraulic system, we could program the amount of fluid cooled by the rooftop cooler and the running of the cooling fans to effectively keep the oil temperature in the proper range during operation.

Vacuum dehydrator and particle counter.

Water is one of the most common and detrimental contaminants of industrial oils and related equipment. Water vapor enters the oil and condenses when temperatures drop. It depletes rust inhibitors and can cause direct corrosion of steel components in the hydraulic system.

We overcame this challenge by incorporating a properly sized vacuum dehydration unit.

Vacuum dehydration is the only comprehensive method to effectively remove water vapor and other dissolved gases from the oil. Through low-temperature distillation in combination with fine filtration, oils can be kept in “like new” condition.

The vacuum dehydrator designed into our system was a stand-alone unit mounted on a structural steel base with an integral drip pan. It is capable of processing more than 1,200 gallons per hour at 1,800 rpm and contains an inline particle counter to monitor the oil cleanliness level. Its PLC communicates via industrial Ethernet to the hydraulic system’s main PLC, sharing critical fluid data.

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Return filter skid. Due to the central hydraulic system’s significant potential flow volume of up to 2,200 gpm, we combined two sets of large duplex filtration vessels on a single steel-base return filtration skid. Each of the four total vessels is populated with seven triple-length 20µ-filter elements.

Accumulator stands.

With the possibility of sudden flow changes due to test stands starting and stopping, we had to account for the resulting “shocks” to the hydraulic system. The solution was to incorporate strategically located banks of accumulators that are used to absorb and store energy. We located 20 accumulator stands throughout the new facility to provide an evenly distributed amount of shock absorption capacity.

Engineered piping. Another challenge to overcome was avoiding the energy lost by improper plumbing. Selecting the proper line size for a hydraulic system is critical to obtaining maximum performance and life from hydraulic components. Undersizing fluid lines results in high pressure loss and heat; oversizing lines increases the cost of the system. In typical applications, lines should be sized as follows: • Suction: 2-4 feet/sec.

• Return: 10-15 feet/sec.

• Medium pressure: 15-20 feet/sec.

• High pressure: 20-25 feet/sec.

We reduced these velocities to prevent excess energy loss.

The almost two miles of piping, located in floor trenches throughout the new facility, used 95% weld-free connection technology, eliminating the risk of corrosion due to stress cracks during welding and increasing the lifespan for the piping system. We used facility CAD data in conjunction with the CNC cold bending machines to manufacture the precise tube segments. Orientable flanges gave the pipe fitters greater flexibility during assembly. This reduced installation time and will simplify maintenance, reduce operating costs, and improve safety.

Providing proper line sizes means improved performance of the hydraulic test equipment throughout the facility. It makes flow more laminar, reduces the effect of shock, decreases potential leak points, increases fitting and connector life, and reduces heat generation.

Controls architecture. For this central hydraulic system, the controls design and integration were part of the turnkey installation.

Operating the hydraulic system 24/7 year-round required redundant PLCs. We designed controls that would monitor, record, and respond to system performance and health. The items monitored and displayed on the system’s main operator interface included: • 120 multiple emergency control stops • System flows and pressure • Reservoir fluid levels • Oil temperature • Multiple vibration sensors • Multiple bearing temperature sensors • Multiple differential pressure sensors (mainly across filters) • Multiple sump alarms • Valve position indicators • Security inputs, such as fire alarm, smoke detector, and sprinkler water flow • Fluid ISO particle count level, as well as water and air content • Status of all the system’s pumps, fans, and motors The customer also required remote-access to the control system via their intranet to monitor, interrogate, or silence alarms. Having all user-editable parameters along with realtime system performance data located on the password-protected human-machine interface greatly enhanced the customer’s efficiency in maintaining the system and maximizing uptime.

The project achieved the customer’s system requirements for flow response, pressure compensation, and energy consumption. The customer received a turnkey custom hydraulic solution tailored to their unique application.

Parker was the source of many system components, including filters, valves, accumulators, KleenVents, proportional valves with controllers, hoses, and fluid connectors.

The results We addressed all the customer’s issues related to the old hydraulic system: • We improved the system’s energy efficiency with the variable displacement pumps.

• We achieved oil cleanliness of ISO 12/10/7, maintainable by a multistage filtration strategy.

• The cleaner oil significantly reduced repairs.

• The modularity of the system’s design and redundant controls led to documented reductions in system downtime.

Using sound fluid power design principals, the new central hydraulic system achieved measurable benefits with a much smaller footprint than the customer’s previous system.

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N F PA U P D AT E

Shipments Grew 20% Last Year Data from the National Fluid Power Association shows that shipments of pneumatic, hydraulic, and total fluid power products continue to grow. From 2020 to 2021, total fluid power shipments grew 20.1%. Raw index data shows that mobile hydraulic and pneumatic shipments were down slightly in December, while industrial hydraulic shipments were up. These charts were drawn from NFPA’s Confidential Shipment Statistics (CSS) program.

Hydraulic and Pneumatic Shipments

SHIPMENTS

Raw Index Data, Index: 2018=100

MONTH

TOTAL FLUID POWER

TOTAL HYD.

TOTAL PNEU.

Oct. 2021

18.6

19.3

16.1

Nov. 2021

20.0

20.3

16.9

Dec. 2021*

20.1

20.9

16.3

*Preliminary data subject to revision.

Shipments – Cumulative year‐to‐ date % change (2021 vs. 2020)

This graph of raw index data is generated by the total dollar volume reported to NFPA by CSS participants and compared to the average monthly dollar volume in 2018. For example, the December 2021 total dollar volume for pneumatic shipments is 96.7% of the average monthly dollar volume in 2018. (Base Year 2018 = 100)

The table above is expressed in terms of cumulative percent changes. These changes refer to the percent difference between the relevant cumulative total for 2021 and the total for the same months in 2020. For example, December 2021 pneumatic shipments figure of 16.3 means that for the calendar year through December 2021, pneumatic shipments increased 16.3% compared to the same time-period in 2020.

Pneumatic, Mobile and Industrial Hydraulic Orders 12/12 Ratio Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. Each point can be read as a percentage. For example, 133.2 (the December 2021 level of the industrial hydraulic series) indicates that industrial hydraulic orders received from January 2021 to December 2021 were 133.2% of the orders received from January 2020 to December 2020.

(Base Year 2018 = 100)

Total ‐ Hydraulic and Pneumatic Shipments 12 Month Moving Average This graph of 12-month moving averages shows that in December 2021, the moving average for shipments increased across the board. (Base Year 2018 = 100)

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I F P S U P D AT E

Executive Profile

CELEBRATING 60 YEARS

Q. H ow did you get started in the fluid power industry?

A. My family owns a business that services heavy equipment in the mining industry. While working for the business, I worked with a few certified fluid power specialists who inspired me to study for the test and become certified myself.

Q. How and why did you get involved in IFPS, and what have you gained professionally and personally?

A. I got involved with IFPS after a colleague, Rocky Phoenix, volunteered and

was elected to the board. He felt I could contribute to the society and would enjoy working with other industry professionals.

Q. W hy did you pursue certification, and how has it helped

your career?

A. I was inspired by others I worked with in our family business. I really looked

up to their knowledge and expertise in hydraulics.

Q. W hat have you learned by working in this industry?

Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM – Vice President, Open Loop Energy

A. I have learned how little I know. There are some amazing people involved with the society and many who have contributed to the industry through innovation, education, and service.

Q. W here do you see the industry heading in the next 10 years?

A. I see a continued trend of using hydraulics as the muscle with electronics as the brains and logic. Hydraulics and pneumatics will continue to fill the niche motion control needs they always have but with improved control and feedback interfaces.

Q. W hat advice would you give someone starting out in

the industry?

A. Stick with the industry. There are many opportunities outside the mainstream

careers. This means more job stability and the possibility of higher paying jobs.

Q. W hat are some of your hobbies and interests?

A. I love aviation, and I’m fortunate enough to fly for work and pleasure. I’ve played golf since I was 10 and still enjoy the game when I find time.

Q. W hat is something people would be surprised to learn

about you?

A. I’m kind of a 1980s computer nerd. I grew up learning computers with DOS

and simple computer games and have kept up with it as I’ve grown older. I’ll still play computer games with my kids. I also enjoy programming for PLCs in the motion control world.

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I F P S U P D AT E

Certify Your Workforce in 2022 »

IFPS CERTIFICATION EMPOWERS fluid power distributors, manufacturers, and end users with:

• Increased credibility • A fully trained and certified workforce • Standards for assessing the skill level of current or potential employees • A safer and more efficient workforce • Competency standards for advances in the industry • Effective sales and recruiting tools MARKETING OPPORTUNITIES with a fluid power certified workforce include: • An IFPS certification-supporter logo for your website • Adding IFPS credentials to an employee’s name in signature lines, business cards, LinkedIn profiles, etc.

• Certificates to display in your office or shop • Your employee’s name and company listed in Fluid Power Journal as a “Newly Certified Professional” ABOUT IFPS CERTIFICATION programs: • IFPS has certified thousands of professionals since 1960.

• Certifications are the industry standard for assessing an employee’s knowledge.

• Certification tests provide an objective third-party assessment of an individual’s skill level.

• Tests are psychometrically evaluated and meet defensible standards.

• Certifications are portable and recognized industry wide.

• Individuals recertify every five years to show their skills and knowledge keeping pace with the industry.

For more information, visit www.ifps.org/ certifications.

Air Compressors

Clean Dry Air Improves Performance...

Clean, Dry Compressed Air Starts with The Extractor/Dryer® Manufactured by LA-MAn Corporation • Point of Use Compressed Air Filter to Improve and Extend Equipment Life • Removes Moisture and Contaminates to a 5-Micron Rating: Lower Micron Ratings are Available • Models with Flow Ranges of 15 SCFM to 500 SCFM Rated Up To 250psi are Standard • Differential Pressure Gauge Built in • Mounting Hardware Included for Easy Installation • Weep Drain is Standard; Float Drain or Electronic Drain Valves Optional

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I F P S U P D AT E

IFPS Launches Employer Resources Web Page

CELEBRATING 60 YEARS

A newly designed page on the IFPS website, Employer Resources for Certification, helps employers decide which IFPS certification best matches an employee’s job responsibilities.

By selecting descriptions of an employee’s job duties, the page leads employers to concise information about the best path to certification. For example: My employee • Designs or sells fluid power systems.

• Troubleshoots or installs, fluid power systems.

• Repairs or maintains fluid power systems.

• Fixes leaks, installs and replaces pipe, tube, or hose.

IFPS certifications are renown as the industry standard for competence in fluid power and automation. A fully trained and certified workforce indicates an increased capability that sets your company apart from the crowd.

The employee’s journey toward certification tests their drive, skill, and desire to advance toward a common corporate goal of excellence.

For more information, visit www.ifps.org/certifications.

Hall of Fame Nominations Open

»

NOMINATIONS FOR THE Fluid Power Hall of Fame are being accepted until April 15.

A panel of judges reviews the applications and announces the inductees on Fluid Power Professionals Day, June 19. Inductees will be honored at an awards dinner during IFPS's fall meeting in October in San Diego.

Anyone can nominate a living or deceased professional who has 25 or more years’ experience in the fluid power industry. Living nominees will be contacted and asked to complete an application.

The Fluid Power Hall of Fame was established to acknowledge individuals who have made significant contributions to the fluid power industry.

To make a nomination, visit www.fluidpowerhalloffame.org.

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I F P S U P D AT E

Newly Certified Professionals December 2021 MASTER MECHANIC

holds IHM, MHM and PM certificaitons David Heldstab, The Boeing Company John Osko, The Boeing Company Christopher Scime, The Boeing Company Michael Sherman, The Boeing Company Paul Younglove, The Boeing Company SPECIALIST

holds HS and PS certifications Jhoanna Hansen, Cargill Jesse Holmes, CERES Leate Rogers, GEFCO Christopher Johnson, Hennepin Technical College Kevin Milligan, Hennepin Technical College Kissinger Moua, Hennepin Technical College Touger Moua, Hennepin Technical College James Siglin, Hennepin Technical College Bridget Obermark, Hyspeco HYDRAULIC SPECIALIST

Ramin Askarifar David Patrick, Airline Hydraulic Cameron Ruggiero, Alfred State College Brandon Dillenbeck, Alfred State College Nicholas Green, Alfred State College Joshua Jeziorowski, Alfred State College Lucas Ott, Alfred State College Dylan Perlino, Alfred State College Jake Young, Applied Engineered Systems (Engineered Sales) Jared Werner, Brand Hydraulics Christopher Heen, Continental Hydraulics Eric Jacobson, Danfoss Power Solutions Matthew Kruse, Danfoss Power Solutions Daniel Hernandez, Engineered Sales Jonathan Jefferson, Engineered Sales Logan Smith, Hennepin Technical College Alexander Broyles, HydraForce Cole Yungerman, HydraForce Gerold Curell, Hydraulic Controls Bridget Obermark, Hyspeco Mike Campbell, John Henry Foster Seth Koetje, MFP Automation Engineering Thomas Kok, Oxbo International Walker Gross, WAR Industrial Services

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PNEUMATIC SPECIALIST

Jhoanna Hansen, Cargill Jesse Holmes, CERES Leate Rogers, GEFCO Christopher Johnson, Hennepin Technical College Kevin Milligan, Hennepin Technical College Kissinger Moua, Hennepin Technical College Touger Moua, Hennepin Technical College James Siglin, Hennepin Technical College Troy Hudson, IMI Precision David Hiscock, Norgren CONNECTOR & CONDUCTOR

Patrick Brister, The Boeing Company Victor Diep, The Boeing Company Ivan Shih, The Boeing Company Brandon Welch, The Boeing Company

Mark Bergerud, Ottertail Power Barry Schleske, Ottertail Power Isaac Fredrick, Terex Utilities Emily Hagge, Terex Utilities David Heldstab, The Boeing Company John Osko, The Boeing Company Christopher Scime, The Boeing Company Michael Sherman, The Boeing Company Sean Wynne, The Boeing Company Paul Younglove, The Boeing Company PNEUMATIC MECHANIC

Miles Conn, Controlled Fluids Joshua Grisolia, The Boeing Company Grant Harvey, The Boeing Company Ryan Keller, The Boeing Company Dylan Longaker, The Boeing Company

MOBILE HYDRAULIC MECHANIC

Kyle Cowell, Alliant Energy Shane Doerscher, Alliant Energy Nick Freeman, Alliant Energy Matthew Haag, Alliant Energy Andrew Martin, Alliant Energy Zach Mason, Alliant Energy Jared McRill, Alliant Energy Micah Stockberger, Alliant Energy Travis Birmingham, Altec Industries Jason Bush, Altec Industries Matthew Deters, Altec Industries Robert Gilpin, Altec Industries Gary Hatcher, Altec Industries Andrew Ramos, Altec Industries Kelsey Rutledge, Altec Industries Meagan Smith, Altec Industries Natividad Guerra, American Electric Power Co.

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I F P S U P D AT E

AVAILABLE IFPS CERTIFICATIONS CFPAI Certified Fluid Power Accredited Instructor CFPAJPP Certified Fluid Power Authorized Job Performance Proctor CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPE Certified Fluid Power Engineer CFPS Certified Fluid Power Specialist (Must Obtain CFPHS & CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist CFPECS Certified Fluid Power Electronic Controls Specialist CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT) CFPIHT Certified Fluid Power Industrial Hydraulic Technician CFPMHT Certified Fluid Power Mobile Hydraulic Technician CFPPT Certified Fluid Power Pneumatic Technician CFPMM Certified Fluid Power Master Mechanic (Must Obtain CFPIHM, CFPMHM, & CFPPM) CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMIH Certified Fluid Power Master of Industrial Hydraulics (Must Obtain CFPIHM, CFPIHT, & CFPCC) CFPMMH Certified Fluid Power Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC)

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

HYDRAULIC SPECIALIST May 2-5, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test May 6.

Aug. 29-Sept. 1, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test Sept. 1.

PNEUMATIC SPECIALIST June 13-16, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test June 16.

CONNECTOR & CONDUCTOR May 24-25, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test May 26.

Nov. 15-16, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written test Nov. 17.

MOBILE HYDRAULIC MECHANIC April 19-21, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written and JP test April 22.

Oct. 10-12, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written and JP test Oct. 13.

Online review for written test. Contact info@cfcindustrialtraining.com. IFPS members can email askus@IFPS.org for a 20% off coupon code. Test fees not included.

INDUSTRIAL HYDRAULIC MECHANIC July 18-20, Fairfield, OH. Contact info@cfcindustrialtraining.com. Written and JP test July 21.

INDUSTRIAL HYDRAULIC TECHNICIAN Onsite review training for small groups. Contact IFPS for details.

MOBILE HYDRAULIC TECHNICIAN For dates, call 513-874-3225 or contact info@cfcindustrialtraining.com.

PNEUMATIC TECHNICIAN and PNEUMATIC MECHANIC For dates, call 513-874-3225 or contact info@cfcindustrialtraining.com.

JOB PERFORMANCE TRAINING Online review. Contact info@cfcindustrialtraining.com. Reviews includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members can email askus@IFPS.org for a 20% coupon code. Test fees not included. To register, contact info@cfcindustrialtraining.com.

LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW Contact info@cfcindustrialtraining.com for information.

CFPMIP Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC) CFPCC Certified Fluid Power Connector & Conductor CFPSD Fluid Power System Designer CFPMEC (In Development) Mobile Electronic Controls CFPIEC (In Development) Industrial Electronic Controls

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I F P S U P D AT E

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

Contact headquarters if you do not see a location near you. Every effort will be made to accommodate your needs.

If your test was postponed due to the pandemic, please contact headquarters so that we may reschedule.

TENTATIVE TESTING DATES FOR ALL LOCATIONS: April 2022 Tuesday 4/5 • Thursday 4/21 May 2022 Tuesday 5/3 • Thursday 5/19 June 2022 Tuesday 6/6 • Thursday 6/23 July 2022 Tuesday 7/12 • Thursday 7/28

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

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

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

CELEBRATING 60 YEARS

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

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

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

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Clippard manufactures a full range of miniature fluid control devices and components including pressure controls, electronic valves, analytical and oxygen clean valves, proportional and proportional isolation valves, pinch and isolation valves, precision regulators, fittings, tubing and more. Clippard continues to be an industry leader in providing innovative products, application engineering and cost-saving solutions for a wide range of applications. Proudly made in the USA.

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COMPONENT SHOWCASE THE FLANGE CONNECTOR YOU NEED – QUICK AS 1, 2, 3 Why use MAIN MANUFACTURING PRODUCTS?

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Highly responsive, with your application specifications, Stiebel can turn around quotes and application files (drawings and CAD files in pdf, stp, dxf …) within an average of 24-72 hours.

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21

TEST YOUR SKILLS

GAS-CHARGED HYDRAULIC ACCUMULATORS A

ccumulators are pressure vessels and are subject to the American Society of Testing Materials standards in addition to the International Standards Organization and the Occupational Safety and Health Administration guidelines. The use of accumulators may be subject to additional regulations, depending on location and application. Local and industry-specific standards should be investigated to confirm compliance. The accumulator manufacturer’s literature should be reviewed for additional recommendations and limitations. Because accumulators are pressure vessels, they cannot be modified in any way except by the manufacturer. Information concerning mounting and securing accumulators is also provided in the standards and guidelines. Note: Accumulators should be mounted vertically.

The precharge pressure of an accumulator is the pressure reading in the bladder when the accumulator is empty of fluid. The precharge requirement of the accumulator will vary based on the application, independent of the accumulator size. Common applications are to supplement pump flow, provide short-term back up power, absorb hydraulic shocks, or maintain system pressure. If the precharge pressure is low, the system operation will be sluggish. Low precharge in accumulators used for surge protection will allow a system with high system shocks to knock and make noise. If the precharge pressure in a bladder-type accumulator is high because the accumulator was precharged to a higher pressure than manufacturer specifications, the bladder may fail. Under normal operation, the bladder is compressed in the shell by hydraulic oil and only expands to rest against the poppet valve in the bottom of the accumulator when the system is off. Higher-than-specified precharge pressures can cause the bladder to pound against the poppet valve in the bottom of the accumulator when system pressure drops but is still within the operating range of the machine. This will make the bladder fail where it is pushed against the anti-extrusion valve.

Accumulator precharge should be checked on a regular basis. Occasionally, the precharge of an accumulator becomes low and must be reset. This requires checking the accumulator for internal and external leaks, and then recharging the accumulator with dry nitrogen. If the accumulator shows dents or obvious damage, it must be replaced. The precharge pressure of the accumulator is temperature sensitive. To accurately test the precharge pressure, it should be done immediately after the machine has been shutdown while it is still at operating temperature.

There are a number of safety precautions that must be observed when charging accumulators. Safety goggles, gloves, and other required protective equipment should be worn, and any external leaks must be stopped before charging the accumulator. In addition, ensure that the potential hazards of working with a gas in a confined space are understood and steps taken as required to keep personnel safe. If there is fluid in the precharge gas in a bladder-type accumulator, the bladder is either 22

MARCH 2022

Gas Valve

Nitrogen Gas Bladder

Anti-Extrusion Valve

Shell

Port

Port

Body

Piston

Nitrogen Gas

Gas Valve

Bladder andpiston-type accumulators.

passing fluid through the bladder membrane or has a leak. If the bladder is leaking, it must be replaced before recharging. If there is fluid in the precharge gas in a piston-type accumulator, the piston seal between the charge gas and system fluid is leaking.

Gas valves will vary with accumulator manufacturers and for pressures over 3,000 psi. Most manufacturers use an ISO 4570-8VI-style valve that may look like an automotive-type Schrader valve. However, it is rated for much higher pressure. The valve is used to charge the accumulator and release gas when necessary.

Steps to check and add to or reduce the precharge on an accumulator are as follows: 1. Ideally, the system will be at operating temperature. Lower all movable machine members, and block those that could move and injure personnel. Follow lock-out/tag-out procedures.

2. The system must be shut down or the accumulator isolated, and the hydraulic pressure side drained to the reservoir.

3. Before connecting the appropriate filling/testing valve and hose assembly to the nitrogen tank, ensure that all the valves are closed.

Use adequate safety precautions to ensure that accidental venting of the accumulator doesn’t render the room uninhabitable due to displaced oxygen.

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ONSITE TRAINING

Accumulator charging valve setup.

4. V erify that the precharge pressure matches the specifications for the application.

5. Remove the safety caps on both the accumulator and fill tank.

6. Gently screw in the T bar handle (CW) to open the charging fill valve to allow nitrogen gas to enter the accumulator. At this time, the actual precharge pressure will be seen on the gauge when gas from the accumulator fills the line.

7. Slowly open the fill valve from the top of the nitrogen tank to start charging the accumulator. Charge slowly and watch the pressure gauge for proper charge pressure. When the gas supply is turned off, the pressure will drop slightly. Add nitrogen as needed to reach the desired charge pressure. If overcharged, the fill valve can be closed and the bleed valve slowly opened to discharge excess gas. It will be extremely cold while venting.

8. After filling, close the fill valve on the nitrogen tank and close the fill valve on the accumulator by turning the T handle (CCW).

9. Open the bleed valve and release the trapped gas in the hose between the

accumulator and the nitrogen tank before disconnecting either end of the charge/fill kit.

10. Disconnect both ends of the charge/ fill kit, and screw the safety caps back on the accumulator and the nitrogen tank. Be sure to secure the nitrogen tank in a proper storage place.

It is a good practice to wait a few minutes and recheck the precharge pressure. If the accumulator was charged too quickly, the expanding gas can be cooled to provide an initial inaccurate reading. Remove the hose and charge valve assembly from the accumulator, and install a tag on the accumulator noting the date and precharge pressure.

Install the charge valve protection cap.

Dry nitrogen is the preferred gas used to charge an accumulator. If the application requires a different gas to be used, ensure it is inert.

must not be used to What would cause hydraulic fluid to come out 1. Oxygen charge a hydraulic accumulator 2. of the gas valve when the precharge gas is released from a bladder-type accumulator? a. Bladder leaks. b. Operation is normal. c. Accumulator is overcharged. d. Hydraulic pressure was not released. e. Foot valve in the accumulator is stuck open.

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TEST YOUR SKILLS

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PRODUCT SPOTLIGHT

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Ordinary heavy duty not heavy enough?

Heavy-Duty Mill Cylinders for: • Induction-Hardened, Chrome-Plated Rods • Heavy Wall Tubing • Replaceable Glands & Retainer Rings • High-Load Piston Design Think indestructible and call Yates. www.yatesind.com

Hydraulic Noise and Shock Suppressor

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Suppressor

Accumulators

Wilkes and McLean manufactures an In Line Noise and Shock Suppressor for hydraulics and is a stocking distributor of Nacol Accumulators. Our suppressors eliminate pulsations, which greatly reduces noise and vibration from applications from a few gallons up to 200 gallons. We stock all of our suppressor sizes as well as Nacol Accumulators and parts from 1/5 of a pint up to 15 gallons, in our Schaumburg, Illinois facility.

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

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MARCH 2022

New—Flat Face Design "TVF" Series Quick Disconnect • Up to 6,000 PSI Operating Pressure— Coupled or Uncoupled • Full 4:1 Safety Factor • Superior Flow Characteristics—Minimal Pressure Drop • RoHS Compliant Plating • Multiple Port Options—Female NPTF, Female SAE O-Ring, Female BSPP, Code 61 & 62 Flange Port/Head P.O. Box 6479 • Fort Worth, TX 76115 817.923.1965 • www.hydraulicsinc.com

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SPECIAL AD SECTION

Protection for All Things Hydraulic, Pneumatic and Fluid Power MOCAP manufactures an extensive range of protective closures to guard pipes, hoses, and hydraulic fittings from dirt, moisture, and damage to help maintain equipment reliability. Included are a variety of sizes and styles of Threaded and Non-Threaded plastic Caps and Plugs for Metric, NPT, BSP, JIC and SAE Threaded Connections, Ports and Fittings. These are in addition to MOCAP’s already extensive lines of low-cost Caps, Plugs, Grips, Netting, Tubing and Tapes for general Product Protection, Finishing and Masking.

All of our stocked items are ready for immediate shipment and available in Box, Mini-Pack and Micro-Pack quantities. Free Samples are always available for testing purposes.

Part number

METARIS TELESCOPIC CYLINDERS – ENGINEERED FOR RUGGED RELIABLE OPERATION You can’t go wrong with our MH TM series line of telescopic cylinders.

HITACHI FLANGELOCK Major design improvements over competing products include a low friction dual lip rod seal; and all stages chrome plated and roller AND CAP KITS AVAILABLE burnished for smoother operation, increased scratch-, impact- and rust-/corrosion-resistance, andmachines greater stability.

Ourof special low Weight (kg) Part description Applicable Number parts friction dual lip rod seal also has many benefits including reduced SWINGFLGLCK2062 Swing hose FlangeLock kit EX3600, EX5600, EX8000 16 x 2062U - red FlangeLock 6.7 running friction for smoother and faster operation, no mis-staging, SWINGCAP2062 no sealSwing circuit cap kit EX5600, EX8000 16 x 2062 - cap 4.5 adjustments areEX3600, necessary, no compression set like standard V-packing, longer seal life than V-packing and a better operating EX3600, EX5600, EX8000 16 x 2462U - purple FlangeLock 7.7 TRAVELFLGLCK2462 Travel hose FlangeLock kit temperature range. Our MH series single acting telescopic cylinders TRAVELCAP2462 Travel circuit cap kit EX3600, EX5600, EX8000 x 2462 - cap 6.4 and function are fit, form interchangeable with16other manufacturers’ 14 x 3262U - black FlangeLock cylindersFront inattachment the market EX3600, today.

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CONTAMINATION CONTROL

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

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

Stop the Mess

THE FLANGELOCK™ TOOL AND CIRCUIT BLANKING CAPS

The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection.

Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps stop the mess.

The FlangeLock™ Tool is the ultimate contamination control tool for protecting HITACHI MAKING systems.

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

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MARCH 2022

25

DriveThrough

By Paola Ipsa, AddiDrive Program Marketing Manager, Poclain Hydraulics

Hydraulic AWD Takes It on the Road

M

aximizing productivity and safety while minimizing CO2 emissions is a top priority for many people in many industries. For companies that use trucks, the challenges they face include maximizing payload, uptime, and material lifetime while minimizing fuel consumption. Add to these challenges recent supply chain constraints all over the U.S. and diminishing spare-part inventories. With all-wheel-drive trucks, finding the right compromise for the job and route is paramount to ensuring a truck gets the job done effectively.

The most popular trucks on the market today are those for on-road applications such as long-haul trucking. Those trucks are optimized for driving on the road but not for rough terrains, as they are not supposed to drive off-road. On the other hand, mechanical AWD versions are perfect off-road but offer limited on-road performance. Having only these two alternatives presents a problem for vocational application truck users who spend nearly all of their time on-road and only a small amount of it off-road. They are based either on a standard long-haul truck that can get stuck in off-road conditions, or, if based on a mechanical AWD transmission, they limit their on-road performance.

Mechanical AWD is a solution for high mobility needs and low distance driving. It is optimal for trucks working almost exclusively off-road. To avoid risk to mobility in this type of application, a common solution is to acquire a mechanical AWD truck that copes with difficult situations with or without load-maximizing uptime. However, mechanical AWD has constraints, such as a reduced turning radius, which dramatically limits maneuverability. Furthermore, AWD necessitates increased ride height, creating constraints when driving on-road. This is especially limiting when it comes to height restrictions on bridges and tunnels, and even more so for utility trucks with over-cab lifts or cranes already at the limit of height regulations. Moreover, mechanical AWD reduces the payload and increases fuel consumption, which makes it not suitable for driving on-road most of time. This makes AWD inappropriate for trucks in applications such as fire and rescue, construction, towing and recovery, or other specialized hauling applications.

A compromise for these types of applications, the best of both worlds, so to speak, is an on-demand AWD hydraulic system that has the capability of a standard truck in off-road situations but maintains its on-road performance. This type of solution delivers optimal mobility in difficult driving conditions, such as mud, snow, slope, or sand, improving maneuverability by keeping a standard turning radius and improving the grip on unstable terrains or in low-adherence situations.

With Poclain Hydraulics’ on-demand hydraulic AWD system AddiDrive, there is no need for 26

MARCH 2022

a cab height increase; the axle fits perfectly with standard chassis integration, which means the same ride height as a standard truck. Having traction in the front wheels does not affect the installation of auxiliaries or truck-height compliance for road regulations. The system has minimal impact on payload and fuel consumption. A truck with the AddiDrive system weighs 600 pounds less than a standard truck, while a truck with a mechanical AWD truck increases its weight by 2,000 pounds. Fuel consumption with the AddiDrive system increases by only 0,5-1% while a mechanical AWD increases fuel consumption by 10-15%. The system increases tire lifetime by avoiding excess slippage. It also lowers total cost of ownership because of reductions in downtime, maintenance, fuel consumption, and tire usage. It boosts productivity by maximizing the daily payload and offering better comfort and safety for the driver.

From a driver’s perspective, keeping the same cabin height as a standard truck improves comfort and optimizes the driver’s visibility and ergonomic accessibility. The system also reduces stress and fatigue on the driver and provides peace of mind that he or she will meet their mileage goals. Additionally, on-demand hydraulic AWD, through increased mobility without added height, reduces the planning required of fleet managers and drivers by optimizing routes and thus driving hours. Even when drivers encounter harsh weather conditions or irregular terrain such as fields, forests, or construction sites, they will not get stuck or lose valuable time.

Besides advantages to end users, an on-demand hydraulic AWD system has a positive impact on the environment. Reduced slippage increases tire lifetime, which reduces waste and fuel consumption, thus limiting emissions. It also means there may be no need to pave access to the work site. Additionally, the system reduces the risk of cash spent for towing a stuck standard truck, which is beneficial to fleet managers, drivers, and the environment. By keeping the same fifth-wheel height as a standard truck, the manager can unify his fleet of trailers.

On-demand hydraulic AWD system architecture is relatively simple.

The new AddiDrive open loop system optimized for U.S. trucks consists of a load-sensing-type pump, a valve, an electronic control unit, and two motors assembled onto an axle that is fitted inside the truck’s wheels.

Besides these components, the system requires a hydraulic tank, a filtration system, and pipes and wiring to ensure connections.

For system integration, the system must be fully adapted to U.S. standards for U.S. trucks. In the new AddiDrive open loop system, the motors are tailored to fit U.S. standard rims, while the axle covers a full range of load capacity. The pump is compact and the tank is easy to integrate without taking up space needed for other components. Thus the system fits trucks from class 6 up to class 8. Moreover, the system is compatible

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

with U.S. truck power take-offs. Allowing assembly of the pump directly onto a transmission PTO makes for a compact and optimized integration that does not interfere with work done by the body’s builder and upfitters, making it fully compatible with their tools. At speeds up to 12 mph, where increased traction is often needed, the system is able to provide 5,000 lbf tractive effort at 5,100 psi (351 bar).

When the system is activated, the pump, powered by the transmission PTO, generates and provides flow to the valve block, which ensures safety and manages the motors’ activation. The valve block splits the flow between two motors, providing traction. The electronic control manages communication and pilots the system.

Contrary to a mechanical axle, on-demand hydraulic AWD delivers torque only at the required level and only when needed. The driver maneuvers a switch on the dashboard, activating the system and allowing it to engage and disengage. In AddiDrive systems, engagement and disengagement can be done on the fly, while the vehicle is moving.

On-demand hydraulic AWD has two modes: traction mode, in which the hydraulic-powered axle delivers torque, and freewheeling mode, in which the two hydraulic motors are disengaged.

In traction mode, the AddiDrive system can drive the truck up to 12 mph, after which it automatically disengages. Depending on the resistance created by the machine to move, maximum pressure may be applied in the hydraulic motors to provide around 5,000 lbf additional tractive effort. Maximum torque can be applied from 0 mph; afterward it will be adapted at higher speed usage, never exceeding maximum power limitation. Maximum tractive effort is optimized depending on the front-axle load and low-adherence conditions typically encountered in difficult situations. While the WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

traction mode is active, the pump displacement is controlled to ensure speed synchronization between the front and rear wheels. Additionally, the driver can adjust the pump displacement to the required level of system pressure.

When the system is disengaged, the pump returns to the neutral position and the two motors switch to freewheeling mode, reducing system drag losses to a minimum.

Generally, integration for this type of system occurs at the OEM level. It offers OEMs an opportunity to differentiate their product. OEMs can deliver more versatile truck models with efficient performance both on- and off-road without the constraints of a mechanical AWD. The front axle is fully equipped with a plug-and-play solution compatible with the chassis installed on the normal axle; only the pipes need to be attached. This type of plug-and-play system offers fast integration at the OEM level requiring low resource.

When specifying a truck AWD solution, the work and application needs to be carefully examined.

Whether a work truck is destined for full or partial off-road driving needs to be analyzed carefully to optimize the total cost of ownership and deliver a right-sized solution for each application.

Having a choice between full-time and on-demand hydraulic solutions allows OEMs and fleets to differentiate themselves further in the market.

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MARCH 2022

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SPECIAL AD SECTION

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SPRING

LITERATURE REVIEW HITACHI FLANGELOCK AND CAP KITS AVAILABLE

Don’t pay for I/O you don’t need! The xtremeDBm is the modular signal and distribution device capable of going anywhere you need it to go, no matter the environmental conditions. With six DEUTSCH ports for up to 26 Amps and both pin-level and LED diagnostics for improved serviceability, the xtremeDBm is the ultimate solution for on- and offhighway machine systems.

TM

Part number

Part description

SWINGFLGLCK2062

Part number

Part description Swing hose FlangeLockTM kit

EX3600, EX5600, EX8000

16 x 2062U - red FlangeLockTM

6.7

Swing circuit cap kit

EX3600, EX5600, EX8000

16 x 2062 - cap

4.5

TRAVELFLGLCK2462

Travel hose FlangeLockTM kit

EX3600, EX5600, EX8000

16 x 2462U - purple FlangeLockTM

7.7

TRAVELCAP2462

Travel circuit cap kit

EX3600, EX5600, EX8000

16 x 2462 - cap

6.4

Applicable machines FRONTATTFLGLCK326162 EX3600, EX5600, EX8000 FRONTATTCAP326162

SWINGCAP2062

Swing circuit cap kit Travel hose FlangeLockTM kit

EX3600, EX5600, EX8000 BOOMARCHCAP3262

TRAVELCAP2462

Travel circuit cap kit

EX3600, EX5600, EX8000

FRONTATTFLGLCK326162

Front attachment FlangeLockTM kit

FRONTATTCAP326162

Front attachment cap kit Boom arch hose FlangeLockTM kit

BOOMARCHCAP3262

Boom arch hose cap kit

EX3600, EX5600, EX8000 BOOMARCHFLGLCK3262

TM

Front attachment Number of parts FlangeLockTM kit

Weight (kg) EX3600, EX5600, EX8000

14 x 3262U - black FlangeLock 4 x 3261U - black & silver FlangeLockTM

8.9

16 x 2062U - red FlangeLockTM Front attachment cap kit

6.7 EX3600, EX5600, EX8000

14 x 3262 - cap 4 x 3261 - cap

9.5

Boom arch hose 16 x 2062 - cap FlangeLockTM kit

4.5 EX3600, EX5600, EX8000

16 x 2462U - purple FlangeLockTM 7.7 Boom arch hose cap kit EX3600, EX5600, EX8000 16 x 2462 - cap

20 x 3262U - black FlangeLockTM

9.9

20 x 3262 - cap

11.3

Stop the Mess

TM

maintenance of hydraulic systems getting the most out of your Hitachi Mining Excavator. While TM are 4 x 3261U - black & silver FlangeLock maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system TM 14 x 3262 - cap EX5600,ofEX8000 9.5 toEX3600, high levels contamination rapidly decreasing component longevity.

The importance of contamination control is sometimes 4 x 3261 - cap overlooked when performing maintenance due to incorrect practices being used.

8.9to vital

FlangeLock

Stops Leaking Hydraulic Lines.

THE ULTIMATE • No Tools Required CONTAMINATION The FlangeLock tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection.

• No Expensive CONTROL Easy on, easy off, they offer aTOOL leak-proof solution to hydraulic systems and environmental cleanliness.

FlangeLock tools and caps Hardware Needed EX3600, EX5600, EX8000

20 x 3262U - black FlangeLockTM

9.9

20 x 3262 - cap

11.3

THE FLANGELOCK™ TOOL AND CIRCUIT BLANKING CAPS ™

EX3600, EX5600, EX8000

™

™

NTAMINATION CONTROL

stop the mess. utine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While MAKING EASY system ntenance plays the largest role in the prevention ofHITACHI unnecessary machineCONTAMINATION downtime, it can also CONTROL expose the hydraulic ™ high levels of contamination rapidly decreasing component longevity.

The importance of contamination control is sometimes Hitachi have packaged FlangeLock tool and caps specifically for Hitachi mining excavators. The Hitachi customised rlooked when performing maintenance due to incorrect practices being used. which component routine maintenance is being performed on, you will always have the exact kits make sure no matter

• No more Rags stuffed into hoses • No more messy Plastic Caps number of FlangeLocks * and caps to help reduce contamination.

E FLANGELOCK TOOL AND CIRCUIT BLANKING CAPS *Note: FlangeLocks are not to be used under pressure • The Ultimate Contamination Control Tool • One hand Installation TACHI MAKING CONTAMINATION CONTROL EASY achi have packaged FlangeLock tool and caps specifically for Hitachi mining excavators. The Hitachi customised • Eliminate Hydraulic Oil Spills & Clean up s make sure no matter which component routine maintenance is being performed on, you will always have the exact mber of FlangeLocks * and caps to help reduce contamination.

• Quick Installation & Ease of Usage ote: FlangeLocks are not to be used under pressure • Industry Acclaimed Call you local Hitachi Muswellbrook representative • Safe fororPersonnel & Environment the branch on 02 6541 6300 for more information.

• 50% Reduction of Labor Costs • 100% Made in USA ™

™

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

™

™

™

Call you local Hitachi Muswellbrook representative or the branch on 02 6541 6300 for more information.

FlangeLock 203.861.9400 • sales@flangelock.com www.flangelock.com

Genuine Metaris Product Catalog In our Metaris Product Catalog you can get an overview of the product lines we carry as New Aftermarket Genuine Metaris, a glimpse of their specs, and also what units/manufacturers they replace or interchange with. It includes Pumps, Motors, PTOs and Telescopic Cylinders. View or download it by visiting our website at www.hydraulex.com.

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

28

MARCH 2022

FluiDyne Fluid Power A4V Piston Pumps

6.4

CONTAMINATION CONTROL 14 x 3262U - black FlangeLock EX3600,and EX5600, EX8000 Routine scheduled

Data Panel Corporation 952-941-3511 www.datapanel.com

Weight (kg)

Swing hose FlangeLockTM kit

TRAVELFLGLCK2462

BOOMARCHFLGLCK3262

Number of parts

SWINGCAP2062 TM

HITACHI FLANGELOCK AND CAP KITS AVAILABLE SWINGFLGLCK2062

Applicable machines

FluiDyne Fluid Power stocks A4V series piston pumps. They carry a complete line of A4V piston pumps that are available in displacement of: 40, 71, 125, 180, 250. Controls include: DR, DRG, FR, FRG, DFR, and LR2. They are available in SAE, thru drive or metric.

The versatile A4V units carry the industry leading 18 month warranty.

Units are fully tested, documented and guaranteed to perform 100% to the original manufacturer’s specification.

FluiDyne Fluid Power 586.296.7200 sales@fluidynefp.com www.fluidynefp.com

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

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

La-Man Corporation 800.348.2463 www.laman.com

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

SPECIAL AD SECTION

Hydraulic Flanges and Components New 120 page catalog includes popular styles of MAIN Manufacturing’s extensive offering of carbon and stainless Hydraulic Flanges and Components – ready for immediate shipment. Metric ordering information, weld specs, and dimensional information included. The “Quick Reference Guide” helps specify less popular items often stocked or quickly manufactured (generally 3-4 days) at our US plant.

MAIN Manufacturing Products, Inc. Grand Blanc, MI 800.521.7918; FAX: 810.953.1385 E-mail: info@mainmfg.com www.mainmfg.com/fpj

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Hydraulic Live Swivels Catalog Inline and 90° hydraulic live swivels.

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

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

MARCH 2022

29

WHERE ARE YOUR FILTERS? If you bought from OFCO, you’d be using them now.

Strainers • Filters • Breathers • Diffusers Stock and Custom Filtration Solutions Ohio Fabricators Company designs and manufactures your hydraulic solutions right here in our Central Ohio factory.

Our quick-ship program for standard products means you receive your shipment within days, not months. Even customfiltration solutions get our unparalleled delivery times.

Proudly Made in the USA • ISO 9001:2015 Compliant

Call or email our sales team today to check our stock and discuss your specifications.

OFCO-FPJ-012022.indd 1

12/13/21 12:19 PM

HYDRAULIC NOISE, SHOCK AND VIBRATION SUPPRESSOR

QUALITY NACOL ACCUMULATORS • Forged shells, no welds • Long lasting, No Seam, Pleated Bladders • We stock 1/5 pint to 15 gallons in Chicago • Sizes available to 40 gallons

Booth # 2376

Wilkes & McLean, LTD.

30

MARCH 2022

Booth # 350

877­534­6445 www.wilkesandmclean.com info@wilkesandmclean.com

info@ohfab.com • 888.354.0291 www.ohfab.com

New!

FLAT FACE DESIGN “TVF” SERIES QUICK DISCONNECT • • • • •

Up to 6,000 PSI Operating Pressure—Coupled or Uncoupled Full 4:1 Safety Factor Superior Flow Characteristics—Minimal Pressure Drop RoHS Compliant Plating Multiple Port Options—Female NPTF, Female SAE O-Ring, Female BSPP, Code 61 & 62 Flange Port/Head P.O. Box 6479, Fort Worth, TX 76115 V. 817/923-1965 www.hydraulicsinc.com

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

CL ASSIFIEDS

10 & 15 mm Electronic Valves Compact, quick, powerful!

Technical Support

HIGH FLOW PROPORTIONAL FLOW CONTROL • 16MM to 50mm • Standard ISO 7368 and DIN 24342 cavity • High performance 5,000 psi • On board amplifier • 0-10 volt command

almomanifold.com

Large Inventory Standard, High Flow, Latching & ISO Series

877-245-6247 HYDRAULIC FLANGES and COMPONENTS THE “SPECIAL” YOU WANT IS PROBABLY ON OUR SHELVES MAIN Mfg. Products, Inc.

Phone: 989.984.0800 Toll Free: 1.877.ALMO. NOW Fax: 989.984.0830

WANTED SURPLUS

Pumps · Motors · Valves · Servo/Proportional

Email, call or fax with a list of your Surplus.

We’ll provide you with a price offer!

1-800-422-4279 | 586-949-4240 Fax: 586-949-5302 | surplus@hydraulex.com

800.521.7918 fax 810.953.1385 www.MAINMFG.com/fpj

IN STOCK FROM 25MM TO 80MM MANY COVERS IN STOCK • Pressure, Flow, Directional • Large Flow 90° Valves

almomanifold.com

• Single DIN blocks • Active Valves • Monitored Poppets

Phone: 989.984.0800 Toll Free: 1.877.ALMO. NOW Fax: 989.984.0830

The correct answers to Test Your Skills on page 23 are 1-c and 2-a.

ADVERTISER INDEX Company............................................................................... Page..........................................................Phone................................................................. Web Adaconn + Inserta .................................................................................27............................ 215-643-1900, 215-643-0192................ www.adaconn.com, www.inserta.com Almo Manifold & Tool Co......................................................................31................. 1-989-984-0800, 1-800-ALMO-NOW.................................................. almomanifold.com CFC-Solar................................................................................................23.......................................................513-874-3225.................. www.CFCINDUSTRIALTRAINING.com Clippard.......................................................................................20, 24, 31.......................................................877-245-6247...................................................www.clippard.com Data Panel Corp...............................................................................11, 28................................................... 1-952-941-3511................................................www.datapanel.com EUFMC....................................................................................................29.......................................................757-220-1795....................................................www.EUFMC.com Flange Lock......................................................................................25, 28.......................................................203-861-9400...............................................www.flangelock.com Fluidyne Fluid Power..................................................Back Cover, 28, 31................................................... 1-586-296-7200.............................................. www.FluidyneFP.com Hunger Hydraulics.................................................................................20................................................... 1-800-248-9232............................................hunger-hydraulics.com Hydraulex................................................................................3, 25, 28, 31................................................... 1-800-422-4279................................................ www.hydraulex.com Hydraulics, Inc..................................................................................24, 30.......................................................817-923-1965.......................................... www.hydraulicsinc.com La-Man Corp.....................................................................................15, 28.......................................................800-348-2463 ..................................................... www.laman.com Lubriplate.....................................................................Inside Front Cover................................................... 1-800-733-4755.................................................www.lubriplate.com Main Manufacturing Products Inc...........................................21, 29, 31................................................... 1-800-521-7918........................................... www.mainmfg.com/fpj MOCAP INC............................................................................................24................................................... 1-800-633-6775....................................................www.MOCAP.com Ohio Fabricators Company (OFCO).....................................................30.......................................................888-354-0291.......................................................www.ohfab.com Stiebel Drive Technology.......................................................................21.......................................................864-286-7152........................ www.StiebelDriveTechnology.com Super Swivels.........................................................................................29................................................... 1-763-784-5531.......................................... www.superswivels.com Wilkes & Mclean...............................................................................24, 30.......................................................877-534-6445...................................www.wilkesandmclean.com Yates Cylinders, Inc............................................................................1, 25 ................................................. 1-586-778-7680.................................................. www.yatesind.com

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

MARCH 2022

31

SUBSCRIBE BY MAIL FILL OUT THIS CARD COMPLETELY, DETACH, AND MAIL OR FAX IT TO START YOUR SUBSCRIPTION MAIL TO: PO BOX 2548 • ORLANDO, FL 32802-9830 • FAX: 1-866-207-1450 YOU CAN ALSO SUBSCRIBE ONLINE AT WWW.FLUIDPOWERJOURNAL.COM. 01  YES! Please start/continue my complimentary subscription to the Fluid Power Journal Signature (required)

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Please Type or Print Clearly: First Name

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 Check here if you would like to keep your name, address, phone and fax numbers confidential, and not released to third parties The address above is my:  Home Address  Business Address Which edition would you like to receive?  Print  Digital  Both (View a sample of our PAPERLESS digital edition at www.fluidpowerjournal.com) 1. Do you specify, select or influence the purchase of components & systems, on new or existing machinery?

If yes, which technologies? (check all that apply) 05  Hydraulic 06  Pneumatic 07  Vacuum 08  Electronic Controls

03  Yes

04  No.

09  None of These

2. What is your primary job title? (check only one) 10  Administration: Chairman, President, V.P., Secretary, Treasury, General Manager, Owner, Business Manager, Director, etc.

11  Plant Operations: VP of Manufacturing/ Operation/ Production, Plant Management/ Director/ Manager/ Supervisor/ Superintendent/ Foreman/ Safety Director, etc.

12  Engineering: V.P. Eng., Eng., Design Eng., Director of Eng., Staff Specialist, Chief Eng., Senior Eng., Maintenance/Production Eng., etc.

13  Technical: Chief Tech., Fluid Power Tech., etc.

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15  Purchasing: VP/Director of Purch., Procurement Manager, Buyer, Purch., etc.

16  Other: (please specify)_________________________________________________________________________________________________ 3. Number of employees at this location?

A  1-19 B  20-49 C  50-99

D  100-249

E  250-499

F  500-999

4. What is the primary business activity at this location?

In the Fluid Power Industry, Outside the Fluid Power Industry 56  Manufacturer 57  Distributor 58  Education 59  Original Equipment Manufacturer (OEM) 61  Other: (please specify)__________________________________________ 5. Which of the following best describes your market focus?

A  Aerospace A  Marine & Offshore Equipment B  Agricultural Machinery B  Material Handling Equipment C  Automotive C  Mining Machinery D  Civil Engineering D  Packaging Machinery E  Cranes E  Plastic Machinery F  Drills & Drilling Equip.

F  Presses & Foundry G  Flame Cutting/Welding Equip. G  Railroad Machinery H  Food Machinery H  Road Construct/Maint. Equip.

I  Forestry I  Simulators & Test Equipment J  Furnaces J  Snow Vehicles, Ski Lifts K  Gas & Oilfield Machinery K  Steel Plants & Rolling Mills L  Heavy Construction & Equip.

L  Truck & Bus Industry M  Military Vehicles M  Textile Machinery N  Construction & Utility Equip.

N  Woodworking Machines O  Machine Tools O  Other (specify)_____________ P  Government Related P  Fluid Power Industry

G  1000+

60  End User of Fluid Power Products

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