Web Marketplace
Position Sensor Technology
Salary Survey
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Spin Old New
on an
Idea p.36
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p.
Motion Control
Technology Advances Aid Precision
Automotive
Manufacturing
Innovative Designs & Publishing
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May/June 2013
the lts
u s e R
p.
Vacuum
&
Hose
Fittings
3245 Freemansburg Avenue , Palmer , PA 18045-7118
Establishing a
Fluid Power
Program at
Alfred State
College
Nonprofit Organization US Postage Paid Bolingbrook, IL Permit #323
SMARTER MOTION CONTROL
brawny &
brainy.
Tough hydraulics with easy-to-use motion control solutions. Whether its re-positioning a large solar panel to soak up more sun, manipulating individual motion-simulator theater seats or any application in between, Continental Hydraulics Valves and Motion Control Solutions simplify machine logic for smarter, more accurate motion control with an intuitive, easy-to-use interface. Our unique solutions are fit-for-purpose, allowing you to dictate valve position, force and flow with exacting precision from a distance. Continental Hydraulics solutions deliver toughness controlled by intelligence: •
Proportional Control Valves – smooth, precise load control with a rugged durability that’s unparalleled.
•
Motion Control Solutions – faster, more accurate, user-adjusted variables all controlled from your Microsoft Windows® laptop.
For stronger, smarter solutions that meet your needs, make the move to Continental Hydraulics.
PUMPS
VALVES
POWER UNITS
952. 895. 6400 | www.continentalhydraulics.com Circle 389
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Fluid Power Journal
m ay/june | Volume 20 | Issue 5
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16
Vacuum Hose and Fittings
Establishing a Fluid Power Program at Alfred State College
Learn about hose and fitting types, selection, common mistakes, and a great tip for finding suppliers online.
A case study of IFPS Certification in Post-Secondary Education
36
A new spin on an old idea Is there a compromise between the traditional, rectangular reservoir and the tiny mobile reservoir that may better address the needs of both industrial and mobile equipment?
44
in This
Issue
24
Position Sensor Technology Comparison for Hydraulic cylinder feedback
40
Results
2013 Salary Survey
Departments
Motion Control Technology Advances Aid Precision Automotive Manufacturing
04 Notable Words 10 Product Spotlight 18 Calendar of Events 20 Professional Development 22 People In The News 26 Web Marketplace 29 Product Review
30 IFPS News 35 FPEF News 38 IFPS Certification Spotlight
39 NFPA News 43 Economic Report 46 Classifieds
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. Fluid Power Journal is the official publication of the International Fluid Power Society
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Get Social with Us!
SUPERIOR ENGINEERING OUTSTANDING PERFORMANCE
Go to work with Muncie Power’s premium performance
Extended stage overlap establishes a strong and stable
Telescopic Hoist Cylinder. With precision engineering and
extension that minimizes bending, while reducing hydraulic fluid
specialized machining in each stage of the cylinder, Muncie’s
usage.
cylinders exceed our competitor's in strength, performance and
These and many more exclusive features by Muncie Power,
durability throughout the life of the system.
provide a superior product for your fluid power applications.
Formed from a solid piece of steel, each stage of the cylinder
For more information about Muncie’s Cylinders, go to
is machined, then polished to exacting standards to ensure
www.munciepower.com/cylinders.
maximum seal performance and reliability.
© 2013 Muncie Power Products, Inc.
Member of Interpump Group
www.munciepower.com Circle 358
Notable Words 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: AskUs@ifps.org www.FluidPowerJournal.com
By Kristine Coblitz, Fluid Power Journal Editor
Fluid Power Journal—Your
New and Improved
L
Online Resource
et’s face it. We all wish we had more hours in the day to accomplish everything on our ever-expanding “to-do” lists. Keeping up with the increasing demands of doing our jobs effectively and keeping our businesses competitive requires a great deal of our attention. Going online to find information shouldn’t be painful or time consuming. We at Fluid Power Journal respect your time and your desire for relevant, easy-to-find articles, event and training schedules, and news announcements. As a result, we are pleased to announce the launch of our new website with better navigation and a fresh look. Features of our updated website now include the following: • The new site template has a better design for easy navigating and reading of content. It's organized with versatile columns and attractive slideshows. Articles are organized by categories complete with breadcrumbs for a more blog-like, userfriendly environment. (Stay tuned for article archive search capability.) • For the first time ever, our website has a search function that allows you to search through our web posts and read related content. • Also very new to the website is the ability for user comments on posted articles. • Find an article you like? You can now share articles of the Journal on Twitter and Linkedin with the click of a button. • There's a Twitter widget so you can keep updated with our tweets. • Signing up for the Journal's e-newsletter has never been easier with the form right on the sidebar of every page. • There's a calendar of our posts so you know when we have updates. • You’ll also notice a lot more of our magazine content on the web than before. For example, we now post Air Teasers, Economic Reports, Notable Words, Safety Focus, …etc. • Our contact page is completely redesigned so you now can send us messages straight from our website.
Fluid Power Journal is committed to being your comprehensive online resource for what’s current in the fluid power industry. We invite you to visit www.fluidpowerjournal.com, take a look around, and explore what we have to offer. Let us know what you think.
Associate Publisher: Marc Mitchell Editor: Kristine Coblitz Technical Editor: Dan Helgerson, CFPS, CFPAI/AJPP, CFPJPP, CFPMT, CFPC&C Account Executive: Bob McKinney Art Director: Quynh Vo VP Operations: Lisa Prass Accounting: Donna Bachman, Debbie Clune Publishing Assistant: Sharron Sandmaier Operations Assistant: Tammy DeLong Circulation Manager: Andrea Karges International Fluid Power Society 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 | Fax: 856-424-9248 Email: AskUs@ifps.org www.ifps.org 2013 Board of Directors President & Chairperson Mark Perry, CFPHS - Fitzsimmons Hydraulics Immediate Past President Patrick J. Maluso, CFPAI/AJPP, CFPS, CFPMHM Western Hydrostatics, Inc. First Vice President Tom Blansett, CFPAI, CFPS, CFPIHT, CFPCC - Eaton Corporation Vice President Education Marti Wendel, CFPE, CFPS - Sprague Products Treasurer Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPMT, CFPSD Cascade Steel Rolling Mills, Inc. Vice President Membership & Chapter Support Richard Bullers, CFPPS - SMC Corporation of America Vice President Certification Rance Herren, CFPECS, CFPSD, CFPMT - National Oilwell Varco Vice President Marketing & Public Relations Justin Sergeant, CFPS, CFPMHM - Western Integrated Technologies Vice President Educational Foundation Jimmy Simpson, CFPAI/AJPP, CFPS, CFPMM Nusim Associates Fluid Power Consultant Directors-at-Large Mike Anderson, CFPS - Motion Industries, Inc. Bill Jordan, CFPAI/AJPP, CFPMHM, CFPMHT - Altec Industries Jose Garcia, CFPHS - Purdue University Jim Lane, CFPAI, CFPS - Motion Industries, Inc. Alan Niesen, CFPS, CFPIHM, CFPMHM - HFI Fluid Power Products D. Dean Houdeshell, PE, CFPAI/AJPP, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM - Sauer Danfoss Kenneth Dulinski, CFPAI, CFPECS, CFPHS, CFPMIH, CFPMMH Eaton Corporation Timothy White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM - The Boeing Company Jeff Kenney, CFPIHM, CFPMHM, CFPMHT - Coastal Hydraulics Scott Gower, CFPS - Gulf Controls Company, LLC Honorary Directors Robert Firth Raymond Hanley, CFPE/AI-Emeritus John Groot, CFPPS Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM IFPS Staff Executive Director: Donna Pollander, ACA Certification Manager: Sue Tesauro Communications Manager: Adele Kayser Membership Coordinator: Sue Dyson Certification Coordinator: Connie Graham Administrative Assistant: Beth Borodziuk Bookkeeper: Diane McMahon Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published bi-monthly with four supplemental issues, including a Systems Integrator Directory, OffHighway 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
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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
www.fluidpowerjournal.com | www.ifps.com
safety of unsolicited art, photographs or manuscripts.
industry news
Parker Hannifin Now Offers Hydraulic Coolers for Mobile and Industrial Market ‰ Parker’s Global Accumulator Division is now the Accumulator and Cooler Division Americas (ACDA), a division of Parker Hannifin Corp. The new ACDA, a merger of the former Global Accumulator Division and Olaer USA, has strengthened its position in hydraulic accumulators and now offers heavy-duty hydraulic oil coolers for mobile and industrial applications. The division has three locations in the United States: Machesney Park, Ill.; Santa Fe Springs, Calif.; and Houston, Tex. www.parker.com/accumulator
Brennan Industries Expands Capabilities in Canada ‰ Brennan Industries, Inc., an international supplier of hydraulic fittings and adapters, expanded its capabilities in Canada by moving into a more efficient distribution facility located in Mississauga, Ontario. The new distribution center is located at 3397 American Drive. The company opened its Canadian distribution center in 2009 to provide customers in Canada with time and cost savings since shipments would no longer need time to clear customs or be subjected to customhouse brokerage fees. www.brennaninc.com
Winters Instruments Celebrates 60 Years of Business ‰ Winters Instruments, a Canadian-owned company, celebrates 60 years in the industry in 2013. The company has been manufacturing pressure and temperature instrumentation since its establishment in 1953, and within the past 60 years has expanded operations nationally and internationally. The company currently has sales and service facilities in Toronto, Calgary, Buffalo, Houston, Buenos Aires, and Shanghai. www.winters.com
PIRTEK Climbs in Franchise 500 Rankings ‰ PIRTEK USA, the business-to-business franchise opportunity, made a substantial climb in Entrepreneur’s Annual Franchise 500 rankings. After showing at #389 in 2011, the company has advanced a total of 129 spots in three years. The annual ranking evaluates a wide variety of franchising opportunities—automotive, food, healthcare, home improvement, education, recreation, retail, hospitality, maintenance, and more, using a mathematical formula that considers financial strength, stability, growth rate, and size of franchise system. www.pirtekusa.com
Flowserve Expands Pump-Testing Facility Capabilities ‰ Flowserve Corp. completed an upgrade of its open-loop test bench at its manufacturing facility in Coslada, Spain. Responding to the market trend for both larger cooling water pumps and increased testing capabilities, the test bench now accommodates flows up to 90,000 m3/h (400,000 gpm) for a total differential head (TDH) of 10.5 m (34.4 ft). The upgraded test loop now covers an area of 1,800 m2 (19,400 ft2) at a depth of 8.5 m (27 ft), fitted with anti-vortex devices to handle the increased flow characteristics. It can accommodate motors up to 5 MW (6,700 hp) with variable frequency drive from 20 to 66 Hz. The addition of a multi-size discharge manifold provides the flexibility to test pumps with discharge ports to 2,750 mm (108.3 in.). www.flowserve.com
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Vacuum Hose and Fittings
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By Daniel Pascoe, Vacuforce, Inc.
ost applications involving vacuum pick-and-place components utilize small-diameter hose and tubing— the same hose and tubing used on similar-sized pneumatic installations involving connection of valves and actuators, for example. The most common type of tubing used in both of these applications is polyurethane, which is more commonly referred to as simply “PU tubing.” Polyurethane tubing (Fig. 1) is suitable for small-diameter applications less than 5/16" (Ø8 mm) internal diameter (ID). Anything larger than this and there is a risk of tubing collapse. Don’t forget that most tubing is rated at an operating or burst pressure, not vacuum. Above 8 mm ID, different tubing should be used. A very popular type would be a wire-reinforced PVC hose (Fig. 2). This type of hose is rated up to 29.9"Hg with internal diameters of about 2"(50mm). That certainly covers most vacuum applications. If larger diameters are required to prevent vacuum loss over long distances or for very high flow applications, rigid pipe such as PVC, ABS, or steel would be required. The bend radius of wire-reinforced PVC is also very good, considering the diameter. For example, a 2" ID hose would have a bend radius of about 5" (125mm) as shown in Fig. 3. This might be difficult to “thread” through a robot arm, which is why in a lot of cases this vacuum hose that could be attached to a large end-of-arm
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vacuum tool would be attached to the outside of the robot arm. Not the prettiest, but effective. In fact, robotic integrators sometimes choose compressed air venturi systems over vacuum pumps for large vacuum tools purely because of this fact. It’s easier to thread compressed air PU tubing through a robot arm than to use a floormounted pump that delivers vacuum through a large-diameter hose. Of course if the tool is one of many that is attached and detached repeatedly via an automatic tool changer, then the integrator has little choice in the matter as there is no auto tool changer, such as the example shown in Fig. 4, that accommodates large-diameter vacuum hose. Not that I have seen, anyway. So there are a couple of basic choices for vacuum tubing or hose: PU and PVC reinforced with wire. I stress that wire-reinforced PVC is NOT the same as braided PVC hose, as shown in Fig. 5. This will collapse at virtually any vacuum level—a common initial mistake made in choosing larger-diameter vacuum hose. So that’s the tubing taken care of, but how do you connect this tubing to vacuum components such as cup fittings, valves, and so on? Of course nowadays the most popular fitting choice for PU tubing would be a push-to-connect (PTC) or push-in fitting (Fig. 6). Fig. 7 shows a vacuum venturi that also uses PTC technology. However, with PTC fittings, make sure they are suitable for vacuum use. The original designs of PTC fittings sealed better under pressure, which in a vacuum installation does not exist. The PTC fitting used
4 robot side
tool side
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should also be tested for leakage under side load. Good PTC fittings won’t present a problem but ensure that side load-sealing ability is present. The real world offers the real test, after all. The more traditional fittings, such as “rapid”type fittings originating from Europe and compression fittings, can be used (as shown in Fig. 8). However, these are very laborious in installation and although, if installed correctly, guarantee a leak-tight seal, the PTC fitting option is certainly faster and less costly. The compression fittings are very much a one-time installation. Once the ferrule is compressed around the OD (outside diameter) of the tubing, it’s permanent. If the fitting is used again, this part of the tubing, including the ferrule, should be discarded. For larger-diameter hose, the PVC-type described previously is not suitable for PTC fittings. Traditional fittings, such as the hose barb and “worm drive” clip, are the most common and certainly most readily available (as shown in Fig. 9). Of course, there are more fancy and elaborate fittings for larger hose, but as the hose is normally a permanent installation, the hose barb and clip are more than adequate. Tubing selection is normally determined by what is available onsite at the time of installation. The reason polyurethane tubing is the most popular is because this is normally used in the
corresponding pneumatic circuits. For larger hose, this is generally not in stock at the end user or machine builder. When selecting vacuum hose, do not search the Internet for simply “vacuum hose.” You will be digging through vacuum cleaner hose suppliers for hours. Try “reinforced vacuum hose” instead. That should bring up a good list of potential suppliers of the appropriate wire-reinforced PVC mentioned earlier.
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This article is intended as a general guide and as with any industrial application involving machinery choice, independent professional advice should be sought to ensure correct selection and installation.
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9 Daniel Pascoe is General Manager of Vacuforce Inc, a manufacturer and distributor of vacuum components and systems for industry in North America. Daniel can be reached via the Vacuforce website at www.vacuforce.com or directly at dpascoe@vacuforce.com. Find Vacuforce on Facebook and keep updated on Twitter.
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Spotlight
CLEAN, QUICK, DRY HOSE & TUBE CLEANING
Proportional & Servo Valves Fluid power software
ADACONN® PORT CONNECTORS The patented Adaconn® Port Connector provides a compact means to join two flanges or flange ports, when used with AdaflangeTM and AdaflangeportTM Socket Head Flange Adapters. Flange ports of the same or different sizes (or even different SAE codes) may be joined together. Prior to assembly the one piece 4-bolt flanges are kept as captive assemblies that are free to rotate 360 degrees about the longitudinal centerlines to facilitate proper alignment. Adaconn® Blue Bell, Pennsylvania • www. adaconn.com • 215.643.1900
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Ultra Clean Hose & Tube Cleaning Systems offer a fast, less invasive and more cost-effective way than traditional flushing methods to clean contaminated hose and tube assemblies. Strip away contamination in seconds. Clean oil will stay clean as it reaches those expensive components, preventing failure and system downtime. Visit www. ultracleantech.com to learn more and download our product literature, including our Product Manual, Clean Seal System, and Clean Seal Flange brochures. • ISO 18/16/13 • Four hand-held launchers 1/4” through 1-1/4”, 2”, 3-1/2”, 4-1/2” • Bench Mount Launcher for production environment • Projectile Verification System • Auto Loader for production environment • Clean Seal System for sealing end of hose and tube assemblies
Ultra Clean Technologies Corp. 1274 Highway 77 • Bridgeton, NJ 08302 Phone 800-791-0111 or 856-451-2176 Fax: 856-453-4975 • Email: Sales@ultracleantech.com www.ultracleantechnologies.com
Corrosion Resistant Window Sights
TORQTITE Adjustable Torque Wrenches
Stainless steel is resistant to corrosion, rust, and staining. It maintains its appearance over long periods and minimizes unwanted bonding between parts. Sight glasses enable viewing inside a reservoir, hydraulic line, or machine compartment. OilRite offers 303 stainless steel window sights with straight or NPT threads. Made in the USA. Oil-Rite Corporation (920) 682-6173 sales@oilrite.com www.oilrite.com
Flaretite’s new adjustable open-end torque wrenches allow all tube and hose ends to be precisely tightened to their correct torque requirements. These new wrenches can be used on all fittings requiring a torque specification. Developed to compliment Flaretite’s patented flared seals for 30, 37 and 45 degree flare fittings, these wrenches are used by quality conscious mechanics in all industries. Torque Wrench Benefits: • Five Sizes with ranges from 7 to 500 ft-lbs (10 - 700 Nm). • Fixed wrench ends with hex sizes (jaw opening) from 7/16” thru 3”. Box ends available as specials. • Ratchet end and adjustable ends also available. • Low profile, reversible, spanner design • Precision quality design with +/- 5% accuracy • Shipped with torque rating tables for all common fittings
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For more information contact: Flaretite, Inc. Fenton, MI, USA Tel: 810-750-4140 • www.flaretite.com
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Product Spotlight | Special Advertising Section
“AA” FLANGE, 1DG SERIES DOUBLE PUMPS “A” FLANGE, 2DG SERIES DOUBLE PUMPS “B” FLANGE 3DG SERIES DOUBLE PUMPS 2DG and 1DG double pumps available from Houston stock. 3DG series based on factory lead time. Honor Gear Pumps Corp. of Taiwan, with U.S. warehouse in Houston, is pleased to announce local availability of double pumps in “AA” flange and “A” flange. The “B” flange doubles are available subject to factory lead times. OEM inquiries through distribution are welcome. In addition to doubles, all single pumps are kept in stock in Houston, in the 4F17, “AA”, “A”, and “B” flange models. Aluminum body with cast iron flanges and rear covers are standard. Standard stock displacements in the 3GB series pump are 2.31, 2.68, 3.17, and 3.66 cu.in./rev. All other displacements are available subject to factory lead times. Honor Gear Pumps Corp. Proudly sold through distribution. Please call to be referred. Honor Pumps U.S.A. 1601 W. 25th St. • Houston, TX 77008 Toll free: 800-984-9727 • Local: 713-984-8144 Fax: 713-461-9631 • Email: service@honorpumps.com Web: www.honorpumps.com
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316 SS long HEX NIPPLES-any size, any length
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Take a look at our new, improved website - buyfittingsonline.com. We are responsive to your needs…from answering your specific technical questions… to quickly shipping the product! BFO for any and all projects original equipment manufacturing, maintenance, repair or replacement! Call 1-800-569-0810.
Stops Leaking Hydraulic LInes Save Time • Save Money • Save Labor • Save Oil • No tools required, one hand installation • No expensive hardware needed • No more rags stuffed into hoses • No more messy plastic caps • The ultimate contamination control tool • Eliminate hydraulic oil spills & clean up 399 • Quick installation & ease of usage • Safe for personnel & environment • Industry acclaimed • 100% Made in USA FlangeLock™ Contact Mike Pearl at 914.980.8890 or email: mike@flangelock.com • www.flangelock.com
Protect Yourself Against Corrosion… Stop rust on steel pipes, tubes, and fittings today with World Wide Metric’s PCS Tape. This type of maintenance free tape can be applied on new or corroded surfaces requiring minimal surface preparation. Our PCS Tape selection includes 4 different size options from 50mm - 200mm that repels against water, salt, alkalis, and acids in a multitude of applications.
H6 Heavy Duty Cylinder The Yates Industries H6 Heavy Duty Cylinder is rated for 3000 PSI and features 1½ to 20” bores standard, 22 different mounting options, is JIC-NFPA interchangeable, and can be customized with nearly limitless combinations of rod ends, cushions, couplers, seals, and ports – all backed by our legendary warranty and repair capabilities. Yates Industries 23050 Industrial Dr. E. • St. Clair Shores, MI 48080 586-778-7680 • www.yatesind.com
For more information contact World Wide Metric at 732-247-2300 or email us at sales@worldwidemetric.com.
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Product Spotlight | Special Advertising Section
PRESSSURE SWITCHES & TRANSDUCERS USA manufactured PRESSURE-VACUUM-DIFFERENTIALTEMPERATURE & LEVEL Switches for Mobile, Industrial, Mining, Forestry, and Agricultural markets • Set points from - 28 inches Hg to 6000 psi • Port sizes in NPT – BSP – SAE & Metric • Field adjustable level switches Excellent • Temperature from 68°F to 293°F Quality at • Electrical terminations of DIN – Excellent Prices Flying Lead – Spade – Integral Deutsch & others to IP 69 rating • Pressure and Temperature Transducers Contact us for a FREE sample www.pvs-sensors.com • sales@pvssensors.com
Adjustable Length Liquid Level Gages Liquid level gages allow viewing of tank contents. Oil-Rite’s proprietary design can accommodate difficult installations with up to 1/2” of variance in the distance between mounting holes. The adjustment is made by hand. No tools or disassembly required. Constructed with durable nylon. Made in the USA.
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CHECK VALVES 4-BOLT FLANGE TYPE
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Inserta® ICFT Check Valves provide an effective way to install a check valve or fixed orifice flow control valve in a piping system that uses SAE 4-Bolt flange ports. These are available in flange port sizes from 1/2“ to 3” in both SAE Code 61 and Code 62 patterns.
Oil-Rite Corporation (920) 682-6173 sales@oilrite.com www.oilrite.com
Inserta® Products Blue Bell, Pennsylvania www.inserta.com
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8901-D Series Control Grip
NEW! Piranhaflex™ Series PFAN388NC Non-Conductive 100R7 Hydraulic Hose Piranhaflex™ Series PFAN388NC is ideal for medium pressure hydraulic lines commonly used on vehicle mounted aerial devices such as Boom Trucks and Cherry Pickers. Hose is lightweight and flexible and complies with the ANSI 92.2 standard for Vehicle Mounted Aerial Devices. Product features less than 50 microamperes leakage when subjected to 75,000 volts/ft. for 5 minutes. Ideal hose for non-conductive medium pressure hydraulic hose applications.
Kuriyama of America, Inc. 360 E. State Parkway • Schaumburg, IL 60173 (847) 755-0360 • Fax: (847) 885-0996 sales@kuriyama.com
www.kuriyama.com
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Cyber-Tech, Inc introduces our new 8901D Series control grip. Made from Die cast aluminum, this control grip will withstand today’s industrial market needs. • Standard pushbutton configurations are: 0, 2, 4, or 6 • Standard rocker configurations are: single rocker, dual rockers, single rocker + 2 pushbuttons or dual rockers + 2 pushbuttons. • Proportional options available: pushbutton, triggers, rockers and thumb wheels. • Nine trigger solutions ranging from a Single Trigger to a deadman Lever. • Easily mounted to any joysticks. • Custom option available. Cyber-Tech, Inc. 1.800.621.8754 www.cyber-tech.net
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Product Spotlight | Special Advertising Section
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100% Guaranteed Reliable and Quality Service Global Servo Hydraulics has been specializing in the sales and service of all Servo and Proportional valves for over the past 20 years. We pride ourselves in offering 100% Guaranteed Reliable and Quality Service. We provide Competive Pricing, Free Evaluations, Free 24 Hr. Emergency Service, along with a 1 year, in service warranty.
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Global Servo Hydraulics, Inc. 800-673-4745 • www.Globalservo.com
The Yuken LSV(H)G Linear Servo Valve The Yuken LSV(H)G Linear Servo Valve is the fastest production servo valve on the market with high end response of 450 Hz (+/- 25% signal) up to 10 GPM, 100 Hz (+/-25% signal) up to 400 GPM, 75 Hz (+/-25% signal) up to 900 GPM. The valve is reliable with high contamination resistance, high vibration resistance and a low mechanical wear design. On board electronics are available, as well as separate from the valve. For more information on this and other solutions, contact the reliability experts at ALA Industries, Limited.
92154-8 Lodar Air Actuator Wireless System LodarUSA wireless remotes come with a five year pro-rated warranty, easy wiring, numerous legend possibilities, customizable options and industry proven design. The actuator series function hand lever applications by simply welding the wirelessly controlled actuator to the lever. Choose from two to 16 functions. OEM discounts and one-off prototypes are available. LodarUSA is made in the UK. For questions or to become a dealer contact Wade Pierce at 940-264-4903 or email him at wade@lodar.com.
Yuken – Master Distributor ALA Industries, Limited www.yuken-usa.com • Tel. (877) 419-8536
D03, D05, D07, D08, D10 VALVES & CIRCUIT STACK MODULARS Power Valve U.S.A. represents, as factory warehouse and sales office, a Taiwan manufacturer of D03, D05, D07, D08, and D10 valves, and modular circuit stack valves. With inventory in the Houston warehouse, all products are competitively priced, and machine tool quality. In fact the parent company, Tai Huei Oil Industry Co., Ltd. has been selling valves for over 25 years to the machine tool industry in Taiwan. All standard AC and DC voltages are available, and all standard spool configurations are in stock. Special spools are available. Pressures to 5000psi and flows from 16GPM (D03) to 211GPM (D10) are standard. With inventory on the shelf and very competitive pricing, we invite your inquiry. Power Valve U.S.A. Proudly sold through distribution. Please call to be referred. Contact the company at 1-888-862-1064 or e-mail to service@powervalveusa.com. View basic specifications at www.powervalveusa.com
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YOULI HYDRAULIC DIRECTIONAL CONTROL VALVES Direct Acting Electric Solenoids...now available: Youli directional control valves, rated to 4600psi, monoblock or sectional styles, are now available from stock in Houston, with electric direct acting solenoids on the MB-4 series, rated to 10GPM. Pneumatic operators are also available on all Youli valves, and also kept in stock. Youli quality is based on 25 years of industrial hydraulic valve manufacturing for the machine tool business in Taiwan. A quality product line with a major commitment to inventory in Houston, Texas, and offered at competitive prices, is growing our reputation. Youli Hydraulic Industrial Co., Ltd. Proudly sold through distribution. Please call to be referred. Contact the company at 1-888-330-8041 or email to service@youli-america.com View basic specifications at www.youli-america.com
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Product Spotlight | Special Advertising Section
NEW Reservoir breather – TBN 310 Zinga Industries, Inc. is pleased to announce a new reservoir breather. The TBN 310 has been engineered to be a strong competitor in the spin-on reservoir breather market.
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Features of the TBN 310: 410 • 10 micron cellulose element • 3/4” NPTF nylon mounting • 40 SCFM normal air flow capacity • Direct interchange for other manufacturer’s 310 models • Private labeling available • Easy installation • Competitively priced Zinga • Made in Industries, the USAInc. is pleased to
TBN 310
HyDraw CAD600 Released New: Interface to ERP data, Assign Pipe/Tube Properties, ISO Compliant Solenoid Information and Solenoid Actuation Chart, Auto Update Properties of Components in Drawing, Display Formatted Multi-Property Labels, Specify Port Operating Parameters and Display of Dual Port Names.
announce a new reservoir breather. The TBN 310 has been engineered to
Zinga be Industries, Inc. a strong competitor in the spin-on www.zinga.com reservoir breather market. Features of the TBN 310: • 10 micron cellulose element
Enhanced: Custom Parts List Template in Excel, External Ports with Through Bolt Holes and O-ring, Display Formats, Assign Properties to multiple components, Export to MDTools - Linked CAD data, and Submit designs to QuickManifolds.com.
• 3/4” NPTF nylon mounting • 40 SCFM normal air flow capacity • Direct interchange for other manufacturer’s 310 models • Private labeling available
Vest, inc. Visit www.VESTusa.com
• Easy installation • Competitively priced • Made in the USA
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Product Spotlight | Special Advertising Section
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IFPS Certification in Post-Secondary Education:
Case Study
Establishing a Fluid Power Program at Alfred State College By Matthew Lawrence, CFPHS, Associate Professor, Alfred State College
Alfred State College is a state university of New York College of Technology located in the southeast corner of the state. Instruction in the field of fluid power has always been part of the two-year and four-year Mechanical Engineering Technology (MET) programs, but in 2010, the MET department made fluid power an area of focus in the program with a dedicated course called Fluid Power Systems Design. The three-credit-hour course is offered in the final year of the four-year program and culminates in an opportunity for students to participate in an onsite offering of the Hydraulic Specialist certification exam offered by the International Fluid Power Society (IFPS). According to Ed Tezak, SUNY distinguished professor and department chair, “Preparing students to successfully obtain industry certification is a school-wide initiative in our technology programs, and adding this course and content to our curriculum has satisfied that goal, as well as given our graduates an opportunity to further distinguish themselves among engineering and engineering technology graduates in the job market.”
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Matthew Lawrence teaches the Fluid Power Systems Design course. For more information, visit www.alfredstate.edu.
For more information:
“There are many degrees in the marketplace, and Alfred State’s forte is creating programs that enable graduates to be well prepared and work ready,” said John Williams, dean of the School of Architecture, Management, and Engineering Technology. “The MET program is validating their students’ education through
In the first three semesters the course was offered, 50 students have taken the course and 45 have opted to sit for the Hydraulic Specialist exam. The results have been very positive, and there are many examples of how IFPS certification is making an early impact in the students’ careers. Chris Dalton, a Hydraulic Specialist and graduate of the MET program, is now a commissioning engineer for a Fortune 300 industrial supply company. “The fluid power class and having the IFPS certification have made a huge difference in my career. I was hired right out of school and now have the ability to approve oil and seal gas systems for our new turbine designs. When I first received the certification, I was unsure what it would do for me, but please tell the next class that it could come in VERY handy to them upon starting their careers. I have used knowledge from that class in Mexico, Germany, and France, as well as a few places in the U.S. Each job had many systems and components that were very similar to the ones that were worked on in lab.” Similarly, Mike Marsigliano noted the following after landing a job in the mining industry right after graduation: “The fluid power systems class and ability to get the certification while still in school solidified my position. They were looking for a hydraulics engineer with the certification as a plus.” The MET program at Alfred State is ABET accredited, and making curriculum changes to an accredited engineering technology program is not a simple process. Alfred State, however, had several factors working in its favor. According to Professor Lawrence, “We are fortunate to have a culture within our department that makes every attempt to align our program offerings—not only the accreditation content requirements of ABET, but also individual areas of expertise. Fluid power is a program outcome specifically identified for mechanical engineering technology by ABET, and I have professional experience in the fluid power industry. Adding this course to our four-year degree was a win-win scenario for the school, program, students, and potential employers.”
valuable industry certifications that set them apart and providing employers with capable and competent engineers. With a certification opportunity incorporated in the program, our tag line of ‘Hit the ground running’ has real meaning for our graduates.”
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calendar of events
June 3 Basic Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
3-5 3-day Level 1 PLC Fundamentals Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
3-7 Principles of Hydraulics Bethlehem, PA Bosch Rexroth Corp. Tel: 610-694-8407 www.boschrexroth-us. com
3-7 3-day or 5-day Level 1 Industrial Hydraulics – In-depth Fundamentals Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
3-14 Industrial Hydraulics Maumee, OH Eaton Corp. Tel: 800-413-8809 www.eaton.com
4 Vacuum Technology Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
4-6 Basic Hydraulic Hands-on Training Tulsa, OK Womack Machine Co. Tel: 800-569-9812 www.womackeducational.com
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7
17
21
26-28
18
Hydraulic Safety Seminar Tulsa, OK Womack Machine Co. Tel: 800-569-9812 www.womackeducational.com
Basic Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
1-day Intro to Mobile Electric with MultiMeters Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
Troubleshooting Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
10-12
3-day Hydraulic Fittings, Tube, Pipe, Hose, and Leak Prevention Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
2-day Hydrostatic Closed-Loop Systems Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
3-day AC and DC Electrical Fundamentals and Safety Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
10-14 Proportional Control Technology Ontario, Canada Bosch Rexroth Canada Tel: 905-735-0510 www.boschrexroth.ca
10-14 5-day Power Distribution Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
11-13 Hydraulic Specialist Certification Review Maumee, OH (Eaton Corp.) Contact IFPS: 800308-6005 www.ifps.org
11-14 Advanced Hydraulic Hands-on Training Tempe, AZ Womack Machine Co. Tel: 800-569-9812 www.womackeducational.com
13 “In the Line of Fire: Cause and Dangers of Fluid Injection Injuries” Webinar: 12:00 p.m. to 1:00 p.m. (eastern) Presented by Dan Helgerson, CFPAI, Cascade Steel Rolling Mills, Inc. Contact IFPS: 800308-6005 www.ifps.org
17-18
18 Electro-Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
18 1-day Lubrication Best Practices Workshop (Complimentary) Parkersburg, WV Des-Case Tel: 615-672-8800 www.descase.com
18-20 Basic Hydraulic Hands-on Training New Orleans, LA Womack Machine Co. Tel: 800-569-9812 www.womackeducational.com
18-20 3-day Electric Motor Drives Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
19-20 2-day Introduction to Pneumatics Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
20 Troubleshooting Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
www.fluidpowerjournal.com | www.ifps.com
24-25 2-day Introduction to Mobile Fluid Power Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
24-28
July 1-3
Principles of Hydraulics Ontario, Canada Bosch Rexroth Canada Tel: 905-735-0510 www.boschrexroth.ca
3-day Troubleshooting Using Industrial Hydraulic Schematics Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
24-28
8-12
3-day or 5-day Level 1 Pneumatics – In-depth Fundamentals Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
Circuit Design Maumee, OH Eaton Corp. Tel: 800-413-8809 www.eaton.com
25 1-day Lubrication Best Practices Workshop (Complimentary) Cincinnati, OH Des-Case Tel: 615-672-8800 www.descase.com
25-26 Connector and Conductor Review with Job Performance Test Maumee, OH (Eaton Corp.) Contact IFPS: 800308-6005 www.ifps.org
25-28 Advanced Hydraulic Hands-on Training Dallas Fort Worth, TX Womack Machine Co. Tel: 800-569-9812 www.womackeducational.com
15 Basic Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
15-19 Principles of Hydraulics Bethlehem, PA Bosch Rexroth Corp. Tel: 610-694-8407 www.boschrexroth-us. com
16 Electro-Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
16-18 Pump Controls Maumee, OH Eaton Corp. Tel: 800-413-8809 www.eaton.com
22-24 3-day Troubleshooting Mobile Equipment Using Hydraulic Schematics Cincinnati, OH CFC-Solar, Inc. Tel 513-874-3225 www.cfc-solar.com
29 Basic Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
29-Aug 2 Mobile Hydraulics Eden Prairie, MN Eaton Corp. Tel: 800-413-8809 www.eaton.com
29-Aug 2 Maintenance, Repair and Setup of Industrial Hydraulic Systems Bethlehem, PA Bosch Rexroth Corp. Tel: 610-694-8407 www.boschrexroth-us. com
30 Energy Saving for Pneumatics Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
31 Vacuum Technology Noblesville, IL SMC Corp. of America Tel: 800-762-7621 www.smcusa.com/ training
Offshore Technology Conference May 6-9, 2013, Reliant Center, Houston, TX Founded in 1969, the Offshore Technology Conference is the world’s foremost event for the development of offshore resources in the fields of drilling, exploration, production, and environmental protection. Each year, OTC attracts more than 80,000 attendees from 110+ countries and 2,500 exhibiting companies. OTC is sponsored by 13 industry organizations and societies, who work cooperatively to develop the technical program. OTC also has endorsing and supporting organizations.
guages being spoken, never-seen-before technologies, and C-suite speakers. 2013 Spotlight On New Technology Fifteen (15) technologies will receive the 2013 Spotlight on New Technology Award, which recognizes innovative new products that provide significant impact for offshore exploration and production. The awards will be presented at the conference.
Top Reasons to Attend OTC 2013 OTC provides access to leading-edge technical information, the industry’s largest equipment exhibition, and valuable new professional contacts. Here’s how: • Quality: The technical program is selected by knowledgeable and experienced professionals. • Value: Attendees can see groundbreaking innovations and meet leading providers of products and services in just four days. • Convenience: 174 nonstop flights, world-class venues and hotels, and nearby public transportation are available. • In the World’s Energy Capital: OTC can be combined with client meetings, business proposals, and company training. • Investing Back in the Industry: OTC’s sponsoring organizations use revenue to provide many other important programs for its members, such as training, and technical journals. • Always Something New: Attendees can encounter different lan-
The Spotlight on New Technology Awards, which are for OTC exhibitors, showcase the latest and most advanced hardware and software technologies that are leading the industry into the future. “Our Spotlight Award winners ask, ‘What if?’ and ‘Why not?’” said Spotlight Award Committee Chair Helge Hove Haldorsen. “It is thanks to them that offshore E&P will continue to play a key role in supplying the world with affordable energy in a sustainable manner.” Winning technologies were selected based on the following five criteria: • New: less than two years old • Innovative: original, groundbreaking, and capable of revolutionizing the offshore E&P industry • Proven: full-scale application or successful prototype testing • Broad Interest: broad appeal for the industry • Significant Impact: significant benefits beyond existing technologies To see a list of the winners, or to get more information about OTC 2013, visit www.otcnet.org
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professional development
Keys to Peer Leadership: An Unlikely Source By Kevin E. O’Connor, CSP
s a small business CEO observed a window washer at the Atlanta airport one day, she asked what she thought to be a straightforward question: “What’s the secret to window washing?” “No secret, ma’am,” the window cleaner said as he continued working. “I just focus on keeping on with my tools and my experience. I keep on going.” The master continued working with repeated, slick motions, his tool remaining fixed to the glass, and leaving not one smudge. Then, true to his word, he kept on going.
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When the CEO asked what was in the blue water, the cleaning professional smiled and said, “I can’t tell you that! If you knew that, you could do my job!” Then, before attacking another pane, he said, “It is very special, though.” When a professional window cleaner uses just the right combination of resources—minimal tools; years of experience; a flowing, non-stop motion; and a secret concoction of suds—his or her work is efficient, engaging, and looks natural—perhaps easy—to those who observe. Unlike the window washer, many team leaders don’t find their work to be efficient, easy, or to appear natural. These leaders often do not have degrees in leadership; they are promoted because they are very good at their jobs. Their former colleagues and friends now report to these “peer leaders.” There is a skill to leading your former peers without encountering resistance, resentment, and regret. When your toolbox contains a simple collection of thinking, communicating, and acting that is coherent, ordered, and intentional, your leadership appears as if it is natural. When you’re charged with leading a team of your peers or former peers, the right combination of resources makes all the difference. The following techniques should be at the core of every peer leader’s toolbox.
1
Minimal tools keep you focused.
The most effective leader uses only one tool: his or her personality. One great peer leader uses his thirst for understanding and information. When a member of his team enters his office, he asks that person to be the teacher while he plays the role of student. “Any questions I ask are merely a student asking,” he explains. “Then, I never use the words ‘I’ or ‘you’…I only use the words ‘we’ and ‘us.’ I want them walking out of my office feeling better than when they walked in.” By using the mindset of education, the pressure is removed from his “teacher” so that no question is off limits. This philosophy sets the tone for education and teamwork. If, instead, he were to use his intellectual curiosity to demonstrate that only he knew the correct answer, he could face resentment. The best peer leaders learn to harness their personality to inspire trust and teamwork.
2
Experience gives you credibility.
Just as window washers have well-exercised wrists, your team wants to see that you still need and relate to them. While your team is working to create the next product, researching relevant case law, or driving across town at a moment’s notice to meet with a customer, they want to know that you’re there with them. Sometimes that means that they want your hands working alongside theirs, and sometimes it just means that they want to know that you understand their daily routines, frustrations, and joys. Regardless of which approach your team members prefer, they want you to guide them in the next, and right, direction.
Your team will remember that you were there with them when you encourage. Today’s culture makes it easy for bosses to find faults, but you will have much greater influence when you frequently ask this question of your team members: “You know what I liked about what you did (or said)?” Be relentless as you look to find the ways that their input, skills, and contributions have benefited the entire team. This is always of interest to the receiver; no one has ever responded, “No, I don’t want to know what you liked!”
3
A flowing, non-stop motion is very intentional.
There are few things more beautiful than a leader who knows how and when to listen and where and when to speak; the times to agree and those to dissent; when to stay with the group and those other times when to go out on a limb. Just as the window washer intentionally follows a specific pattern, the successful leader never allows these moments to be chance events. Instead, they are always intentional. While employees sometimes want to be inquisitive, your peers want to be connected with you. With intimacy comes great trust and loyalty. A consistent engagement with your team on a personal level (within the business environment) turns your role from that of a boss to one of a fearless leader, mentor, and teacher. This intimacy comes when you go beyond their favorite sports team to learn about their childhood passions, when you understand their family’s immigration experience deeply affected their outlook on international business, and that their self-directed nature comes from their Eagle Scout training. To the inexperienced leader, these characteristics are mere factoids. The best peer leaders know that an understanding of these experiences and traits lead to unbreakable loyalty, an impassioned work ethic and—most importantly to the company’s owners—higher profits.
4
Ask your team members what they believe to be your “secret sauce,” and be ready to listen without judging their responses. You may find that your team wants you to talk more at meetings, even though you might think you talk too much. Your team may want you to consult them but ultimately make a firm decision, while you may lead by consensus for you fear making decisions alone. When your team tells you what they want, find a way to do what they have asked!
Your secret formula keeps you ever useful.
Famous chefs sometimes share their secret recipes, for they know what many of us have learned after carefully following the same recipe three times: there are just some techniques that can’t be explained with words. Food rarely tastes the same way twice and rarely as good as it does in your favorite restaurant! The window washer humorously refused to share the ingredients in his bucket for fear of being replaced. The best peer leaders are afraid that their talents and “secret concoction” may go unused, so they focus on how their team is furthering the company’s mission. When leading a group of your peers, you must have a firm hold on the secret formula that lies within you.
About the Author Kevin E. O’Connor, CSP, is a facilitator, medical educator, and author. His latest book is Fearless Facilitation. For more information, please visit www.kevinoc.com.
Dolly Parton said, “Figure out who you are and then do it on purpose.” All of what you do as a leader must be naturally intentional, obviously purposeful, yet elegantly skillful.
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people in the news
William A. Clippard Clippard Instrument Laboratory ‰ William A. Clippard (Bill Jr.) has been promoted to vice president of operations. He joined the company in 1992, serving as apprentice in various production departments and later as a buyer in the purchasing department. He worked as purchasing manager and also general manager of the Fairfield plant. In addition to establishing purchasing procedures, Mr. Clippard has been instrumental in establishing many international supply channels.
Robert S. Clippard Clippard Instrument Laboratory ‰ Robert S. Clippard joined the company in 1998, working in the IT department. He developed the company’s new website, e-commerce business, and the Value Added department. He has also held positions as regional sales manager and international sales manager. In his new role, Mr. Clippard will continue to be involved in numerous aspects of the company, from application engineering to value-added assemblies and distributor sales.
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Jennifer Clippard-Caunin Clippard Instrument Laboratory ‰ Jennifer Clippard-Caunin joined the company in 1998, working in the personnel department. In 2004 she was promoted to human resources manager where she has been instrumental in establishing many new company policies in recruiting, preventive health care, education, vision program, and health insurance resulting in cost reductions while increasing the number and value of the benefit program. She also serves as corporate secretary.
Noel Laukaitis Jr. Lehigh Fluid Power, Inc. ‰ Noel Laukaitis Jr. has been promoted to vice president and appointed to the company’s board of directors. Mr. Laukaitis joined the company in 2002 as senior product engineer and was promoted to engineering manager in 2006. He has been responsible for product designs and continued innovation in the areas of water hydraulics, spring cylinders, locking cylinders for the valve industry, and specialized large bore cylinder design.
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Jim Jung Trico Corp. ‰ Jim Jung has been promoted to vice president with a focus on strategic planning. He will work on company affairs and explore the opportunity for expansion in new markets, as well as executing the initiatives outlined in the corporate strategic plan. Mr. Jung most recently worked as director of operations.
Jeanne Capachin Graber Associates ‰ Jeanne Capachin has joined the company as senior consultant. She is responsible for expanding the suite of services the company now offers to its domestic and international clients. For the last 13 years, she has been an industry analyst in the banking and technology sectors. In more than 25 years of banking, she held positions in product management, operations management, and systems development and integration.
Eric Cline Hydrotex® ‰ Dr. Eric Cline has been named director of research and development. He most recently held the position of CEO and chief scientist at ZT Solar, a DFW-based startup developing antireflective coatings for solar cell and optical applications with support from the National Science Foundation and Air Force. His previous experience also includes various positions at Merck and Southwest Research Institute.
John Alecu Hydrotex® ‰ Dr. John Alecu has been named research and development manager. He has spent the past three years at University of Minnesota and Massachusetts Institute of Technology as a postdoctoral research fellow, performing research in the areas of experimental and theoretical combustion chemistry. Dr. Alecu’s expertise includes kinetics, thermodynamics, quantum mechanics, combustion chemistry, atmospheric chemistry, physical-organic chemistry, computational chemistry, and free radical chemistry.
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Position
Sensor Technology Comparison
u a r yd H r
By Edward E. Herceg, Chief Technology Officer, Alliance Sensors Group (a div. of H.G. Schaevitz LLC)
Position feedback sensors for hydraulic or pneumatic cylinders have used one of three traditional technologies: magnetostrictive, variable resistance, and variable inductance sensors. While other sensor technologies have occasionally been used successfully in this application, the focus of this article is the comparison among these three most popularly used technologies. As the demand for increased control and functionality has increased over the years, sensor-instrumented cylinders are becoming more important in the heavy industry, subsea, and mobile equipment worlds. Ultimately, a user or systems integrator must determine the requirements of the application and which technology best satisfies it on a total installed cost versus performance basis. The strengths and weaknesses of magnetostrictive, variable resistance, and variable inductance sensors are discussed below, along with a chart for feature-by-feature comparisons. Technology Embedded Mount Port Mount Reliability Shock and Vibration Resistance Max Operating Temperature Contactless Requires Magnet Power Consumption Non-Linearity Repeatability Resolution Field Calibration Cost
fo
Initially, a point to be noted is that all of these common sensing technologies utilize a long probe that extends into a deep, small-diameter blind hole that has been gun-drilled into the internal end of the cylinder rod. Magnetostrictive technology has been the preferred technology for high-accuracy applications. The sensor, often called an “LDT” or “MLDT,” incorporates a stainless steel tubular probe and a short toroidal permanent magnet assembly around it that is installed in a counterbore in the piston. The most common package is designed to thread the sensors’ electronics housing into an o-ring port in the back of a cylinder, with the long slender probe inserted into the rod’s bore. It uses the “time of flight” principle to determine the magnet’s position with
Magnetostrictive Potentiometer * Yes Yes No Fair Poor Fair Good 75°C 85°C Yes No Yes No 100 mA 10 mA Max. 0.05% FS 0.10% FS 0.01% 0.10% 0.01% 0.10% No No $$$ $ * manufacturer dependent
Position Sensors Comparison Chart
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Inductive Yes Yes Excellent Excellent 125°C Yes No 35 mA 0.15% FS 0.05% 0.05% Yes $$
high accuracy and moderate response time. The magnet is used to reflect a torsional mechanical pulse, which is transmitted along a special wire inside of the probe called a “waveguide.” Typically, each of the magnetostrictive sensor manufacturers has its own style of magnet with unique mounting features like the number of holes, the hole pattern, etc. Magnetostrictive sensors can consume a fair amount of power and are not the most mechanically rugged sensors. They offer electrical performance over mechanical robustness because they are subject to shock and vibration issues. Yet, while there are some potential drawbacks mechanically, the magnetostrictive sensor’s package design is tailor-made for port-mounted, in-cylinder use. Variable resistance potentiometer-type sensors, commonly called “pots,” are selected in situations where purchase cost is a driver and high accuracy is not paramount. A resistance pot is usually embedded into the cylinder’s rear end plate, as opposed to the port mounting of magnetostrictive sensors. It uses an insulated round carrier, which is attached to the internal end of the gun-drilled cylinder rod and supports an electrically conductive wiper that contacts the surface of a partially conductive plastic probe. As the wiper moves along this plastic element, its resistance changes in a linear fashion, making it fairly easy to determine the carrier’s position and, thus, the rod’s position. Pots have been seen as a good position measurement solution for use in cylinders because of their ruggedness, favorable stroke-to-length ratio, and their large analog DC voltage output, which is a big percentage of the input voltage. The major drawback to resis-
tance pots is that they wear out, especially if the cylinder is actuated at a high frequency or even more importantly, dithered over a short range to improve a system’s dynamic characteristics. Since a resistance pot is embedded into the cylinder, replacement of a worn-out pot can be very time consuming and expensive, and could even result in the need for a completely new cylinder. Variable inductance position sensors have been used in the cylinder industry but have not had the widespread recognition of magnetostrictive sensors or resistance potentiometers. This non-contacting technology has many significant advantages over resistance potentiometers regarding product life and long-term reliability, and usually can compete favorably with the performance of magnetostrictive sensors in terms of linearity, resolution, and frequency response, but at a significantly lower cost. Equally important is the fact that variable inductance sensors can withstand much greater shocks and vibration, such as those commonly found in heavy industrial and mobile equipment applications. Linear variable inductance sensors cover the middle ground between the higher level of performance and external port-mounting flexibility associated with a magnetostrictive sensor and the ruggedness and price of an embedded resistance potentiometer. These sensors operate by measuring the resonant frequency of an oscillator circuit that uses an inductive probe whose inductance is varied by the position of the gundrilled rod over it. Typically offered in full-scale ranges of 4 inches (100 mm) to 36 inches (900 mm), both port-mounted and embedded packages are available, with connector and cable terminations that match those found on most catalog magnetostrictive sensors. These sensors offer either an analog DC voltage or current output, with an SSI digital output available for OEM applications. The variable inductance sensor presents a non-contacting solution that does not require a ring magnet. In fact, if a variable inductance sensor were installed to replace an existing magnetostrictive sensor, the magnet can be left in place in the cylinder rod end without interfering with the sensor’s basic operation. In the past few years, the requirements for instrumented cylinders for subsea applications have dramatically increased. Variable inductance sensors can be offered in a pressure-sealed version that allows a user to install the sensor/ cylinder in a subsea environment in depths of 10,000 feet (3,000 m) with 3,000 psig of internal hydraulic pressure. Remote field calibration is a standard feature offered on many variable inductance sensors. This feature permits a user to scale the output of the sensor while it is being installed on the cylinder. With a simple push of a button to set the zero and the full-scale output points, the sensor will give the desired full-scale output over its newly set range, so it is no longer necessary to scale the unit in an operating control system.
In another fluid power application, though not commonly used inside of hydraulic cylinders, LVDTs are often used in spool position feedback applications for two-stage hydraulic valves. A short-range variable inductance sensor with its simple inductive probe inserted into a hole in the end of the main spool is very often an easier installation than an LVDT that requires an isolation tube to seal off its core from the valve’s pilot pressure. Where there are still many fluid power applications where resistance potentiometers and
magnetostrictive sensors are a good solution, these applications tend to fall to either side of a bell curve. Recent electronic advancements and the flexibility of package designs make variable inductance sensors very cost effective for mainstream in-cylinder applications that tend to be near the peak of that bell curve.
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Web
www.ametek.com
www.continentalhydraulics.com
AMETEK, Inc.
Continental Hydraulics
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Marketplace
AMETEK, Inc. is a leading global manufacturer of electronic instruments and electromechanical devices with annual sales of $3.3 billion. AMETEK has nearly 14,000 colleagues at over 120 manufacturing locations around the world. Supporting those operations are more than 80 sales and service locations across the United States and in more than 30 other countries around the world. Special Ad Section
www.cyber-tech.net Cyber-Tech, Inc. Circle 416
AMETEK, Inc. 1100 Cassatt Road, P.O. Box 1764 Berwyn, PA 19312 USA Tel: 610-647-2121, Fax: 215-323-9337
Food processing tough. Smarter motion control. Quietly thrives in harsh environments. Continental Hydraulic’s long-lasting hydraulic pumps, valves, power units and motion control solutions maximize your uptime and lifetime value. With a commitment to personalized customer support and innovative engineering, Continental delivers what your market and applications demand. From brick and block and automotive to oil and gas, stay tough with Continental. Contact us for more information: 5505 West 123rd Street, Savage, Minnesota 55378 Phone:(952) 895-6400, Fax:(952) 895-6444
www.flinthydrostatics.com www.hydraulex.com
www.fluidynefp.com
Flint Hydrostatics – A Hydraulex Global Company
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FluiDyne Fluid Power
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Cyber-Tech, Inc. designs and manufactures custom industrial grade control handles, control pendants, mechanical and proportional joysticks with a consistent reputation for being rugged and reliable, while delivering a level of customer service that is superior in the industry. Visit our website and give us a call so we can assist you in your control needs. www.cyber-tech.net 1.800.621.8754
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Flint Hydrostatics, part of the Hydraulex Global family, provides Hydraulic Pumps, Motors, Valves, Servo/Proportional Valves, and Parts for a variety of industries including: Construction, Mining, Plastic Injection Molding, Steel Mills, Paper Mills, Energy, Marine, Dump, Refuse, Agriculture, Logging, Crane & Recycling. We also offer Repair and Return Services for most all major manufacturers, as well as, Service Exchange Units. Whatever your needs, Hydraulex Global is sure to be able to help. Visit our website for more information (www. flinthydrostatics.com), give us a call 1-800-422-4279, or email us at sales@ahx1.com.
At FluiDyne Fluid Power, our “People Make the Difference” is the driving force behind our fast growing business. Our wide line of remanufactured Vickers and Rexroth products allow our people to quote what you need at a price to save you money. Our new FluiDyne products include popular Vickers Vane, Veljan, Vickers Piston, Rexroth A10V, and Char-Lynn. Call or email us and see what our people can do for you. 586.296.7200 sales@fluidynefp.com www.fluidynefp.com
Web Marketplace
www.laman.com
www.mainmfg.com
www.munciepower.com
La-Man Corporation
Main Manufacturing Products
Muncie Power Products
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La-Man Corporation is a leading manufacturer of compressed air filtration products. With over 30 years of experience, we truly understand the importance of protecting valuable machinery, tools, and finished products from dirty, wet, contaminated air. La-Man’s line of products include the patented Extractor Dryer, .01 micron filter, as well as, LA-MAN-Air Breathing Systems™, SuperStar™ Membrane Dryers, and the Refrigerated Extractor/Dryer. La-Man Corporation PO BOX 328 Mazeppa, MN 55956 800-348-2463
MAIN’s website provides quick access to the most popular styles of HYDRAULIC FLANGES AND COMPONENTS. “About Us” gives background of this US manufacturer. “Create-A-Flange” offers more parts than the catalog — by picture. If it’s not here, or for questions, E-mails may be sent to get your answer quickly. MAIN Mfg. Products, Inc. 1-800-521-7918 E-mail: info@mainmfg.com
Muncie Power Products has once again extended their reach with their new single-acting telescopic cylinders. These uniquely designed cylinders provide performance and value through advanced machining and the use of proprietary seals to deliver extended life without need for adjustment. The cylinders have been engineered with machined hard stops to guarantee reliable stopping at the end of every stroke. The bore size of the final stage is larger but the average displacement of the stages has been reduced. This allows Muncie’s cylinders to require less oil than the competition and ultimately leads to faster cycle times with the ability to lift more using the same pressure. 800-367-7867
www.oilrite.com
www.peterpaul.com
www.rotorclip.com
Oil-Rite Corporation
Peter Paul
Rotor Clip Company, Inc.
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Corrosive resistant properties make stainless steel gages suitable to a variety of applications. OilRite offers 304 and 316 stainless steel liquid level gages in sizes from 3” to 60”. A red line on a white background enhances liquid level visibility. Available with adapters and thermometer. Made in the USA. Visit Oil-Rite’s online product catalog for detailed information at the item level.
We at Peter Paul put a heavy emphasis on the word quality. In describing our products, quality is the most important term. One of the results of being in a specialized business like ours, for over 60 years, is a thorough knowledge of all facets of manufacturing and development of superior valves and operators. Peter Paul has kept pace with every technical improvement that has been made available both in material and techniques. Accurate, high speed manufacturing, and top quality components are only part of the picture.
Rotor Clip manufactures a full line of inch, DIN, ANSI metric and JIS retaining rings to world standards, as well as a complete line of constant section rings, spiral retaining rings, wave springs & hose clamps. Installation tools also available. ISO/TS 16949 certified. Free samples & online quotations.
Oil-Rite Corporation PO Box 1207 • Manitowoc WI 54221-1207 Phone: (920) 682-6173 • Email: sales@oilrite.com www.oilrite.com
| Special Ad Section
Rotor Clip Company, Inc. 187 Davidson Avenue Somerset, NJ 08873 1.800.557.6867
Contact us: 480 John Downey Drive • PO Box 1180 New Britain CT 06050-1180 • 860-229-4884
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Web Marketplace
| Special Ad Section
www.santest.co.jp
www.yatesind.com
www.youngpowertech.com
Santest Co., LTD.
Yates Industries
Young Powertech, Inc.
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Yates Cylinders Offer: • H6 Series - Heavy Duty Hydraulic (3000 PSI) • H4 Series - Medium Hydraulic (up to 1500 PSI) • A4 Series - Heavy Duty Steel Air (250 PSI) • A2 Series - Aluminum Air (250 PSI) • Air/Oil Intensifiers • All Stainless Steel Cylinders • Air/Hydraulic Welded & Mill Type Cylinders • Special Cylinders per Customer Supplied Prints and Specifications
Young Powertech Inc, is a manufacturer and distributor of Hydraulic Motors, Electronic Radio Remote Controls, Hydraulic Gear Pumps and Gear Motors, Planetary Gear Reducers, Hydraulic Radial Piston Motors, Steering Control Units and Steering Valves, Steering Columns, Wheel and Track Drives as well as other Mechanical Components for mobile, marine, mining and industrial applications. Young Powertech Inc. was started by Exclusive North people with decades of experience American Partner of: in the field and are dedicated to bringing products and service to the customer at a higher level.
It Makes Technological Sense Santest develops and manufactures extraordinarily high quality non-contact magnetostrictive displacement and liquid level transducers, adaptive servo controllers, and logistic shock recorders. Through advancing the state-of-the art contributions while maintaining high quality standards, Santest has dedicated its efforts towards optimizing the performance of such products.
U.S. Contact Yates Industries, Inc. Yates Industries South, LLC Exsenco, LLC 23050 Industrial Dr. E. 55 Refreshment Place PO Box 271348, Corpus Christi, TX 78427 St. Clair Shores, MI 48080 Decatur, AL 35601 Phone: 361-510-3264, Fax: 469-519-3514 586.778.7680 ph 256.351.8081 ph Email: info@exsenco.com 586.778.6565 fax 256.351.8571 fax AMETEKAPT10017-R_eBrick-7.625x4.875_FPJ_APT10017 09/11/12 10:30 AM Page 1 www.exsenco.com
The new 955 eBrik linear displacement transducer.
Price and performance so well balanced, it just might displace potentiometers. At last, there’s a purely electronic solution to position sensors. Our new 955 eBrik uses magnetostrictive technology so there’s no contact, no moving parts, nothing to wear out. No erratic position signals. Available in 1" to 72" stroke lengths, it’s economical and versatile enough for many applications, field-programmable, and the perfect replacement for old-style potentiometers. Learn more at our website or send e-mail to gemco@ametek.com.
ametekapt.com ©2012 AMETEK Inc. All rights reserved.
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product review PVCS Control Module ‰ The PVCS is a joystick/proportional driver controller module that can be easily programmed for use with applications such as speed and directional controls, proportional valves, solenoids, coils, lifts, hoists, and attachments. Features include • Single-axis and dual-axis configurations • Up to 10 proportional pulse width modulation and/or switching outputs • Up to four proportional analog outputs • Custom switching patterns • Adjustable PWM ramping, deadbands, and proportional slopes • Full-time LED diagnostics that show activated outputs and direction of movement • Regulated +5V reference for local command joysticks, potentiometers, halls, etc. • Sealed IP67, IP69K enclosure with internal heatsinks • Compatibility with most proportional joysticks and proportional sensors
Cyber-Tech www.cyber-tech.net
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Piranhaflex™ Plus Series PFP354NC Non-Conductive 100R7 Hydraulic Hose The ideal hose for medium pressure hydraulic lines used on utility equipment.
• The “Plus” refers to the specially
engineered low friction cover compound; helps in eliminating hose routing problems when used with utility equipment. • Use of Piranhaflex™ Plus helps in extending hose service life with less frequent replacement. • Allows for increased flexibility and easier routing when hoses are bundled.
Kuriyama of America, Inc. 360 E. State Parkway • Schaumburg, IL 60173 (847) 755-0360 • Fax: (847) 885-0996 sales@kuriyama.com
www.kuriyama.com Circle 379
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society News
Become an IFPS Accredited Instructor or Job Performance Proctor IFPS accredited instructors (CFPAI) are certified professionals who educate and prepare candidates for IFPS certification programs. Accredited Instructors have extensive backgrounds and instructional experience in the fluid power industry. In addition to their instructor accreditation, they are committed IFPS members and hold various IFPS certifications. Job Performance Proctors are individuals who hold various IFPS certifications and proctor the job performance portion of Mechanic, Technician, and Connector/Conductor hands-on tests. Accredited Instructor Training Workshop
August 5-6, 2013 CFC Solar, Inc. • Fairfield (Cincinnati), OH Registration Deadline: July 8, 2013 Fee: $350 Job Performance Training Workshop
August 7, 2013 CFC Solar, Inc. • Fairfield (Cincinnati), OH Registration Deadline: July 8, 2013 Fee: $160
ifps 2013 IFPS Web Seminars
Connector and Conductor (CC) Job Performance Training Workshop*
August 8, 2013 CFC Solar, Inc. • Fairfield (Cincinnati), OH Registration Deadline: July 8, 2013 Fee: $160 *Candidate must hold Connector and Conductor certification. Visit www.ifps.org for more information or call 800-308-6005. Visit www.ifps.org to register or call 800-308-6005.
IFPS Members: Free • non-members: $40.00
June 13, 2013
December 4, 2013
August 22, 2013
Archived Energy-Saving Web Seminars
October 17, 2013
Archived Hydraulics Web Seminars
Archived Pneumatics Web Seminars Archived system design Web Seminars Other
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Visit www.ifps.or g to view.
IFPS newly certified professionals Justin Allen, PS Parker Hannifin Corporation
Michael Covin, HS Gulf Controls Company, LLC
Ryan Huot, HS Huot MFG
Alex Morlock, PS Force America, Inc.
Zachary Amundson, MHM Tampa Electric Co.
Matthew Davenport, S, PS Parker Hannifin Corporation
Benjamin Jaffe, PS
Sergey Moskvin, HS St. Jude Medical
Linh Ba, S, PS
Steve Davis, MHM Tampa Electric Co.
Alex Baker, MHM Altec Industries, Inc. Ryan Batt, HS Brand Hydraulics Jorge Beltran, PS Hydraulic Supply Company Abraham Bensend, HS Oxbo International Corp. Shaun Boddy, MHM Tampa Electric Co.
Jonathan Johnson, S, PS Motion Industries, Inc.
Jason Kamrath, PS Parker Hannifin Corporation
Kevin Bresnahan, S, PS Parker Hannifin Corporation Paul Brightenfield, HS Unique Automation Glenn Carley, MHM Altec Industries, Inc. James Carrier, S, HS Henry Chin, HS Bardex Corporation James Cooley, MHM Amerit Fleet Solutions
Certification Designations Available
Dennis Courtright, ECS Eaton Corporation
Glenn Kincaid, MHM Amerit Fleet Solutions
Benjamin Fann, HS Applied Industrial Technologies
Jeff Philibin, S, PS Parker Hannifin Corporation
Michael Trowbridge, MHM Altec Industries, Inc.
Kelsey Pombo, S, PS Parker Hannifin Corporation
Timothy Verret Jr., PS Viking Drill & Tool Inc.
Scott Queiser, HS Oxbo International Corp.
Matthew Walley, S, PS Parker Hannifin Corporation Stephen West, HS Ivy Technical Community College
William Logan, HS Elwood Corporation
Tom Grim, MHM Altec Industries, Inc.
Derek Majewski, HS Parker Hannifin
Andy Hall, HS
John Malloy, S, PS Parker Hannifin Corporation
Gregory Quenemoen, HS
Steven Malone, MHM CFC-Solar, Inc.
Casey Rogers, MHM Altec Industries, Inc.
Kelly Matheny, PS Parker Hannifin Corporation
Ervin Scott, Jr., HS Sun Hydraulics Corporation
Doug McAnulty, MHM Altec Industries, Inc.
Nathan Shafer, PS Hennepin Technical College
Shawn McNevin, PS
Jeffrey Sharpe, PS
Ismael Mellina, HS Morse Hydraulics Corporation
Chang Soo Shim, S, PS Parker Hannifin Corporation
Derek Miller, S, PS Parker Hannifin Corporation
Porter Spencer, HS Bardex Corporation
Eric Harvey, HS Roderick Hathaway, S, PS The Leen Co.
Trent Hinrichs, PS Force America Dan Hufford, HS Custom Mold & Design
Certified Fluid Power Specialist (Must obtain CFPHS, CFPPS)
David Weston, IHM Alcoa Mill Products, Inc. Chelsea Wilhelm, S, PS Parker Hannifin Corporation John Woolridge, PS
‰ CFPHS
‰ CFPMEC – in development Mobile Electronic Controls ‰ CFPIEC – in development Industrial Electronic Controls
Certified Fluid Power Hydraulic Specialist
‰ CFPMT
‰ CFPAJPPCC
‰ CFPPS
Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor
Certified Fluid Power Pneumatic Specialist
Certified Fluid Power Master Technician (Must obtain CFPIHT, CFPMHT, & CFPPT)
‰ CFPECS
‰ CFPIHT
Electronic Controls Specialist
Certified Fluid Power Industrial Hydraulic Technician
Certified Fluid Power Engineer
Nicholas Torgerson, PS Force America, Inc.
Kevin Glenn, MHM Altec Industries, Inc.
‰ CFPS
‰ CFPE
Anna Pavlou, S, PS Parker Hannifin Corporation
Glenn Lake, Jr., HS Action Hydraulic Inc.
Carl Hall, S, PS Motion Industries
Jeremy Taylor, MHM Altec Industries, Inc. Joseph Tiessen, HS Aggressive Hydraulics Inc.
Corie Fisher, S, PS Parker Hannifin Corporation
Jason Hinchcliffe, MHM Altec Industries, Inc.
John Szmall, MHM Tampa Electric Co.
Jeremy Palm, PS
Kevin Kobold, PS Alexander Kummer, E Weatherford
Certified Fluid Power Accredited Instructor
Certified Fluid Power Authorized Job Performance Proctor
Andrew Palchak, S, PS Parker Hannifin Corporation
Margaruette Finney, HS
‰ CFPAI
‰ CFPAJPP
Michael Mueller, S, PS Parker Hannifin Corporation
Chris Stephens, S, PS Motion Industries
Zach Ollman, HS
Tom Engstrom, HS Dow Chemical
David Bodossian, S, PS Sarah Borsuk, S, PS Parker Hannifin Corporation
John Stanley, HS Jem Technical Nick Steen, HS
Todd Mowry, MHM Altec Industries, Inc.
Cole Joos, PS Marcus De Souza, HS Walt Disney Company
Wade Sprengeler, HS
Tyrone Wright, S, PS Parker Hannifin Corporation
‰ CFPMHT
‰ CFPMHM
‰ CFPMIP
Certified Fluid Power Mobile Hydraulic Technician
Certified Fluid Power Mobile Hydraulic Mechanic
‰ CFPPT
‰ CFPPM
Certified Fluid Power Master of Industrial Pneumatics (Must obtain CFPPM, CFPPT, & CFPCC)
Certified Fluid Power Pneumatic Technician
Certified Fluid Power Pneumatic Mechanic
‰ CFPCC
‰ CFPMM
‰ CFPMIH
Certified Fluid Power Connector & Conductor
Certified Fluid Power Master Mechanic (Must obtain CFPIHM, CFPMHM, & CFPPM)
Certified Fluid Power Master of Industrial Hydraulics (Must obtain CFPIHM, CFPIHT, & CFPCC)
‰ CFPIHM
‰ CFPMMH
Certified Fluid Power Industrial Hydraulic Mechanic
Certified Fluid Power Master of Mobile Hydraulics (Must obtain CFPMHM, CFPMHT, & CFPCC)
‰ CFPSD Fluid Power System Designer
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IFPS
Certification Review Training
IFPS Event Calendar
Connector & Conductor (CC) Review w/ Job Performance Test
Review and testing offered through Eaton Corp. June 25-26, 2013 / Maumee, OH
Visit www.ifps.org for registration information.
Meetings and Conferences IFPS 2013 Annual Meeting
September 25 - 28, 2013 Buffalo, NY
Fluid Power Systems Conference
IFPE 2014 Annual Meeting
November 2013 Chicago, IL
January 28 – February 1, 2014 Orlando, FL
IFPE 2014
March 4-8, 2014 Las Vegas, NV IFPS 2014 Annual Meeting
September 24-27, 2014 Charleston, SC
Mobile Hydraulic Mechanic (MHM) Review w/ Job Performance Test
Review and testing offered through CFC-Solar, Inc. October 7-10, 2013 / Fairfield, OH Industrial Hydraulic Mechanic (IHM) Review w/ Job Performance Test
Review and testing offered through CFC-Solar, Inc. August 13-16, 2013 / Fairfield, OH Hydraulic Specialist (HS) Certification Review
Distance Learning Review Sessions offered through CFC-Solar, Inc. Fall 2013 classes available. Review and testing offered through CFC-Solar, Inc. December 2-3, 2013 / Fairfield, OH Review and testing offered through Eaton Corp. June 11-13, 2013 / Eden Prairie, MN November 19-21, 2013 / Eden Prairie, MN Pneumatic Specialist (PS) Certification Review
Review and testing offered through CFC-Solar, Inc. May 20-22, 2013 / Fairfield, OH Distance Learning Review Sessions offered through CFC-Solar, Inc. Fall 2013 classes available. Electronic Controls Specialist (ECS)
Review and testing offered through CFC-Solar, Inc. September 16-19, 2013 / Fairfield, OH Job Performance Review With Job Performance Test (Mechanic & Technician)
Review and testing offered through IFPS Chapter 49/50 Orlando, FL Review: September 12-13, 2013 Job Performance Test: September 14, 2013
Accredited Instructor and Job Performance Proctor Workshop Cincinnati, OH Accredited Instructor Training Workshop August 5-6, 2013 Job Performance Proctor Workshop August 7, 2013 Connector and Conductor Job Performance Workshop - August 8, 2013
Web Seminars June 13, 2013
“In the Line of Fire: Cause and Dangers of Fluid Injection Injuries” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Dan Helgerson, CFPAI, Cascade Steel Rolling Mills, Inc. August 22, 2013
“Compressor Lubrication and The NEED for Coalescing Filters” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Clayton Fryer, CFPAI, Consultant October 17, 2013
“Beat the Leak: Best Practice Approach to Becoming Connector and Conductor Certified” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Gwyn O’Kane, CFPAI/AJPPCC, Pirtek USA Circle 371
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December 4, 2013
“Slip-In Cartridge Valves” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Jim Lane, CFPAI, Motion Industries, Inc.
IFPS
IFPS Certification Testing Locations I
ndividuals wishing to take any IFPS written certification tests are able to select from approximately 325 convenient locations across the United States and Canada. The IFPS is able to offer these locations through its affiliation with The Consortium of College Testing Centers (CCTC) provided by National College Testing Association (NCTA).
To register for an IFPS written certification test: 1. Fill out an IFPS certification test application including your desired location by visiting www.ifps.org. 2. Submit your application with payment to IFPS headquarters. 3. Upon receipt of your application, you will be e-mailed instructions. Testing dates for any locations listed below are as follows: may 2013 Tuesday, 5/7 Thursday, 5/16
june 2013 Tuesday, 6/4 Thursday, 6/20
july 2013 Tuesday, 7/2 Thursday, 7/18
august 2013 Tuesday, 8/6 Thursday, 8/15
september 2013 Tuesday, 9/3 Thursday, 9/19
october 2013 Tuesday, 10/1 Thursday, 10/17
november 2013 Tuesday, 11/5 Thursday, 11/21
Questions? Please call IFPS headquarters at 800-308-6005 or e-mail Connie Graham at cgraham@ifps.org.
ALASKA University of Alaska Anchorage Anchorage, AK ALABAMA Alabama A&M University Normal, AL Jacksonville State University Jacksonville, AL University of AL in Huntsville Huntsville, AL ARKANSAS Northwest Arkansas Community College | Bentonville, AR ARIZONA Arizona State University Tempe, AZ Arizona Western College Yuma, AZ Coconino Community College Flagstaff, AZ Eastern Arizona College Thatcher, AZ Glendale Community College Glendale, AZ Mesa Community College Mesa, AZ
Irvine Valley College Irvine, CA La Sierra University Riverside, CA National Test Center San Diego, CA National University San Diego, CA Santa Rosa Junior College Santa Rosa, CA Skyline College San Bruno, CA The Taft University System Santa Ana, CA UC San Diego Extension San Diego, CA University of California Irvine, CA Yuba Community College Marysville, CA COLORADO Community College of Aurora Aurora, CO
Florida Gulf Coast University Ft. Myers, FL Florida Memorial University Miami Gardens, FL
Georgia State University Atlanta, GA
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University of Georgia Athens, GA
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HAWAII BYU-Hawaii Laie, HI
Waubonsee Community College Sugar Grove, IL
Florida Southern College Lakeland, FL
IOWA Hawkeye Community College Waterloo, IA
Hillsborough Community College Plant City, FL
University of Iowa Iowa City, IA
Indian River State College Fort Pierce, FL
Wartburg College Waverly, IA
Open Campus Florida Community College at Jacksonville, FL
Western Iowa Community College Sioux City, IA
College of Southern Idaho Twin Falls, ID
University of South Florida Tampa, FL
Eastern Idaho Technical College Idaho Falls, ID
Valencia Community College Orlando, FL
Lewis-Clark State College Lewiston, ID
University of Colorado at Boulder Boulder, CO
GEORGIA Albany State University Albany, GA
University of Idaho Moscow, ID
University of Northern Colorado Greeley, CO
Clayton State University Morrow, GA
ILLINOIS College of DuPage Glen Ellyn, IL
CONNECTICUT Yale University New Haven, CT
Columbus State University Columbus, GA
College of Lake County Grayslake, IL
Columbus Technical College Columbus, GA
Illinois State University Normal, IL
Darton College Albany, GA
John A. Logan Community College Carterville, IL
Front Range Community College Larimer Campus | Ft. Collins, CO
Foothill College Los Altos Hills, CA
Florida Atlantic University Boca Raton, FL
Northern Illinois University De Kalb, IL
University of Florida Gainesville, FL
Pima Community College Tucson, AZ
Chapman University Orange, CA
Daytona State College Daytona Beach, FL
Georgia Southern University Statesboro, GA
Brigham Young University Rexburg, ID
Fort Lewis College Durango, CO
California State University, Fresno Fresno, CA
FLORIDA Brevard Community College Cocoa, FL
Lincoln Land Community College Springfield, IL
Santa Fe Community College Gainesville, FL
Paradise Valley Community College Phoenix, AZ
California Polytechnic State University San Luis Obispo, CA
University of Delaware Newark, DE
Georgia Gwinnett College Lawrenceville, GA
IDAHO Boise State University Boise, ID
Community College of Denver Denver, CO
CALIFORNIA Allan Hancock College Santa Maria, CA
Delaware Technical and Community College Georgetown, DE
Polk State College Winter Haven, FL
Northern Arizona University Flagstaff, AZ
Rio Salado College Tempe, AZ
Fullerton Community College Fullerton, CA
Pikes Peak Community College Colorado Springs, CO Pueblo Community College Pueblo, CO
DELAWARE Delaware State University Dover, DE
INDIANA Indiana University Indianapolis, IN Ivy Tech Community College/ Bloomington | Bloomington, IN Ivy Tech Community College/ Columbus | Columbus, IN Ivy Tech Community College/ Evansville | Evansville, IN Ivy Tech Community College/Gary Gary, IN Ivy Tech Community College/ Indianapolis | Indianapolis, IN Ivy Tech Community College/ Kokomo Kokomo, IN Ivy Tech Community College/ Lafayette | Lafayette, IN Ivy Tech Community College/ Lawrenceburg | Lawrenceburg, IN Ivy Tech Community College/ Madison Madison, IN Ivy Tech Community College/Muncie Muncie, IN Ivy Tech Community College/ Richmond | Richmond, IN Ivy Tech Community College/ Sellersburg | Sellersburg, IN Ivy Tech Community College/South Bend | South Bend, IN
may/june 2013
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IFPS Ivy Tech Community College Terre Haute, IN
Michigan State University East Lansing, MI
Southeast Community College Lincoln, NE
Southwestern Oregon Community College | Coos Bay, OR
Texas A&M International University Laredo, TX
Purdue University West Lafayette, IN
Schoolcraft College Livonia, MI
University of Oregon Eugene, OR
Texas A&M University College Station, TX
KANSAS Johnson County Community College Overland Park, KS
NEW JERSEY Brookdale Community College Lincroft, NJ
Southwestern Michigan College Dowagiac, MI
Gloucester County College Sewell, NJ
PENNSYLVANIA Bucks County Community College Newtown, PA
Texas A&M University-Commerce Commerce, TX
Mercer County Community College West Windsor, NJ
HACC Gettysburg Campus Gettysburg, PA
Raritan Valley Community College Somerville, NJ
Harrisburg Area Community College Harrisburg, PA
NEW MEXICO Eastern New Mexico University Portales, NM
Harrisburg Area Community College York Campus | York, PA
Kansas State University Manhattan, KS
Washtenaw Community College Ann Arbor, MI
University of Kansas Lawrence, KS
MINNESOTA Minnesota State University, Mankato Mankato, MN
Wichita State University Wichita, KS
University of Minnesota - Twin Cities Minneapolis, MN
KENTUCKY University of Louisville Louisville, KY
University of Minnesota Morris, MN
San Juan College Farmington, NM
Western Kentucky University Bowling Green, KY
MISSOURI Avila University Kansas City, MO
LOUISIANA Bossier Parish Community College Bossier City, LA
Metropolitan Community College-Penn Valley Kansas City, MO
University of Louisiana at Monroe Monroe, LA
Missouri Western State University St.Joseph, MO
Nicholls State University, Thibodaux, LA
Southeast Missouri State University Cape Girardeau, MO
College of Southern Nevada Green Valley Campus Henderson, NV
University of New Orleans New Orleans, LA
St. Charles Community College Cottleville, MO
College of Southern Nevada Henderson Campus, NV
State Fair Community College Sedalia, MO
NEW YORK Brooklyn College - CUNY Brooklyn, NY
MARYLAND Anne Arundel Community College Arnold, MD Carroll Community College Westminster, MD Chesapeake College Wye Mills, MD College of Southern Maryland La Plata, MD Frederick Community College Frederick, MD Harford Community College Bel Air, MD Hagerstown Community College Hagerstown, MD Howard Community College Columbia, MD University of Maryland College Park, MD MASSACHUSETTS North Shore Community College Danvers, MA University of Massachusetts Boston, MA MICHIGAN Baker College Online Flint, MI Delta College University Center, MI Ferris State University Big Rapids, MI Henry Ford Community College Dearborn, MI Kalamazoo Valley Community College Kalamazoo, MI Lake Superior State University Sault Ste. Marie, MI Lansing Community College Lansing, MI Macomb Community College Warren, MI
34
Three Rivers Community College Poplar Bluff, MO University of Central Missouri Warrensburg, MO Webster University St. Louis, MO MISSISSIPPI Holmes Community College Goodman Campus Goodman, MS
NEVADA College of Southern Nevada Charleston Campus Las Vegas, NV College of Southern Nevada Cheyenne Campus North Las Vegas, NV
Rochester Institute of Technology Rochester, NY OHIO Central Ohio Tech College OSU-Newark | Newark, OH
MONTANA Montana State University Bozeman, MT
The University of Toledo Toledo, OH
Fayetteville State University Fayetteville, NC Guilford Technical Community College Jamestown, NC Mount Olive College Mount Olive, NC North Carolina Central University Durham, NC The University of North Carolina Wilmington, NC NORTH DAKOTA Bismarck State College Bismarck, ND North Dakota State University Fargo, ND NEBRASKA Bellevue University Bellevue, NE
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University of Akron Akron, OH OKLAHOMA Northern Oklahoma College Tonkawa, OK Oklahoma State University Stillwater, OK Oklahoma State University-Tulsa Tulsa, OK University of Central Oklahoma Edmond, OK University of Oklahoma Norman, OK OREGON Central Oregon Community College Bend, OR
University of Texas Brownsville Brownsville, TX University of Texas at Arlington Arlington, TX University of Texas El Paso El Paso, TX
Midlands Technical College Columbia, SC
Weatherford College Weatherford, TX
Orangeburg Calhoun Technical College Orangeburg, SC
UTAH Brigham Young University Provo, UT
Piedmont Technical College Greenwood, SC
Davis Applied Technology College Kaysville, UT
Spartanburg Community College Spartanburg, SC
Salt Lake Community College Salt Lake City, UT
Technical College of the Lowcountry Beaufort, SC
Utah Valley State College Orem, UT
Trident Technical College Charleston, SC
TENNESSEE East Tennessee State University Johnson City, TN
The Ohio State University Columbus, OH
University of Houston Houston, TX
Victoria College Victoria, TX
Franklin University Columbus, OH
University of Mississippi University, MS
Tyler Jr. College Tyler, TX
Horry-Georgetown Technical College Conway, SC
York Technical College Rock Hill, SC
Rhodes State College Lima, OH
NORTH CAROLINA East Carolina University Greenville, NC
SOUTH CAROLINA Coastal Carolina University Conway, SC
Columbus State Community College Columbus, OH
Mississippi State University Mississippi State, MS
The University of Montana Missoula, MT
Harrisburg Area Community College-Lancaster Campus Lancaster, PA
Texas Tech University Lubbock, TX
VIRGINIA Old Dominion University Norfolk, VA WASHINGTON Central Washington University Ellensburg, WA Olympic College Bremerton, WA
Middle Tennessee State University Murfreesboro, TN
Western Washington University Bellingham, WA
Southern Adventist University Collegedale, TN
WISCONSIN Lakeshore Technical College Cleveland, WI
Tennessee State University Nashville, TN The University of Memphis Memphis, TN Walters State Community College Morristown, TN TEXAS Abilene Christian University Abilene, TX Austin Community College Austin, TX Eastfield College Mesquite, TX
Marian University of Fond du Lac Fond du Lac, WI University of Wisconsin Oshkosh Oshkosh, WI University of Wisconsin-Milwaukee Milwaukee, WI WYOMING University of Wyoming Laramie, WY CANADA Lethbridge College Lethbridge, AB Canada
El Paso Community College El Paso, TX
Saskatchewan Institute of Applied Science and Technology Saskatchewan, Canada
Grayson County College Denison, TX
Thompson Rivers University Kamloops, BC Canada
Clackamas Community College Oregon City, OR
Lamar Institute of Technology Beaumont, TX
Mt. Hood Community College Gresham, OR
Midwestern State University Wichita Falls, TX
Portland State University Portland, OR
Sam Houston State University Huntsville, TX
RCC-SOU Higher Education Center Medford, OR
Southern Methodist University Dallas, TX
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Support the Future of the Fluid Power Industry – Your Source for Tomorrow’s Employees and Customers Your charitable, tax-deductible donation to the Fluid Power Educational Foundation will enable future student scholarships, curriculum development and deployment, and outreach efforts to engage more people in fluid power technology and training. Help prepare skilled employees and knowledgeable customers by supporting FPEF.
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www.trengineering.com Circle 382
may/june 2013
35
Sp n A New
on an
Old Idea
I am going to go out on a limb to make a suggestion. Now, for me, this is not all that unusual. I have been described as someone who thinks “outside the box” and have been accused of not even remembering where the “box” is anymore. In fairness, this is not a brand-new idea, nor is it entirely mine. I had an opportunity to read an article by Bård A. Harang of Hymatic AS, Trondheim, Norway, where he describes a reservoir that would provide a way to more efficiently keep the hydraulic fluid clean. The more I thought about his concept, the more potential benefits I could see. I am not using his words but, with his permission, I am using some By Dan Helgerson, of his thoughts.
CFPAI/AJPP, CFPS, CFPECS, CFPMT, CFPSD, Cascade Steel Rolling Mills, Inc.
In our Hydraulics 101 course we learned that there are four primary purposes for a hydraulic reservoir: to store hydraulic fluid, to allow gas bubbles to rise to the surface, to allow particulate to settle out, and to allow the fluid to cool. Experience has shown that it takes about two minutes for the average hydraulic fluid in a quiescent state to release the air and particulate it carries into the reservoir. This is the information that brought about the “rule of thumb” that a reservoir should be at least two times the average pump flow and if two is good, three or four would be even better. More fluid in the reservoir allows for a longer quiescent time. The longer the quiescent time, the more the bubbles, particulate, and heat can be removed. This seems to make good sense and has been
36
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the adopted standard of most industrial facilities and power unit designers and fabricators. The typical hydraulic reservoir in an industrial facility is a rectangular container as in Fig. 1. A reservoir with this arrangement can be purchased as a standard item, and as a result, designers often simply determine the approximate reservoir capacity, order the next size larger, and leave it at that. However, there are some issues with this design. Remember the four purposes of the reservoir? This design certainly does allow for the release of gas bubbles and the settling out of particulate, but where does the particulate go? It settles onto the bottom of the tank. The baffles and braces add places where the contaminants will collect. The clean-out plates are there to allow the periodic cleaning out of the reservoir, but it can be a nasty job and is often not part of a routine maintenance schedule. It requires the complete draining of the reservoir and then for someone to reach in (or crawl in) to the tank to scrub out the floor and the corners. The fluid will need to be stored and run
through a filter cart when it is reintroduced to the reservoir. Consequently, the clean-out job does not usually get done until there is some other catastrophe that requires draining the reservoir. If the reservoir is not cleaned out, there is the danger of a sudden inrush of fluid that will stir up the sediment, which could then be drawn into the system through the suction line. Another issue is the ability of this type of reservoir to allow the fluid to cool. Hydraulic fluid has a relatively low specific heat, which means it resists taking on or giving up heat. Fluid molDan Helgerson works for Cascade ecules moving through the center of the reserAbout Steel Rolling Mills, Inc. He is the IFPS vice president of membership and the voir are essentially insulated from the exterior Author chapter support, and also the technical wall by all the other fluid in the tank. Even the editor for Fluid Power Journal. He can fluid by the exterior wall has to deal with the be reached at dan@cfpsos.com. resistance of carbon steel to transfer its heat to the atmosphere. There are a couple of manufacturers who are now making reservoirs specyclonic effect produces a lower pressure in the center, drawing all the parcifically designed for mobile equipment and that take an extremely different ticulate and gas toward the middle of the reservoir and away from the inlet approach. The reservoirs are cylindrical in shape and hold a tiny fraction of line to the pump. The gas escapes through the breather and the particuthe average pump flow. One company with whom I had a discussion uses late drops to the bottom where it is drawn out to the kidney-loop system. a 5-liter reservoir for a 75-lpm pump flow. That is not a misprint. I am seriA smooth seam where the cone is joined to the cylindrical tank prevents ous. They successfully use a 5-liter reservoir for a 75-lpm pump flow. The any of the sludge buildup found in the rectangular tank, and so there is no design takes the return line from the pump and causes it to spin around at need for the scheduled clean out. This is what BĂĽrd A. Harang wrote about high velocity toward the suction port. This actually causes a positive presand has experienced in the field. sure at the suction port and assures good inlet conditions for the pump. The The additional value I see to this arrangement relates to heat exchange spinning motion causes a cyclonic effect that pulls the air bubbles to the and the reduction in the necessary volume of the fluid. The returning fluid center so they can exit through the vent cap. The benefits to this design are carries the heat generated by the inefficiency of the working system. Enterthe decrease in size, the lower volume of fluid to be purchased, the reduced ing tangentially to the cylindrical reservoir, the fluid remains against the weight, and the limited amount of fluid that would be spilled in the event outer wall as it rotates around. This should result in a better heat exchange of a hose failure. The disadvantages are that the units provide no cooling, to atmosphere. A cylinder is stronger than a rectangular box, and so this no filtration, and require an almost constant flow. Variable displacement reservoir can be made of thinner material. Making the reservoir out of pumps are not easily accommodated because, if the fluid velocity entering aluminum dramatically increases the ability of the fluid to give up heat the reservoir is reduced, the cyclonic effect is less effective in removing the through the wall (aluminum has a specific heat of 0.12 as compared to carair. Large displacement cylinders are also a problem because there is not bon steel with a specific heat of 0.22). All this means is that the amount enough volume for the reservoir to breathe as the cylinders stroke. of fluid to be stored can be reduced because there is no need for the long I think there is a compromise between the traditional, rectangular resquiescent time. The reservoir can be sized simply for the change in volume ervoir and the tiny mobile reservoir that may better address the needs of used by the actuators and/or supplying the accumulators. both industrial and mobile equipment. It is still a cylindrical reservoir, but Another advantage is that the cylindrical reservoir has a smaller footlarge enough to meet the other needs of the system. print than a rectangular reservoir of the same capacity. The combination Given a cylindrical reservoir with a conical bottom as in Fig. 2 and with of a smaller footprint, a fraction of the required fluid that needs to be purthe return line entering tangentially to the tank, think about what hapchased, and the potential for eliminating or reducing the size of the heat pens. The return flow causes a gentle rotation of the fluid within the tank. exchanger may make it possible to have a very competitive installed cost. Instead of a centrifugal force pushing the particles against the wall, a Think about it.
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It’s our turn!
Circle 383
may/june 2013
37
IFPS certification spotlight
Pneumatic Mechanic (PM) Certification Spotlight he International Fluid Power Society is the only organization that provides comprehensive technical certification offerings for all professionals in the fluid power and motion control industry. IFPS certifications are portable and are recognized throughout the industry. IFPS certifi-
T
cation tests provide an objective, third-party assessment of an individual’s skill level. Individuals who successfully master the Pneumatic Mechanic’s level of competency are issued the credential “CFPPM” signifying an elevated status in the workforce. IFPS defines a Pneumatic Mechanic as an
individual who fabricates, assembles, services, maintains, and tests industrial pneumatic equipment. The mechanic understands pneumatic symbols, reads system schematics, and understands electrical principles. The mechanic is skilled in using hand tools, power tools, micrometers, calipers, and test equipment. All mechanic certifications require a three (3)-hour written and a three (3)-hour job performance (hands- on) test. If you’re interested in testing for the PM level certification, registration information can be found at www.ifps.org. Summary • Provide field repairs: 99 Fix inoperable machinery at the worksite 99 Change hoses and hard plumbing that failed 99 Change out cylinders, motors, control valves, seals, and gauges • Perform major repairs under clean conditions and bench tests repairs • Replace faulty components • Aid in system flushing and commissioning • Service the air supply system and make necessary adjustments • Provide “leak-free” plumbing • Service air preparation equipment to eliminate contaminates • Make up hose assemblies • Promote compressed air safety Test Your Skills 1. Which port would be fitted with a restrictor to achieve meter-in flow control for both extension and retraction of a double-acting cylinder?
A. Port 2 D. Port 3
B. Port 4 E. Port 5
C. Port 1
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3. A pressure of 100 psia converts to a gauge pressure of A. 114.7 psig B. 100.0 psig C. 85.3 psig D. 14.7 psig E. 0 psig
1=C, 2=D, 3=C
2. A V-belt drive measures 20 inches between the motor shaft and compressor shaft. When pulling on the belt with a force of 1-½ pounds midway between the pulleys, the belt should deflect A. 0.2 inches B. 1-½ inches C. 20/100 inches D. 5/16 inches E. 5/64 inches
2013 NFPA Detroit Regional Meeting
2013 Industry & Economic Outlook Conference August 12-14, 2013 Westin Chicago North Shore, Wheeling, IL
2014 NFPA Annual Conference February 3-5, 2014 The Ritz-Carlton, Palm Beach, Manalapan, FL
2014 IFPE March 4-8, 2014 Las Vegas Convention Center, Las Vegas, NV
Circle 385
id you know that there’s a Career Resources section on NFPA’s website? It introduces students to careers in fluid power and provides helpful links to job seekers. Career Resources was recently updated and reorganized. It’s revamped into two sections for two different audiences: those looking for jobs in fluid power and those looking for information on the education needed to get a job in fluid power. Do you want to know . . . 99 what types of jobs are available in the fluid power industry? 99 how much these jobs pay? 99 what type of education you’ll need to enter the industry? The site has answers to these questions and more. There are expanded sections for job descriptions, finding a career in fluid power, salary information, and certification courses. There’s even a current listing of employment opportunities available at NFPA member companies. To access the site, go to www. nfpa.com, choose Education & Careers, then Career Resources. For further information, contact Carrie Tatman Schwartz at 414778-3347 or ctschwartz@nfpa.com.
D
May 22, 2013 Somerset Inn, Troy, MI
association News
NFPA’s Career Resources Connects Job Seekers to Jobs
Calendar of events
NFPA
Circle 386
may/june 2013
39
2013
Salary
Survey Results
Age? 18-25 1.9% 26-35 23.3% 36-45 27.7%
97.1%
46-55 29.6%
2.9%
56-65 14.6% 66+
Gender?
2.9%
years
Fluid Power Journal, in collaboration with the International Fluid Power Society (IFPS), established an online salary survey for 2013 in order to create a baseline resource for professionals in the fluid power industry. The survey ran from January 3 through March 15 with several hundred participants. Thank you to those who participated in the survey!
How many have you been in the fluid power industry? 5 years or less 15.0%
21-25 years 13.1%
6-10 years 18.9%
26-20 years 11.7%
11-15 years 13.1%
31+ years
16-20 years 12.1%
Your Job? Mechanic 10.7% Journeyman 2.4% Specialist 17.5% Sales 39.8% Technician 9.7%
Engineer
How many
< 50
27.2
%
40
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16.0%
40.3%
employees work at your company? 50-100
100-250
12.1
20.9
%
%
250-500
7.8
%
> 500
32.0%
years have you been in current position?
How many your
›› ›› ›› ›› ›› ››
Up to 5 years 6-10 years 11-15 years 16-20 years 21-25 years 26+ years
What is the
36.9% 26.7% 13.1% 7.8% 7.8% 7.8%
High School or equivalent 8.7% Some College 20.9% Associate Degree 23.3% Bachelors Degree 35.0% Masters Degree 10.7% Doctoral Degree 1.5%
How many people report to you? 1-2 reports 13.6% 3-4 reports 10.2% 5-9 reports 6.8% 10-19 reports 6.8% 20-25 reports 1.5% 26+ 1.5%
No direct reports
59.7
%
highest formal
education you have received?
25%
5%
Certification is mandatory
Increased credibility
15%
3%
No effect on salary and/or job position
32% Not certified/ not sure
19%
certification has
1%
supported you
2.4%
13.2%
.5%
in the fluid power industry?
14.4% 5.5%
67.8
18.1
%
What Certifications Have You Earned?
30.9%
Annual Salary?
16.3%
12.3%
16.3%
7.9%
7.9%
7.9%
IHT Industrial Hydraulic Technician
IHM Industrial Hydraulic Mechanic
8.6% PT Pneumatic Technician
MHM - Mobile Hydraulic Mechanic
9.9% C&C Connector & Conductor
13.2%
MHT Mobile Hydraulic Technician
15.8%
E - Engineer
PS - Pneumatic Specialist
Slight impact on salary and/or job position
How do you feel
%
HS - Hydraulic Specialist
Significant impact on salary and/or job position
PM - Pneumatic Mechanic SD - Systems Designer
$20,000 - $29,000 $30,000 - $39,000 $40,000 - $49,000 $50,000 - $59,000 $60,000 - $69,000 $70,000 - $79,000 $80,000 - $89,000 $90,000 - $99,000 $100,000 - $199,000 $200,000+
6.6% 3.3%
(Percentages based on 74% of people who answered the question)
In which region of the country do you live? • Northwest • Southwest • Southeast • Northeast
80.6
16.5% 9.7% 13.6% 15.0%
Midwest
45.1%
% thought their job to be secure
ownership
What is the of your company?
Sole Proprietorship ........13.7% Partnership .....................11.1% S Corporation ..................22.6% C Corporation ..................34.2% Limited Liability Corporation LLC ..............17.9% Limited Liability Partnership LLP ............... 0.5%
63.6%
believed they are compensated fairly
Are you satisfied with your job? Very satisfied Satisfied Somewhat Satisfied Dissatisfied
35.4% 38.8% 22.3% 3.4%
may/june 2013
41
How many hours of
How would you describe your company operations?
›› ›› ›› ››
overtime do you work per week?
Local ............................ 10%
Regional ................... 18.5% National ................... 13.5%
< 8 hrs
< 16 hrs
< 24 hrs
> 24 hrs
None
13%
5%
2%
1%
78%
International ................ 58%
Does your company offer any other time-off policies?
What other benefits do you receive in addition to your base salary? 78.6%
• 401K
Paid maternity/paternity, adoption leave ................................... 50% Paid Military Leave ............................ 42%
55.8% Employer Matched
• Profit Sharing • Bonus • Commission
16%
29.1% 53.4% 15.5%
Which of the following are used to determine employee raises? 39% Yes 60% Yes 11% Yes
Cost of Living Adjustment Annual Merit Raise Lump Sum (in lieu of merit increase) Variable Pay Plan (bonus-awarded incentives, recognition bonuses) No Raises (salaries are frozen at current level) No Set Policy for Raises (discretionary each year)
54% Yes 12% Yes 43% Yes
Approximately how many employees at your company are fluid power certified? 0 – 10 49% 11- 20 7% 21 - 30 3%
31- 40 2% 41 – 50 6% 50 -100 7%
How many
72%
Responders who received a promotion or bonus due to certification
What percent of medical insurance is paid by your employer?
21 Days +
2%
Not Sure
1%
61% 54% 14% 13% 41% 69% 30%
94% Yes 93.5% Yes 76% Yes 17% Yes 87% Yes 62% Yes 85% Yes 82% Yes 78% Yes 36% Yes
89.3%
After 10 Years
After 15 Years
53%
43%
77%
52%
www.fluidpowerjournal.com | www.ifps.com
11-20 Days 23%
Dependent Coverage Dental Plan Vision/Optical Plan Retiree Medical Insurance Coverage Prescription Drug Plan Mail-Order Drug Plan Group Term Life Insurance Long-Term Disability Insurance Short-Term Disability Insurance Long-Term Care Insurance
80-100% 44.7% 50-70% 42.2% 20-40% 6.8% 10% 1.5% none 4.8%
Up to 4 weeks
74%
0-10 Days
What other health benefits are offered?
days of vacation do you receive?
Up to 3 weeks
Paid holidays?
Flexible Spending Account for health expenses Flexible Spending Account for Dependent Care Expenses Flexible Spending Account for Adoption Assistance Child Care (allowance or facilities) Flexible Work Scheduling Educational Assistance for Employees Pre-Retirement Counseling
After 5 Years
Up to 2 weeks
Yes ............... 44.2% No ................ 35.4% Not Sure ...... 23.8%
Does your company offer the following employee benefit programs?
After 1 Year
Up to 1 week
42
100+ 7% Not sure 18%
Paid jury duty
Does your company offer health care savings accounts?
More than 4 weeks
Not sure
Says they are not represented by a union
22.8% Says their company has a severance plan
economic report
Global Manufacturing Update By Chad Moutray, Chief Economist, National Association of Manufacturers
Year-Over-Year Growth in Real GDP for the United
&
4t h
Qu ar te r
i
States and Its 10 Largest Trading Partners
3r d
March 8, 2013 - Last month, we noted that many of our largest trading partners were experiencing progress in their economies, with improving levels of manufacturing activity and other economic indicators. That trend has mostly continued into February. Some countries, such as China and the United Kingdom, have either weakened or slowed down the pace of growth, whereas new orders were strong enough in Germany to allow its manufacturing sector to start expanding again, albeit quite modestly. While the composition of growth has shifted in the past month, seven of the top 10 markets for U.S.-manufactured goods had Purchasing Managers’ Indices (PMIs) greater than 50—the threshold for expansion—in February, suggesting continued improvement from some of the challenges from last fall. The JP Morgan Global Manufacturing PMI has been greater than 50 for three straight months, even as it eased somewhat in the most recent figure. The United States is growing modestly, making it one of the brighter spots in world economic markets. The Institute for Supply Management’s most recent report found that new orders rose from 53.1 in January to 54.2 in February, with the principal driver being higher sales. In addition, while real GDP barely grew in the fourth quarter of 2012, the data also show that consumers and businesses increased their spending moderately, helping to lessen the blow of reduced federal defense spending and lower inventory replenishment. Nonetheless, manufacturers continue to worry about the U.S. fiscal situation and sales. Non-petroleum goods exports did not change much in January from their December rates, and the 5.5% pace of manufactured goods exports in 2012 was well below the 15.9% pace of 2011. The economic woes in Europe continue to negatively impact manufacturers. Manufactured goods exports were essentially flat last year, with the Eurozone’s recession deepening. Real GDP for the continent fell 0.6% in the fourth quarter, its fifth straight quarter of declining output, and the Markit Eurozone Manufacturing PMI has contracted for 16 consecutive months. However, all of Europe is not the same. As noted above, Germany’s economy appears to be stabilizing, while others continue to experience reduced sales, production, and hiring. The unsettled election in Italy has exacerbated the Eurozone’s problems, reminding world markets about Italy’s large debt obligations and bringing Europe’s sovereign debt crisis once again back into the public eye.
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* Excerpt reprinted with permission. For the full report, visit www.nam.org.
The National Association of Manufacturers (NAM) represents small and large manufacturers in every industrial sector and in all 50 states. For more information, visit www.nam.org.
Circle 387
may/june 2013
43
By Bill Savel a, Delta Compu ter Systems, In c.
Fig. 1: Metal stamping presses at Spartanburg Steel used to manufacture automotive body panels
Motion Control Technology Advances
S
Aid Precision Automotive Manufacturing
ometimes it’s not enough to simply close the control loop. Traditional control algorithms rely on eliminating an error between what is happening (as indicated by feedback from sensors in the system) and what you want to have happen. High-speed motion controllers have become good at doing this quickly. But what if, for reasons of product quality, there can be no striking errors in the first place—for example, if a metal car part is being stamped and the risk of making the impression too quickly or too heavily must be avoided? The stamping press could be moved more slowly, but the productivity of the machine would be limited. To perform the process as quickly as possible requires some innovation in how the control algorithm is set up. Dayton Die Cushions of Eden Prairie, Minn., is doing just such innovation. Die cushions are hydraulically operated platforms that reside under the die in a stamping machine and move to cushion and oppose the motion of the main press ram (Fig. 1). A die cushion typically pinches the periphery of a work piece (which starts out as a flat metal blank) with various pad pressures in order to control the rate at which the work piece is pressed into the die
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by the main ram. Use of die cushion devices enables automotive components, such as body panels, to be manufactured to tighter tolerances and with features, such as bends, that would not be attainable with press-only stamping operations. Fig. 2 shows a CAD drawing of a die cushion manufactured by Dayton Die Cushions to retrofit a stamping machine in use by Spartanburg Steel Products of Spartanburg, S.C. The Spartanburg machine wasn’t initially designed with a die cushion, but plant managers understood that in order to supply more of the new-generation body panels to the car companies, they would need the capabilities and precision that a die cushion could give them. So they contacted Dayton Die Cushions and asked them to perform the retrofit. Challenges that needed to be met in the course of the retrofit project included fitting the new machine components within the physical constraints of the existing machine. “We had to take the motion of the existing ram into account in order to make sure that the new cushion could work with it,” said Tom Pedersen, manager of Dayton Die Cushions. “The old press had a distorted
bed, and we needed to align the structure before we would add our hardware. We reconstituted the bed with adjustable guides that were aligned with a 3D laser to within 0.001 inch.” The new die cushion needed to come into contact with the work piece as the press ram was already in motion and moving at a very high velocity, which in turn required the hydraulics to come alive before the die was actually contacted by the ram. This is in contrast to traditional presses, which wait until the ram hits the cushion before the cushion moves. The contact causes the hydraulic pressure to spike and generates an error in the closed-loop algorithm, which produces a response according to the algorithm. But that method wouldn’t work in this application. “We couldn’t tolerate the collision,” said Pedersen. “Instead, we looked for a way of predicting the collision and beginning to take action before the ram hits the work piece.” Another problem issue was the responsiveness of the valve. If the cushion’s hydraulic controller waits too long to begin increasing oil flow to the valve, the time lag could cause damage to the work piece. The oil needs to get moving in time to move the cushion just as the ram is about to make contact. The solution that Dayton Die Cushion worked out was to use a programmable motion controller that was capable of setting up a virtual motion axis that a physical axis could be geared to. “Gearing” refers to the ability for the motion of a slave axis to follow a master axis, which can be another physical axis or a virtual one that exists only inside the motion controller. “We create a virtual closure of the die cushion control loop before the ram hits the cushion,” said Pedersen. “No one had ever done this before.” With the virtual control loop closed, the oil flow is initiated before the die cushion comes into contact with the ram, so the two hydraulic systems come together smoothly, even though the ram is moving quickly with tremendous kinetic energy. To get high dynamics, the Dayton Die Cushions team selected a servo valve that had high flow but very low mass. Another design objective was to minimize the volume of oil flow, reduce the size of the HPU, and reduce oil conditioning (cooling, filtering, etc.). If the die cushion application was done entirely with hydraulics, it would be difficult to get enough fluid moving in the volume and time required (the cushion in the Spartanburg press measures 125 inches x 69 inches and must be capable of providing 250 tons of maximum holding force), so Dayton Die Cushions incorporated two passive pneumatic cylinders beside the hydraulic cylinder to reduce the amount of hydraulic oil that must be moved (the cylinders are shown in Fig. 2). The pneumatic cylinders provide the base tonnage of the cushion, and the variable tonnage that assists in shaping the work piece is provided by the hydraulic cylinder. To implement the hydraulic controls, Aleksandra Spiess, an engineer at Dayton Die Cushions,
selected the RMC75 electrohydraulic motion controller (Fig. 3) from Delta Computer Systems, Inc., Battle Ground, Wash. “The RMC75 can run four separate task execution engines simultaneously,” said Pedersen. Within Delta’s RMCTools software, each task can also run any of several user programs, one at a time. “We assigned one of the tasks to be a dedicated computation engine working in the background. A PLC wouldn’t have been fast enough to do what the RMC does.” The motion controller connects to two servo valves, which can be controlled independently. Each valve is assigned to a separate control axis of the RMC75 (the RMC75 can control up to two axes at the same time). “We want to be able to move extra oil to the tank when we need to move the die cushion very quickly,” said Pedersen. “The ram moves very fast when the cushion first hits and then slows down as the compression operation completes.” The new die cushion uses two Balluff magnetostrictive linear displacement transducers (MLDTs) with synchronous serial interface (SSI) inputs to the Delta motion controller and Hydac high-speed pressure sensors. One LDT measures the position of the ram and the other measures the position of the cushion. Just before the ram contacts the cushion, the RMC75 opens the valves and starts moving oil through the manifold. Then, at ram contact, the RMC75 runs a pressure control loop as the cushion moves down. At the bottom of the stroke, as the ram reverses direction and goes back up, the RMC is programmed to switch to position control mode, causing the die cushion to quickly rise, just in time to meet a robotic arm that picks the finished part out of the die. “The cushion needs to be up in a certain time window, repeatably, to meet the transfer arm,” said Pedersen. “This required adaptive closed-
or more information, visit www.deltamotion.com. loop control since the temperature and hence the flow properties of the oil are changing dynamically.” Another challenge that was met by the Delta controller was being able to work with existing offthe-shelf valves, which Dayton had to use since the lead times for any new-valve manufacturing were too long to meet the goals of the project. The Dayton Die Cushions team took three iterations to complete the motion control program for the Delta controller. The last one was in conjunction with the plant’s own controls engineers. “As we went through the iterations, we had a tremendous amount of help from Delta’s engineers,” said Pedersen. “For example, they taught us how to use the RMC-75’s S-curve instruction, which initiates a smooth acceleration and deceleration to avoid hydraulic shock. They also helped to incorporate feed-forward parameters into the control loop, predictive terms that help speed up the response of the control algorithm.” The team used Delta’s RMCTools Plot Manager software to prove the functionality of the system graphically and optimally tune the control-loop gains. Saving time in completing the design was important because Dayton’s customer, Spartanburg Steel, was in a hurry to put tooling in place to support the new automotive model year. The die cushion design by Dayton Die Cushions is an example of how hydraulic control systems are getting smarter in order to meet the increasing productivity and quality demands of modern automotive manufacturing. A key component of the new machines that makes this possible is the programmable electro-hydraulic motion controller.
Fig. 2 (left): CAD drawing of the die cushion. Fig. 3 (top): RMC75E motion controller from Delta Computer Systems, Inc.
may/june 2013
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