Fluid Power Journal October 2019 by Innovative Designs & Publishing, Inc.

October 2019

www.fluidpowerjournal.com

SALARY

SURVEY RESULTS See p.34

hydraulic

drives in mining FO R H IG H IT Y V I T C U D O R P

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

LVDT Position Sensors in Extreme Environments

Nonprofit Organization US Postage PAID Bolingbrook, IL Permit #323

Where smart Engineers go for

smart Solutions From sensor technology and data analytics to robotics and

automation, you’ll see all of the latest innovations in fluid power, all in one place. Even better, you’ll have many opportunities for in-depth

technical conversations with other engineers to spark new ideas, and

you’ll be able to talk with suppliers about your specific challenges and the solutions they offer. Bring your questions—and leave with smart new solutions to solve your most pressing technical problems.

SEE WHO’S EXHIBITING AT IFPE.COM CIRCLE 232

INTERNATIONAL FLUID POWER EXPO MARCH 10-14, 2020 LAS VEGAS, NV, USA

SHOW OWNERS:

CO-LOCATED WITH:

Whether You’re Digging for Coal or Drilling for Oil…

Yates Cylinders Keep You Powered up and Running Because when you’re searching for treasure, you can’t afford to waste any time. The challenging businesses of running oilfields and mines place some pretty hardcore demands on cylinders. From oil rigs to hydraulic hammers - and everything in between - you need reliability and durability to keep operations running smoothly. The versatile Yates Welded Heavy (WH) series features cylinders used specifically in these demanding industries. Our welded cylinders live up to the standards of quality that customers have come to expect from Yates Industries for over 45 years. Plus, Yates works closely with many companies to help solve their cylinder failures, first determining the cause and in many cases recommending upgrades for a rebuilt cylinder. The process not only eliminates the original problem, it also offers an extended life for the cylinder at a fraction of the cost of a new one. With three regional locations offering full service capabilities and around-the-clock service, Yates is one of the largest and most complete cylinder manufacturing and repair companies in the country. See what we can do for you.

Yates Industries Inc.

Yates Cylinders Alabama

Yates Cylinders Georgia

23050 Industrial Dr. E. St. Clair Shores, MI 48080 Phone: 586.778.7680 Fax: 586.778.6565 sales@yatesind.com

55 Refreshment Place Decatur, AL 35601 Phone: 256.351.8081 Fax: 256.351.8571 decatur@yatesind.com

7750 The Bluffs Austell, GA 30168 Phone: 678.355.2240 Fax: 678.355.2241 salesga@yatesind.com

www.yatesind.com CIRCLE 211

IN THIS ISSUE

OCTOBER 2019

VOLUME 26 • ISSUE 10

Features 7 Assemble a Hydraulic Pilot-Operated Pressure Relief Valve 8

LVDT Position Sensors Enable Next-Gen Hydraulics and Robotics Working in Extreme Environments

10 Sheet Metal to Egg Crate Foam – Selecting the Right Vacuum Cup

12 Motion + Power Technology Expo 2019 Expands to Meet Demand 23 Strategic Vacuum Cup Economics 30 Can You Dig It? High-productivity Mine Invests in Hydraulic Drives 34 2019 Salary Survey Results are in!

30 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.

37 Air/Oil Tandem Actuators: A Control-Emphasized Solution

Departments 4 6 18 26 33 38

Notable Words Compressed Air Systems Product Spotlight IFPS Update Figure It Out Classifieds

CIRCLE 212

N OTA B L E WO R D S

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

Here’s to the Next 25 By Robert McKinney, Associate Publisher, Fluid Power Journal

AS I REFLECT upon this year with Fluid Power Journal thus far, my mind travels back to last fall when we were planning for the 2019 Editorial Calendar. We set three goals—the first of which was to reach out to more of fluid power’s ever-increasing markets such as civil engineering, food processing, and the medical industry. We quickly realized that we needed to publish the Fluid Power Journal monthly in order to engage these markets. It would also guarantee that there would be no communications gap with our subscribers. We also decided to increase the frequency of our digital offerings to a monthly basis as well. Another goal that we had was for the Journal to increase its relevance to the fluid power audience by “telling our clients’ stories.” We embarked on an aggressive Sponsored Content program with both print and digital offerings. We added new features such as the Component Showcase section that focuses on a specific product category, and the Ask The Expert section, where companies can share their expertise on a particular topic so as to help our readers solve their problems. We also rejuvenated our white paper and video programs with dedicated pages on our website, www.fluidpowerjournal.com. Additionally, we started a very popular Targeted Display Advertising program that reaches out to the fluid power audience

Congratulations to

1st Place Winner - Don DeRose who won a $100 Amazon card, and 2nd Place Winner - Ines Boehnert who won a $50 Amazon card. Thank you for your participation in the Fun Facts Crossword Puzzle from the August 2019 issue. 4

OCTOBER 2019

through a digital programmatic platform. We also further developed our Creative Resources program that helps companies define and support their brand strategy. Our third objective in 2019 was to celebrate the Fluid Power Journal’s 25th Anniversary with our readers and clients. We decided to celebrate throughout the entire year with our Then & Now articles in all the issues about changes in fluid power technology and best practices. This culminated in our official 25th Anniversary issue in August. From the Notable Words column written by our founders to the 25-year timeline of our magazines’ growth to the Then & Now feature about advances in fluid power over the last 25 years by our Technical Editor, Dan Helgerson, to our very interesting Fun Facts Crossword Puzzle section, the August issue “told the entire story” of the Fluid Power Journal. Our vision now continues with this issue’s Salary Survey and Motion & Power Technology Expo guide, November’s focus on forestry and wood processing, and our December’s Tech Directory. It has been a wonderful and challenging ride for the fluid power industry the last 25 years. Now we can look forward to another exciting 25 years of growth and challenge as the Fluid Power Journal commits to being an even greater resource to the fluid power professional community. 

CROSSWORD USE THE FUN FACTS ON THE LEFT PAGE AND THE ARTICLES IN THIS ISSUE FOR A CHANCE TO WIN TO FILL OUT THE PUZZLE. PRIZES, SCAN OR TAKE A PICTURE OF THIS COMPLET EMAIL IT TO ART@FLU ED PUZZLE AND IDPOWERJOURNAL.COM. DEADLINE FOR SUBMISS ION IS AUGUST 31, 2019.

2 4

ACROSS

Name the author of the Journal's "Figure It Out" column.

This year, the IFPS Annual Meeting will be held in this city. 6 Which trade show will be held at the Kentucky Exposition Center in October? 7 Name the author of the "Vacuum Pick and Place" 10 What is the last name of the two founders of the Fluid Power Journal? 13 Name one of the two main types of compressors discussed in Ron Marshall's article. 14 Pat Byce's article is focusing on which processing manufactur ers? 15 This company was founded because another bellows company burned down. 17 This company is featured in the Then and Now column. 21 Which company wowed the IFPS with their Fluid Power Professionals' Day celebration? 22 Fluid Power Journal was born as the brainchild of this association. 23 This company's modular valves was used in a famous movie of the 1980s. 24 Which company patented first adjustable shock abs the orber?

DOWN

1 This company's name originated from combining their two founders' names. 3 The Fluid Power Journal is celebrating how many years in the industry? 5 How many fluid power ha ll of fame inductees are there? 7 This author wrote the "25 Years" article and is also the Technical Editor of the Fluid Power Journal. 8 This company's heritage dates back to the invention of air valves. 9 This company's founder is still active in business now. 11 This company changed name to reflect the growits ing product offering. 12 This company has the third

Founders: Paul and Lisa Prass Associate Publisher: Bob McKinney Editor: Candace Nicholson Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Art Director: Quynh Fisher Eastern Region Acct Executive: Norma Abrunzo Western Region Acct Executive: Cindy Hamm Director of Creative Services: Erica Montes Accounting: Donna Bachman, Sarah Varano Circulation Manager: Andrea Karges INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org 2019 BOARD OF DIRECTORS President & Chairperson: Timothy M. White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM - The Boeing Company Immediate Past President: Dean Houdeshell, PE, CFPAI/AJPP, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM - Cemen Tech Inc. First Vice President: Jeff Kenney, CFPIHM, CFPMHM, CFPMHT - Hydradyne, LLC Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. Vice President Certification: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC Eaton Corporation Vice President Marketing & Public Relations: Scott Nagro, CFPS HydraForce, Inc. Vice President Education: Kenneth Dulinski, CFPAI/AJPP, CFPECS, CFPHS, CFPMIH, CFPMMH - Macomb Community College Vice President Membership: Rocky Phoenix, CFPMHT, CFPMHM - Open Loop Energy, Inc. DIRECTORS-AT-LARGE Chauntelle Baughman, CFPHS - OneHydrauics, Inc. John A. Bibaeff, Jr., CFPHS, CFPCC - Lamb Services, Inc. Randy Bobbitt, CFPHS - Danfoss Power Solutions Cary Boozer, PE, CFPE, CFPS - Motion Industries, Inc. Elisabeth DeBenedetto, CFPS - Argo-Hytos Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. Garrett Hoisington, CFPAI, CFPS, CFPMHM - Open Loop Energy, Inc. James O’Halek, CFPAI/AJPP, CFPMM, CFPCC - The Boeing Company Edwin Rybarczyk, CFPAI/AJPP, CFPS - E. R. Consultants, Inc. Scott Sardina, PE, CFPAI, CFPHS - Waterclock Engineering Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPS - Northrop Grumman Corp. HONORARY DIRECTORS Paul Prass - Innovative Designs & Publishing Elizabeth Rehfus, CFPE, CFPS, Robert Sheaf, CFPAI/AJPP - CFC Industrial Training IFPS STAFF Executive Director: Donna Pollander, ACA Communications Manager: Adele Kayser Technical Director: Thomas Blansett, CFPS, CFPAI Certification Logistics Manager: Susan Apostle Certification Coordinator: Kyle Pollander Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk

Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published bi-monthly with four supplemental issues, including a Systems Integrator Directory, Off-Highway Suppliers Directory, Tech Directory, and Manufacturers Directory, by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs or manuscripts.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

CIRCLE 213

COMPRESSED AIR SYSTEMS

Compressed Air Maintenance By Ron Marshall, Marshall Compressed Air Consulting

LIKE ANY INDUSTRIAL equipment, the air compressors, dryers and associated components on your compressed air system need occasional attention. It is very tempting to stay out of that dark, hot and dirty compressed air room, especially if the air compressor is running trouble-free, but maintain the system you must. Maintenance intervals can be stretched for a while, but it usually comes back to haunt you in the end, like the old Fram oil filter commercial says, “Pay me now or pay me later.” If you have compressors that run continuously, you need to be especially diligent. It is often quite easy to relate the oil changes of your compressor lubricant to the oil changes for your own personal vehicle, thinking infrequent oil changes are acceptable, but for a compressor that runs all the time, it is important to ensure the lubricant stays in good condition, requiring timely changes to

The compressed air system in this food processing plant is contaminated with lubricant due to failure of filtering elements.

the compressor oil, often more frequent than you would expect. Air compressor lubricant for oil-injected screw compressors is fairly expensive, but for a few good reasons. The duty inside a screw compressor is not normal. The lubricant reduces friction in the internal parts, like all lubricants, but it is also in direct contact with compressed

Stops Leaking

FlangeLock™

HYDRAULIC LINES SAVE TIME SAVE MONEY SAVE LABOR SAVE OIL For more information contact Mike Pearl at 203.861.9400 or email: sales@flangelock.com

• • • • • • • • • •

No tools required No expensive hardware needed No more rags stuffed into hoses No more messy plastic caps The ultimate contamination control tool One hand installation Eliminate hydraulic oil spills & clean up Quick installation & ease of usage Safe for personnel & environment Industry acclaimed

100% This product is Patented, other Patents pending.

CIRCLE 214

OCTOBER 2019

www.flangelock.com

air at high pressure, exposing it to the negative effects of oxygen. The oil is also used as a coolant, carrying away the heat of compression. It captures particles of dirt that are sucked into the compressor and get past the inlet filter, reducing its quality. And it traps the condensed moisture that forms when air is compressing, contaminating it further. Compressor lubricants have additives to prevent oxidization and to extend its life in these harsh conditions, but these measures only last for so long. Once the lubricant reaches the end of its lifetime, if pushed beyond normal, damaging deposits will start to form inside the compressor that will clog up bearing and cooling surfaces with varnish. Its only a matter of time before overheating, bearing wear, and oil carryover cause major rebuild costs, or worse, the total failure of the compressor. SOME TIPS ABOUT COMPRESSOR MAINTENANCE: • Compressor lubricant failure is a major cause of problems with air compressors. Do not skimp on regular and timely oil changes with high-quality lubricant. lubricant and inlet filters need reg• Compressor ular replacement. Think twice about buying inexpensive replacement filters from third parties. Always ensure any filter meets the required extreme duty for air compressors. screw compressors, the condition of the • For oil separator is quite important. Failure of this item can cause high quantities of compressor lubricant to pass downstream so regular maintenance is required, as well as timely replacement. • Compressor coolers must be kept clean, and ambient conditions reduced to a cool environment as much as possible. The major output of an air compressor is heat, overheating the compressor lubricant greatly reduces the life of the lubricant and causes premature compressor failures. main and fan motors need to be • Compressor kept clear of debris as clogging of internal cooling air passages will lead to early failure. compressed air filters and water drains • Keep well-maintained so contaminants do not pass downstream. 

Visit www.compressedairaudit.com. Join the LinkedIn discussion group: Compressed Air Efficiency WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

A HYDRAULIC PILOT-OPERATED PRESSURE RELIEF VALVE Relief valves are used to limit maximum pressure in hydraulic systems. When system pressure begins to exceed the pressure setting of the relief valve, a controlled amount of hydraulic fluid by-passes through the relief valve to the tank port and limits the system pressure to the valve setting. The two basic types of relief valves are direct acting (simple) and pilot operated (compound). Several important terms must be understood with respect to the operation of relief valves. These are: cracking pressure, full-flow pressure, and reseat pressure. • Cracking pressure - pressure at which the poppet valve unseats. • Full-flow pressure - pressure at which a relief valve diverts full flow to the reservoir. • Reseat pressure - pressure at which a relief valve closes after being open. In a simple relief valve, a spring holds the poppet against a seat. When system pressure is high enough to overcome the spring force, the poppet moves off the seat to allow fluid flow through the bypass. The spring compression is set so that the poppet opens to divert sufficient flow to limit the pressure to the preset value. In a compound relief valve, a light spring holds the main stage piston so that the discharge port is normally blocked. A small amount of fluid flows past the main stage piston through an orifice in the main piston to the pilot stage of the relief valve. The pressure of the fluid on the pilot valve exerts a force on the pilot valve poppet. If the force exceeds the spring force, the poppet is unseated, allowing a small amount of fluid to flow through the drain. The vent port on a ventable pilot-operated remote control valve may be used as a remote control or plugged if not used. The pressure drop resulting from flow past the pilot valve poppet is experienced on the back side of the main stage piston, and the piston shifts, opening the valve. In operation, the compression on the pilot stage spring is adjusted so that the main stage piston opens at a specified pressure. As with all precision machined components, care must be exercised when assembling a pilot-operated relief valve. Cleanliness is of the utmost importance. Components, particularly the balanced piston, should be lubricated with clean oil prior to assembly. The cap or pilot section of the valve must be carefully aligned over the piston. Some relief valves use locator pins to ensure alignment. Bolts must be torqued properly. Operation of the valve should be tested before placing the valve back in service. If the valve fails to function properly due to piston binding, the cap may be loosened and tapped gently to achieve proper alignment. Bolts must be retorqued following this adjustment. 

DIRECT ACTING

PILOT OPERATED

Direct Acting and Pilot Operated Relief Valves (Also called balanced piston, compound, or two stage valves) (Courtesy of Eaton Corporation)

TEST YOUR SKILLS

What would happen if the pilot orifice in the main piston of a pilot-operated relief valve became plugged? a. Valve would function normally. b. Valve would never open. c. Valve would work normally, but would only divert a small amount of fluid to the tank port. d. Increasing the pressure on the pilot stage spring would decrease the cracking pressure of the valve. e. Valve would open once, then remain open.

What do you do with the vent port on a pilotoperated relief valve? a. Connect to tank above fluid level. b. Connect to tank below fluid level. c. Use as a remote control port. d. Always use a gauge port. e. Vent to atmosphere.

Visit page 38 for the solutions.

CIRCLE 215

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

POSITION SENSORS

Enable Next-Gen Hydraulics and Robotics Working in Extreme Environments By Mike Marciante, Business Development Manager, NewTek Sensor Solutions

Hydraulic and robotic systems are performing more often in areas with temperature, pressure, and radiation extremes. Withstanding these environments is the goal for the next generation of instrumentation and sensors these systems rely on. Many hydraulic and robotic systems require linear position sensors that operate reliably under continuous high pressures and temperatures while fitting into restrictive spaces. Hydraulics with linear sensors used in oil drilling and material testing now operate in temperatures sometimes exceeding 400°F (204°C), and pressures approaching 30,000 psi (2068 bar). Robotics and automated equipment in nuclear power plants and clean-up zones operate in radiation environments now exceeding 30 MRad. For the next generation of hydraulic and robotic systems, LVDT linear position sensors offer many benefits—chief of which is excellent measurement quality—while operating reliably in high temperature, pressure, and radiation exposure.

LVDT TECHNOLOGY THAT MAKES IT POSSIBLE LVDTs are non-contact sensors, meaning that the housing containing the windings and the core never need to touch. This frictionless operation gives LVDTs infinite mechanical life, making them ideal for applications where replacement costs can be high and long-term reliability is key. Available with a lightweight, low-mass core and a compact diameter as small as 0.188 inches (4.7 mm), LVDTs can be miniaturized, well-suited for high-response dynamic measurement required in hydraulic and material testing systems where space is at a premium. Beneficial when compared to other linear position sensing technologies, LVDTs are AC-operated with no on-board printed circuit board (PCB) for signal processing or conditioning, allowing them to operate in very high pressures. In vented designs specialized for embedding in hydraulic systems, holes expose the coils inside the sensor to the fluid. Since the sensor is completely immersed, even rapid spikes in pressure will not cause damage to the LVDT during operation. Any fluid to which the LVDT is exposed must be electrically non-conductive and chemically benign, which is a very common trait among hydraulic fluids and oils, so vented LVDTs are compatible for immersion into most hydraulic systems. The absence of on-board electronics enables production of these sensors with radiation-hardened materials that will not become brittle or decay when exposed to radiation. These are able to withstand total integrated flux of 30 MRad, and even 100 MRad in some cases. 8

OCTOBER 2019

TAKING ROBOTICS INTO RADIATION “HOT” ZONES Renewed interest in nuclear safety and space travel for governmental and commercial purposes will send more robots to places with elevated radiation exposure. Rovers, tools, and other robotic machinery traveling through space or in orbit may encounter direct sun exposure and radiation without the protection of the Earth’s atmosphere. When they are commissioned into service, accurate position feedback is key from robotic actuators that are controlling sensitive operations, experiments, or repairs. Radiation hardened LVDTs operating in vacuum and cryogenic conditions are rugged and dependable enough to survive the journey into space. While there, they deliver high quality position feedback with infinite resolution and fast response times, as is often required by these systems. Radiation-hardened robots are working here on Earth too. They have been used to clean up contaminated sites all over the world, including present-day Ukraine, Japan, the U.S., and throughout Europe. Sites of nuclear incidents and retired uranium enrichment plants have all benefited from robots going in areas where humans cannot. These robots gather information to create maps of hazard zones, while also transporting or breaking up contaminated debris and fuel rods. Actuators and position sensors enable their legs, working arms, and grippers. Radiation-hardened LVDTs coupled to these actuators deliver a fast position feedback response to the robots’ controls, allowing them to move very precisely and smoothly. Built to withstand even heavy exposures to 100 MRad, the use of these position sensors can help prolong the service life of these robots, often tasked with projects spanning years or decades. WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

DEEP BELOW THE SURFACE Oil reserves are now being extracted from previously inaccessible locations. Access to these reserves involved exposure to temperatures and pressures legacy machinery could not withstand. On next-generation multi-directional drills, LVDTs are being used to deliver position feedback used to accurately control the actuators setting the drill’s direction. Within existing wellbores, multi-finger calipers are used to accurately profile the walls to identify signs of fatigue or abnormalities. Multi-finger calipers extend their arms to make contact with the walls. Within the caliper, the fingers are mechanically linked to an LVDT that measures their position as they travel through the bore. The LVDT readings are transmitted to the surface so the wellbore can be accurately profiled. Each of these critical operations employ LVDT position sensors designed to be embedded in hydraulic fluid up to 30,000 psi (2068 bar) and over 400°F (204°C). Because of the reliability of LVDT technology, the sensor itself can remain operational for the lifetime tools and equipment that use them. The ability to remain rugged and reliable with an infinite mechanical life, as well as high temperature and pressure designs, have made LVDT position sensors the preferred selection in the most demanding and cutting-edge requirement in robotics and hydraulics. 

“

I need smart valve systems that support multiple protocols.

We Talk Your IoT Performance Get reliable, IoT-ready control with advanced valve systems from Emerson. Rely on our AVENTICS™ family of pneumatic Advanced Valves (AV) — compact, lightweight and easily configured for your application. Combine them with AVENTICS Advanced Electronic System (AES) to put smart technology to work for your connected facility. Find the robust control technology you need at www.Aventics.us/AVvalves

CIRCLE 216

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

Sheet Metal to Egg Crate Foam –

SELECTING THE RIGHT

Vacuum

CUP

By Mike Parzych, Product Marketing Manager, IMI Norgren

Vacuum – the difference in atmospheric pressure on one side of a vacuum cup and the other – has been used in robotics and traditional manufacturing for decades to move objects and materials. Now collaborative robots (cobots) are making automation more affordable and accessible for smaller, more versatile operations like mixed product assembly or order fulfillment, creating more opportunities than ever to use vacuum. And where there is vacuum, there are vacuum cups to connect the vacuum source with the object being moved. So how does one select the right cup?

Cup size and type

Vacuum can lift all sorts of materials, even those with rough or uneven surfaces, if the right cup is used.

Force equals pressure times area To begin, there are three basic factors to consider when using vacuum: force, pressure, and area. Force is the weight of the object being moved, multiplied by a safety factor. Pressure is the expected vacuum level – the negative pressure or suction created by the pump. Area is the size of the contact between the vacuum cup and the object. This is where vacuum exists. The basic calculation, Force = Pressure x Area, defines the starting point for choosing a cup and using vacuum to move a load.

Non−porous objects For flat non-porous surfaces like this rigid plastic bowl, a flat vacuum cup does the job.

The force generated depends on both the vacuum level and on the area. The vacuum pump generates the suction and the cup transfers that power to the object. Both vacuum level and cup configuration are variables a designer can control. The larger the cup, the lower the pressure required of the pump, meaning less energy is consumed to generate the vacuum. Conversely, increasing the pressure delivered by the vacuum pump makes it possible to use smaller cups if needed to accommodate the shape of the product being picked up.

OCTOBER 2019

Cups sizes are identified by cup diameter, so once the desired area is known, refer to manufacturers’ specifications for the appropriate cup size. Differences in application requirements can guide a decision between using a large diameter cup with a lower vacuum level or a smaller cup with a large vacuum pump (for example, to meet space or size limitations). Cup types include bellows, multi-bellows, round oval, flat with or without cleats, and cups with removable fittings or permanent fittings. To choose the right type of cup, consider the characteristics of the object being picked up. Is it non-porous or porous? Is it flat, irregularly shaped or flexible? In general, use flat cups for flat objects and bellows cups for irregular objects. Every situation is unique, but some examples of typical materials in industrial applications serve as a starting point.

To use vacuum for picking up objects with solid, non-porous surfaces, knowing force, pressure, and area is enough. The vacuum is created and contained between the cup and the object and full force is achieved and maintained until the vacuum is released. Examples of non-porous materials include steel, glass, laminated chipboard, and rigid plastic. Flat cleated cups are widely used for non-porous applications because the rigid, low-profile design means they resist peeling away. Some non-porous objects, for example large sheets of thin metal, may bend slightly. In a case like WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

this, using multiple pliable bellows cups ensures that all the cups make full contact with the sheet as it bends.

Porous or uneven surfaces These may include corrugate, woven materials, or objects with extremely rough or uneven surfaces. When handling porous materials, it is important that the flow path between the object and the vacuum pump is large enough to allow the pump to draw in the air that leaks through the surface (e.g., cheesecloth) or from gaps between the cup and the surface (e.g., corrugated cardboard). Because no complete seal is formed between the cup and the object, free air will continue to flow through the pump.

Different combinations of vacuum pumps and bellows cups can be used to lift porous materials like this cardboard. The pump needs to be large enough to draw in the air that continues to flow through the porous surface, but oversizing a pump wastes energy.

The balance here is generating the required vacuum force and flow, and optimizing compressed air consumption. There are a variety of pumps and cup types to help optimize flow, but in the end, it often requires trial and error to fine tune a process to the right flow.

Flexible materials When handling flexible materials, for example wraps used in packaging, it is critical that the pump cup, fitting, and vacuum line are large enough to handle the required flow. Flexible materials wrinkle, causing large, unpredictable leak paths. The cup and pump must be sized to accommodate a high leak rate. The bore of the fitting must be close to half the diameter of the cup to allow for large flows. The good news is that, typically, flexible materials are not heavy. Calculating cup holding force precisely may not be required. A cup with a very thin, flexible lip will more easily conform to the wrinkled material. Multi-bellows cups work well because they are so flexible. With so many variables involved with flexible materials, consider sending a sample of the material to a cup supplier for testing so they can make pump and cup recommendations.

Versatility Vacuum cups can be made from a variety of materials. Some popular materials include vinyl, polyurethane, chloroprene, nitrile, silicone or natural rubber. Each material has different working temperatures, durometers, and resistance to oil or water. Vacuum is extremely versatile and can be used to do things no other technology can do. It is highly controllable and since it exerts negative pressure instead of pushing WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Flexible materials like this plastic wrap wrinkle, allowing substantial unpredictable leakage. A bellows cup with a thin, flexible lip will more reliably conform to the material.

Vacuum is highly controllable so it can be used to lift delicate, irregular objects as easily as large, heavy materials.

or pressing, it can be used to move delicate or irregular materials as well as large, heavy objects. Today’s wide variety of cup designs, sizes, and materials means that designers can access the advantages of vacuum for a wider variety of applications than ever before. 

CIRCLE 217

OCTOBER 2019

OCTOBER 15-17, 2019 DETROIT, MICHIGAN TCF CENTER

2019 EXPANDS TO MEET DEMAND T

he Motion + Power Technology Expo (MPT Expo) connects the top manufacturers, suppliers, buyers, and experts in the mechanical and gear power, electric power, and fluid power industries for three action-packed days in Detroit’s TCF Center. Attendees can shop the latest technology, gear products, and services, and compare benefits side-by-side while gaining best practices and new ideas from like-minded colleagues as well as cross-sector collaboration. More than 300 exhibitors from across the supply chain including gear companies, machine tools suppliers, and electric drive solutions will conduct demos, host information-rich seminars, and offer technical expertise. Some of the industry leaders showcasing new products and services include Timken Power Systems, Meritor, EMAG LLC, Gleason Corporation, Kapp Group, Mitsubishi Heavy Industry America, among others. Fluid power industry professionals can learn from 16 subject matter experts on the latest topics affecting their fields, including cybersecurity, supply chain, 3-D printing, robotics, and more in a two-track seminar series called the MPT Conference. The Expo will also offer the American Gear Manufacturers Association (AGMA) Fall Technical Meeting and short course technical seminars hosted

by AGMA and the National Fluid Power Association in several education courses. The education courses provide exclusive access to a wide-ranging series of technical seminars taught by industry leaders and insiders. From novice to expert, there are courses for all career-levels. Each course is conveniently situated just steps from the MPT Expo floor — so you can combine classroom learning with hands-on experience with the equipment. This one-of-a-kind trade show and conference will also bring 4,000 professionals together to exchange insights and network with colleagues from across the mechanical power transmission, fluid power, and electrical drive industries during receptions, private meetings, one-on-one time with suppliers, and exchanges in the education sessions throughout the show. Expanded to three days due to popular demand, the MPT Expo (formerly known as the Gear Expo) provides an evolving motion and power transmission marketplace. Additionally, top researchers from across the globe will provide the latest information on their peer-reviewed gear industry research and share what is in the future for the industry. The conference is designed for both thinkers and doers, bringing speakers who will provide the most current information and unmatched opportunities to make connections and shop the latest products, services, and technologies for the highly focused motion + power system audiences, including a unique Fluid Power Pavilion. Throughout the Expo, exhibitors represent a variety of fields, including automotive, material handling, machine tool manufacturing, agriculture, automotive, off-highway, construction, and more. Just a few days spent meeting with experts will help keep businesses ahead of the curve for years to come.

FLUID POWER EXHIBITORS

For a complete list of all exhibitors and floor map, visit www.motionpowerexpo.com. Alro Steel & Plastics........................................................................ 2628 ASCO Sintering Co.......................................................................... 3237 Casappa Corp.................................................................................. 2734 Cleveland Deburring Machine Co................................................... 3435 Delaware Manufacturing Industrial Corp. (DMIC)......................... 2535 Donald Engineering......................................................................... 2536 Dura-Bar.............................................................................. 2937 Fanuc America Corp....................................................................... 3536 Federal Fluid Power, Inc.................................................................. 4626 Filtrec North America, Inc............................................................... 3437 Fluidyne Fluid Power............................................................ 2631 Follett Hydraulics............................................................................ 2739 Galdabini SpA.................................................................................. 3339 Hoffman Filter Corp........................................................................ 3022 Hydra-Lock Corp............................................................................. 3944 Hydrapulse........................................................................... 2831

OCTOBER 2019

IC Fluid Power, Inc........................................................................... 2539 International Fluid Power Society.......................................... 2834 IPM, Inc............................................................................................ 3240 National Fluid Power Association.......................................... 2731 OEM Controls, Inc........................................................................... 3803 Peninsular Cylinder Co................................................................... 2835 Premier Thermal Solutions............................................................. 4039 R & J Cylinder and Machine............................................................ 2936 SCHUNK........................................................................................... 3231 Techniques Surfaces USA, Inc....................................................... 2839 Timken Steel Corp........................................................................... 3431 Tribute, Inc....................................................................................... 2733 TTP-API Heat Transfer.................................................................... 2531 Tuson Corp...................................................................................... 2934 Yates Cylinders.................................................................... 2636 Fluid Power Journal advertisers are in bold.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

M+PTE CONFERENCE SESSIONS WEDNESDAY, OCTOBER 16 9:00 AM – 10:00 AM Supply Chain — Improve In-Transit Visibility to Reduce Supply Chain Risk Jeff Newman, VP, Supply Chain Visibility Solution Sales, CalAmp Advances in IoT technology provide greater visibility and insights through real-time data and monitoring to eliminate tracking blind spots across providers and modes. IIoT — Simplifying Industrial IoT for Discrete Manufacturers Stacy Pease, Director of Customer Success, MachineMetrics The IoT revolution is picking up speed and as it does, it is changing the manufacturing world forever. Of the many manufacturers in pursuit of digitization, a large number are unlikely to succeed. What’s the secret sauce to Industry 4.0 success?

10:30 AM – 11:30 AM Market Info — Economic Outlook and Trends within the Industrial Fluid Power Market Chloe Parkins, Fluid Power Specialist, Oxford Economics The aim of this session is to provide an understanding of the economic backdrop faced by industrial fluid power manufacturers and purchasers. Electric Drive Technology — The Future of eMobility in the Commercial Vehicle Space John Bennett, VP and CTO, Meritor Commercial vehicles are currently undergoing a shift in powertrain technologies driven by the need for lower GHG emissions and the desire for lowest total cost of ownership.

2:00 PM – 3:00 PM Blockchain — Blockchain: The Future of Manufacturing Joel Neidig, CEO and Co-Founder, SIMBA Chain Blockchain has many manufacturing applications. Automotive supply chains are one of several useful cases that will be discussed for this topic.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

3D Printing — Processes and New Machines for 3D Printing Metal Kirk Rogers, PhD, Senior ADDvisorSM, The Barnes Group Advisors The additive manufacturing/3D metal printing scene has exploded in the last three years with several new players and several new technologies. Kirk will outline the seven different additive manufacturing technologies, as defined by ASTM Committee F42.

3:30 PM – 4:30 PM Supply Chain — Effective Contract Negotiations: The Path to Commercial Success with Large OE Customers Tom Rouse, Founder, Rouse Contract Consultants, LLC Robotics — The End of Fear: How Collaborative Industrial Robots Will Change Durable Goods Manufacturing Alberto Moel, PhD, VP, Business Development, Veo Robotics

THURSDAY, OCTOBER 17 9:00 AM – 10:00 AM Market Info — The Evolution of the Automotive Powertrain Casey Selecman, Director – Advisory Services, IHS Markit IIoT — Standards for IIoT Interoperability Russ Waddell, Director, MTConnect Manufacturing data and information systems are rapidly evolving to enable myriad new technologies around software and networking. Underlying this evolution is a set of standards and protocols developed by industry, academia, research organizations, and governments.

10:30 AM – 11:30 AM Workforce — Workforce Development Using a Farm Team Approach Tony Velotta, Organizational Development Leader, Scot Forge There is a significant deficit in the number of workers needed and the number

available to most companies. Scot Forge Company has a program to develop the future workforce to be ready when needed similar to major league sports teams using a farm team concept. Electric Drive Technology — Losing Teeth? The Future of Gear Trains in the Age of Electrification Jeff Hemphill, CTO, Schaeffler The rate of electrification seems to be accelerating every day. Major OEMs make regular announcements about battery electric vehicles and Tesla continues to disrupt its segments.

2:00 PM – 3:00 PM Cybersecurity — Cybersecurity Hygiene in Motion James McQuiggan, CISSP, Chapter President, (ISC)2 Central Florida Chapter When it comes to hygiene, we grew up understanding what is good hygiene, washing our hands before dinner, brushing our teeth before bed, and taking a shower at least every other day. In cybersecurity, similar hygiene can be applied to our daily lives that can help not only at home, but also in the places we work. 3D Printing — Materials Challenges and Solutions in Additive Manufacturing Jeff Grabowski, Materials Specialist, QuesTek Innovations, LLC

3:30 PM – 4:30 PM Workforce — Hire Like Nobody’s Business Todd Palmer, Founder and President, Diversified Industrial Staffing Companies cannot locate enough of the talent they need today. This translates to missed deadlines and to company leaders trying to do more with less. There is a solution. Robotics — Collaborative Operation in Industry Today Rick Maxwell, Collaborative Robot Team, FANUC America Corporation In order to successfully implement and use collaborative technology, it is important to understand what collaborative operation is and how it can fit into your facility.

OCTOBER 2019

M+PTE TECHNICAL MEETINGS MONDAY, OCTOBER 14 1:00 PM – 5:00 PM TECHNICAL SESSION I: APPLICATION, DESIGN, AND RATING MODERATOR: JASON DAUBERT, FLSMIDTH, INC. Electric Vehicle Transmissions with Hypoid Gearset (19FTM01) Dr. Hermann Stadtfeld, The Gleason Works This paper presents a new design concept which utilizes a super reduction hypoid with a ratio between 8 and 15. Misalignment Compensation Splines Design (19FTM02) Davide Marano, Ferrari (Italy) Crowned spline teeth are frequently used to avoid interferences between

shaft and hub teeth. Currently, a precise determination of the misalignment and crowned teeth influence on spline load capacity can only be performed by finite element method, (FEM), or other powerful numerical simulations. This paper proposes an analytical model. Spline Centering, Piloting, and Toggle: Torsional Stiffness, Shaft Bending, and Centering of Moment Loads (19FTM03) Steve McKenny, General Motors Company Common practice for a splined joint is to assume that the load is theoretically transmitted along the entire length of the tooth face, but several factors, including axial spline length and the ratio of hub to shaft torsional stiffness, can impact how the load is distributed along the tooth face. Optimal Polymer Gear Design: Metal-to-Plastic Conversion (19FTM04) Dr. Alexander Kapelevich, AKGears, LLC Unlike machined metal gears, polymer

gears produced by injection molding allow for a deep optimization of gear tooth macro and microgeometry. Design of a Double Spiral Bevel Gearset (19FTM05) Horácio Albertini, CEFET MG, Federal Center of Technological Education of Minas Gerais (Brazil) The most common bevel gear geometries are straight, spiral, and helical (skew), and all these types of gearset subject the bearings to three types of forces, namely: axial, radial, and tangential. This paper presents a double spiral bevel gear design. Specific Dynamic Behavior of Planetary Gears (19FTM06) Burkhard Pinnekamp, RENK AG (Germany) This paper describes theory of noise generation in a gear mesh and the specific application on planetary gear systems. The results are illustrated by an example with test bench measurements.

FLOW EZY FILTERS Magnetic Filtration

Flow Ezy Filters Magnetic Filtration

Magnetic filtration operating principle: It is the most effective means of removing ferrous particles from industrial fluids.  For pressures up to 1160 psi  High intensity rare earth magnetic material filtration operating principle: It is the most effective means  Sub-micron filtrationMagnetic of removing ferrous particles from industrial fluids.  Suitable for all machining • Foroperations pressures up to 1160 psi • Environmentally • High intensity rare earth responsible  Environmentally responsible magnetic material • No consumables • Sub-micron filtration • Can be cleaned in 30  No consumables • Suitable for all machining seconds (tools included) operations  Can be cleaned in 30 seconds (tools included) Ann Arbor, MI, USA Flow Ezy Filters Ann Arbor, MI, USA Phone: (800) 237-1165 Phone: (800) 237-1165 flowezy@flowezyfilters.com flowezy@flowezyfilters.com www.flowezyfilters.com www.flowezyfilters.com CIRCLE 218

OCTOBER 2019

CIRCLE 219

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

TUESDAY, OCTOBER 15 8:00 AM – 12:00 PM TECHNICAL SESSION II: EFFICIENCY, LUBRICATION, NOISE, AND VIBRATION MODERATOR: WALT WEBER, FLENDER CORPORATION (RETIRED) Phase Management as a Strategy to Reduce Gear Whine in Idler Gear Sets (19FTM07) Robert White, John Deere Gear whine is controlled by managing transmission error. Idler gear sets affect gear whine by phasing the meshes. This paper shows how, by cleverly selecting the number of teeth on the idlers, their tooth thicknesses, and the idler location, the forces from transmission error force vectors that must be reacted by the idler bearings can be substantially reduced, thereby reducing the excitation on the gearbox that causes noise.

Reduction of the Tonality of Gear Noise by Application of Topography Scattering for Ground Bevel Gears (19FTM09) Marcel Kasten, Laboratory of Machine Tools and Production Engineering (WZL) of RWTH Aachen University (Germany) Computing Gear Sliding Losses (19FTM10) Caleb Gurd, Eaton Corporation *2018 recipient of an AGMA Foundation scholarship. This paper evaluates eight different algorithms available in the literature for determining coefficient of friction and calculating gear sliding loss, and their applicability to commercial vehicle transmissions. Opportunities of Efficiency Improvement by the Use of Hydro Lubricants (19FTM11) Matthias Pfadt, Kluber Lubrication Muchen SE & Co. KG (Germany) The majority of industrial lubricants are based on mineral oils. Hydro Lubricants, which use water either as a base oil or as an additive, offer a more sustainable solution and are potential candidates for a wide range of industrial applications.

1:30 PM – 5:00 PM TECHNICAL SESSION III: MATERIALS AND HEAT TREATMENT MODERATOR: MICHAEL HE, SCOT FORGE Evaluation of Steel Cleanliness by Extreme Value Statistics and its Correlation with Fatigue Performance (19FTM12) Trishita Roy, Eaton India Innovation Centre (India) Tooth Root Testing of Steels with High Cleanliness (19FTM13) Moritz Trippe, Laboratory of Machine Tools and Production Engineering (WZL) of RWTH Aachen University (Germany) 4D High Pressure Gas Quenching: A Leap in Performance vs. Press Quenching (19FTM14) Tom Hart, SECO/VACUUM Performance and Properties of New, Alternative Gear Steel (19FTM15) Lily Kamjou, Ovako AB (Sweden)

Driving the FUTURE of Fluid Power • Electro-Hydraulic Power on Demand • Up to 70% More Energy Efficient • 66% Smaller than Traditional Systems • Less Complex – Easier Integration • Directional and Proportional Control • Fully Integrated Pump, Motor, and Controller f • Power Options from 1.5 to 30 kW

CIRCLE 220

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

T WEDNESDAY, OCTOBER 16 8:00 AM – 12:00 PM

Influence of Manufacturing Variations of Spline Couplings on Gear Root and Contact Stress (19FTM18) Hareesh Balakrishna Kurup, Eaton Technologies Pvt. Ltd. (India) This study investigates how manufacturing variations of spline couplings affect AM gear – TUESDAY, OCTOBER 15 | 9:00 performance.

A Comparison of Surface Roughness Measurement Methods for Gear Tooth Working Surfaces (19FTM21) Matthew Wagner, Applied Research Laboratory — Pennsylvania State University

EXHIBIT HALL HOURS

6:00 PMPM – 5:00 PM 1:30

WEDNESDAY, OCTOBER 16 | 9:00 AM – 5:00 PM TECHNICAL SESSION V: Micro Skiving — (r)evolution of a Known

OPTIMIZATION, GEAR WEAR, THURSDAY, OCTOBER 17 | 9:00 AM – 4:00 PM Production Process (19FTM19)

TECHNICAL SESSION IV: Hervé Baour, Louis Belet SA (Switzerland) MANUFACTURING, INSPECTION, AND QUALITY CONTROL Rapid and Precise Manufacturing of MODERATOR: MIKE D’ARDUINI, THE To search a complete list of exhibitors by Special Involute Gears for Prototype GLEASON WORKS Testing product (19FTM20) category, visit Christian Weber, Gear Research Center (FZG), Chamfering of Gears — New Innovative Technical University of Munich (Germany) Cutting Solutions for Efficient Gear In this paper, alternative methods for a fast Production (19FTM17) and cost-efficient production of asymmetric Gottfried Klein, Gleason Corporation (Germany) gears for prototype tests are presented.

AND FAILURE MODERATOR: FRANK UHEREK, REXNORD GEAR GROUP

name or

MotionPowerExpo.com

Air Compressors

Clean Dry Air Improves Performance... Clean, Dry Compressed Air Starts with The Extractor/Dryer® Manufactured by LA-MAn Corporation • Point of Use Compressed Air Filter to Improve and Extend Equipment Life • Removes Moisture and Contaminates to a 5-Micron Rating: Lower Micron Ratings are Available

Effects of the Load-Dependent Shift of Gear Center Distance on Calculated Load Capacity and Excitation Using Analytical Mesh Stiffness Approach (19FTM22) Dr. Stoyan Radev, FVA GmbH (Germany)

• Differential Pressure Gauge Built in • Mounting Hardware Included for Easy Installation

• Weep Drain is Standard; Float Drain or Electronic Drain Valves Optional

Calculated Scuffing Risk: Correlating AGMA 925-A03, AGMA 6011-J14, and Original MAAG Gear Predictions (19FTM24) John Amendola, Artec Machine Systems

Andrew Milburn, Milburn Engineering, Inc. This paper explains why case hardening is beneficial and the risks involved, and compares the methods for calculating and specifying case depth per the ISO 6336-5 and ANSI/AGMA 2101-D04 gear rating standards and guidelines presented in the MAAG Gear Handbook. Sizing of Profile Modifications for Asymmetric Gears (19FTM26) Dr. Ulrich Kissling, KISSsoft AG

CIRCLE 221

OCTOBER 2019

Each know

New Standardized Calculation Method of The Tooth Flank Fracture Load Capacity of Bevel and Hypoid Gears (19FTM23) Josef Pellkofer, Gear Research Center (FZG), Technical University of Munich (Germany) A newly developed standardized calculation method for determining the tooth flank fracture load capacity based on the geometry of virtual cylindrical gear according to the standard ISO 10300 will be explained in detail.

Your MPT Expo badge gives you access to the co-located 2019 ASM International • Models with Flow Ranges of 15 SCFM Optimum Carburized and Hardened to 500 SCFM Rated Up o 250psi are recognized by Heat Treating Society Conference & TExposition, industry, academia, Case Depth (19FTM25) Standard and government professionals as the premier heat treating event in North America.

This provi Netw ques

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

M+PTE EDUCATION SESSIONS TUESDAY, OCTOBER 15

THURSDAY, OCTOBER 17

8:00 AM – 12:00 PM

Hydraulic Fluid Properties, Efficiency, and Contamination Control Paul Michael, Research Chemist, MSOE

Taming Tooth Deflections: The Case for Profile Modifications Raymond Drago, P.E., Drive Systems Technology

Supply Chain Management Dr. Justin Jones, Ranken Technical College Technical Overview of Automotive Differentials William Mark McVea, KBE+, Inc.

1:00 PM – 5:00 PM Overview of Fluid Power Components and Systems Thomas Wanke, CFPE Director, Fluid Power Industrial Consortium and Industry Relations, MSOE Technical Overview of Automotive Powertrain Lubricants William Mark McVea, KBE+, Inc. Why Bearings Are Damaged ABMA

WEDNESDAY, OCTOBER 16 8:00 AM – 12:00 PM Fundamental Understanding of Electro Fluid Power Technology Dr. Medhat Khalil, CHFPS, CFAPI, Director of Professional Education and Research Development Gearbox Field Inspection — Load Distribution, Lubrication, and Condition Monitoring John B. Amendola, John B. Amendola III, and Dereck Yatzook, Artec Machine Systems

Durable

8:00 AM – 5:00 PM Basics of Gearing William Mark McVea, KBE+, Inc. Materials Selection and Heat Treatment of Gears AGMA and ASM International

1:00 PM – 5:00 PM Loaded Tooth Contact Terry Klaves

Precise

Flexible

Ultra Versatile Edge Welded Bellows

ISO 9001:2015 Certified

By offering OEM manufacturers valuable features like high strength stainless steels, the lowest leak rates and highest cycle life, BellowsTech can supply finished products sooner without compromising design.

Rugged enough to use as: • Vibration dampener • Mechanical seals • Shielding devices • Flexible conduits • Linear actuators

FREE Design Engineering Assistance

Order Bellows Online!

8:00 AM – 5:00 PM Basics of Gearing William Mark McVea, KBE+, Inc. Reverse Gear System Engineering — Why, When, and How Raymond Drago, P.E., Drive Systems Technology

bellowstech.com/shop CIRCLE 222

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

SPECIAL AD SECTION

PRODUCT SPOTLIGHT Pneumatic Cylinders, Pneumatic Assemblies, Grippers, Vacuum Cups Introducing—9S Series Investment Cast Swivels The "9S" Series swivels represent one of the most complete range of sizes and configurations available to industry. This series has been redesigned to incorporate a one-piece barrel arrangement, thus eliminating the need for braze joints. These swivels are pressure balanced with operating pressures up to 5,000 psi. All configurations are designed with a 4:1 Safety Factor and include RoHS compliant zinc plating.

MOCAP manufactures an extensive range of protective closures to guard pipes, hoses, and hydraulic fittings from dirt, moisture, and damage to help maintain equipment reliability. Included are a variety of sizes and styles of Threaded and Non-Threaded plastic Caps and Plugs for Metric, NPT, BSP, JIC and SAE Threaded Connections, Ports and Fittings. These are in addition to MOCAP’s already extensive lines of low-cost Caps, Plugs, Grips, Netting, Tubing and Tapes for general Product Protection, Finishing and Masking. All of our stocked items are ready for immediate shipment and available in Box, Mini-Pack and Micro-Pack quantities. Free Samples are always available for testing purposes.

P.O. Box 6479 • Fort Worth, TX 76115 V. 817/923-1965 • www.hydraulicsinc.com

sales@mocap.com www.mocap.com

CIRCLE 234

CIRCLE 235

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

Protection for All Things Hydraulic, Pneumatic and Fluid Power

OCTOBER 2019

CIRCLE 236

New OEM Miniature Parallel Gripper The PHD Optimax® Series OGZ Pneumatic Miniature Parallel Grippers feature an integral linear guide for high rigidity and precision. They are available in four sizes with base dowel mounting for accurate locating and standard magnets on pistons for externally mounted switches and fulfill a variety of applications. 800.624.8511 phdinfo@phdinc.com www.phdinc.com/ogz CIRCLE 237

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

SPECIAL AD SECTION

Vac Cubes Multi Venturi Vacuum Pumps With over 30 years of proven results Vac Cubes and our multi stage venturi vacuum pumps are a great fit for your vacuum application. They are designed to provide higher vacuum flows with less air consumption. Multiple models available with maximum vacuum up to 27”hg and vacuum flows up to 25CFM and the ability to manifold together.

info@vac-cube.com 727.944.3337 www.vac-cube.com CIRCLE 239

Hydraulic Noise and Shock Suppressor Electro-Hydraulic Smart Pumps • • • • • •

Up to 70% More Efficient 66% Smaller than Traditional Systems Less Complex — Easier Integration Directional & Proportional Control Fully Integrated Pump, Motor, Controller Models from 1.5 to 30 kW

Wilkes and McLean manufactures an In Line Noise and Shock Suppressor for hydraulics and is a stocking distributor of Nacol Accumulators. Our suppressors eliminate pulsations, which greatly reduces noise and vibration from applications from a few gallons up to 200 gallons. We stock all of our suppressor sizes as well as Nacol Accumulators and parts from 1/5 of a pint up to 15 gallons, in our Schaumburg, Illinois facility. 877.534.6445 info@wilkesandmclean.com www.wilkesandmclean.com

www.hydrapulse.com • info@hydrapulse.com +1 916-245-9660

Suppressor

Accumulators

CIRCLE 240

CIRCLE 238

VacMotion introduces a new line of long-lasting general-purpose flat suction cups. Above and Beyond Products and Services The shortest mini slide on the market, our DGST series is a powerful twin-piston actuator that features a recirculating ball bearing guide, high feed forces and symmetrical mounting interfaces. Its slide and yoke plate make up one single part— ensuring high rigidity, precision and angular alignment. Slides feature two sensor slots and integrated proximity sensors so there are no projecting parts.

Visit Festo.us for more information. CIRCLE 241

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

VacMotion's newest style of suction cups with internal cleats are designed for lifting flat or slightly curved materials such as cardboard, sheets of wood, metal and other soft porous materials. The internal cleats prevent deformation of the item being handled, and their high resistance to lateral forces allows the handling of loads vertically. These cups are available in NBR, FDA Silicone, HNBR, and Viton with outside diameters of 10mm to 77mm.

Order online or call us at 866-554-2877. We are a proud member of PMMI. www.vacmotion.com CIRCLE 242

OCTOBER 2019

SPECIAL AD SECTION

Save time, Save Money, SWIFTFIT. Machinery in most facilities come from different parts of the world, creating a problem identifying thread type. This creates multiple costly challenges from increased repair time to damaged components. Not anymore! The Aignep USA SWIFTFIT works with most common thread types in the industry. Before the thread pitch changes, SWIFTFIT seals using our form fitting sealing technology eliminating the need for any pipe tape or sealant. Save time, save money, SWIFTFIT. www.aignepusa.com 615-771-6650

Stainless Steel Flange Type Ball Valves Inserta® Products Flange Type, 2-Port Ball Valves, Stainless Steel, provide a simple means to install a ball valve in a circuit that uses SAE J-518 4-bolt flange patterns in both Code 61 and Code 62 patterns. Internal and external metallic components are stainless steel for use in corrosive environments, or with fluid media that would typically be incompatible with the materials of the standard Inserta® IBF Flange 2-Port Ball Valves. These valves are designed for high pressure service with a 4:1 safety factor to burst. Fastener clearance holes are compatible with either UN or metric fasteners. Product is available to ship from stock. Inserta® Products Blue Bell, PA • www.inserta.com • 215.643.0192

CIRCLE 243

CIRCLE 244

Contact us to showcase your products and services in the Product Spotlight. This special section is a high-profile area offering productspecific advertising. Visit fluidpowerjournal.com for more information or to view our media guide.

Go ahead. Push me. Ordinary heavy duty not heavy enough? Heavy-Duty Mill Cylinders for: • Induction-Hardened, Chrome-Plated Rods • Heavy Wall Tubing • Replaceable Glands & Retainer Rings • High-Load Piston Design Think indestructible and call Yates. www.yatesind.com Corporate 586.778.7680 Alabama 256.351.8081 Georgia 678.355.2240 CIRCLE 245

VIAIR 450-IG Compressor P/N 45050 – 150 PSI / 1.80 CFM – (12V) P/N 45058 – 150 PSI / 2.20 CFM – (24V) VIAIR Corporation, an ISO Certified company, is the leading manufacturer of fractional horsepower DC air compressors, known in the industry for providing consistent, reliable, and durable products along with excellent customer service & support. VIAIR’s Industrial Grade (IG) compressors are widely used as the vital air source in various pneumatic applications, which can be found in a wide assortment of fluid power based systems. VIAIR’s 450C-IG compressor is available in both 12 volt and 24 volt options, with an impressive Duty Cycle of 100% @100 PSI and a maximum working pressure of 150 PSI. All VIAIR IG compressors have been tested and certified to an Ingress Protection (IP) rating of 67, and feature outstanding sealing properties that stand up against the elements. Phone: 949-585-0011 Email: sales@viaircorp.com www.viaircorp.com/industrial CIRCLE 246

OCTOBER 2019

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

SPECIAL AD SECTION

Parker P2M Industrial Ethernet

Manual Valves with Limit Switches Valves with limit switches provide interlock security for critical manual valves in your process system. Limit switch feedback on critical manual valves will provide control systems the ability to prevent automated valves or pumps from turning on if the manual valve with limit switch is not in the correct position. A variety of limit switches are available to meet your area classification: NEMA 4X, NEMA 7 explosionproof and bus protocols.

https://assuredautomation.com/manual-valves/?p=MVWLS

With the introduction of a cost efficient Industrial Ethernet network node, Parker enables its partners to increase productivity and profitability, while reducing complexity. Connected valve technology enables better machine-to-machine control in a cost-effective way.

To learn more visit: www.parker.com/pdn/P2M_IE CIRCLE 248

CIRCLE 247

Metal Bellows Ideal for Mechanical Feedthroughs! Genuine Donaldson Internormen-Eaton Velcon-Parker We're hydraulic filter experts. We've been doing it for over 30 years. We're very competitive and happy to serve your needs. If you need hydraulic filter application help, we know the right questions, and we can give you the right answers. J/T Hydraulics & Service Co. Inc. 1601 W. 25th Street • Houston, TX 77008 Local: 713.984.9727 • Toll Free: 800.591.8280 Fax: 713.861.2250 • www.jthydraulics.com

The BellowsTech proprietary diaphragm manufacturing process creates high yield, high strength bellows allowing movement of a tool within a sealed environment under vacuum or positive pressure. BellowsTech can customize size, shape, material, weight, length, and mounting connections to fit any assembly. Learn more.

bellowstech.com/products/applications/ mechanical-feedthroughs CIRCLE 250

CIRCLE 249

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

SPECIAL AD SECTION

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 • Quick installation & ease of usage • Safe for personnel & environment • Industry acclaimed

Now Available! Full MTRs and Lot Traceability MAIN Manufacturing Products, Inc. now offers full MTRs and lot traceability on all common flanges. Carbon, stainless, and coppernickel alloy are available. If not part of our 7000+ in-stock products, MAIN can manufacture and ship quickly. 4-5 days is common from our US facility.

Contact Mike Pearl at 203.861.9400 or email sales@flangelock.com www.flangelock.com

MAIN Manufacturing Products, Inc. Phone: 800.521.7918 • E-mail: info@mainmfg.com

CIRCLE 251

CIRCLE 252

CIRCLE 223

OCTOBER 2019

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

STRATEGIC VACUUM CUP

By Dane Spivak, Davasol

Figure 1

The following is an opinion article written by Dane Spivak of Davasol Incorporated, an industrial brand management firm with many clients. This article is written in partnerhsip with one client, Vacuforce LLC, based in Indianapolis, Indiana, USA. The example numbers enclosed have been arbitrarily chosen and do not reflect a real-life company financial situation. If you have any questions, contact Dane Spivak at dspivak@davasol.com.

INTRODUCTION

CONTROVERSIAL CUP SELECTION Depending on the product surface to be gripped or lifted, there are many different vacuum cups that can provide a good seal. If we consider a piece of glass, for example, there are thousands of cup models that can seal against its flat smooth surface. Alternatively, creating a cup seal on a bag proves to be more challenging and limits available choice. However, there are still many models that can do the job. So how do we choose the ideal cup? More often than not, machine builders or vacuum cup users select a particular cup simply because it was readily available in stock. The easy choice is to use a familiar model that is on hand, and as long as it provides a decent seal, all is well. So generally speaking, not much thought is put into this process. Then, the cup is implemented into the production line, but its durability might become a liability. Since

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Figure 2

It is widely accepted and understood that vacuum cups are a consumable product by nature. A vacuum cup may last many months or only a day or two. Although vacuum cups in general are not often seen as a substantial corporate expense, they can possibly incur a larger cost than one would expect. This article discusses the significance of vacuum cup selection and how it ties into the overall cost within a business. We will also touch on how to select an appropriate vacuum cup model based on economic and production needs.

vacuum cups may need replacement—some as often as every day—using a long-lasting cup can be crucial, especially if you are a high-volume user. The following offers recommendations in strategy for identifying the best cups for the application.

BUILDING BLOCKS TO INCREASE CUP LIFE Vacuum cups come in all shapes, sizes, and materials. These features play an important role in the performance and longevity of the cups. Let’s start by analyzing the cup style. Figure 1 shows three styles including flat, single bellows, and multiple bellows. Intuition tells us the flat cup provides a sturdier and more secure grip on the product whereas the multiple bellows cup is not as stable. The bellows creates more stress on the cup body and lip. This concept suggests that a cup with more bellows is typically not as durable. So to increase cup life, flat cups are ideal, or if possible, reduce the number of bellows.

The cup lip thickness affects its life too – refer to Figure 2. Since this is the point of contact with the product, it is certainly a critical factor. For the most part, thicker cup lips last longer. A vacuum cup will have its lip wear away until it can no longer provide a satisfactory seal. At that point, the cup needs to be changed. Lower quality cups can crack at the lip or bellows. This is an indication that the cup is not being used to its full potential as it is prematurely breaking instead of wearing away. This is often referred to as work hardening. Material selection is arguably the primary characteristic in determining cup durability. Various cup materials are used, but the most commonly supplied are foam, vinyl, silicone, NBR, and polyurethane. This is in respective order of average cup life from shortest to longest; foam being the quickest to wear and polyurethane, arguably, the most durable. The cup features influence each material, though considering like-for-like models this rule of thumb applies. The product being gripped can also “fight back” against the cup material and cause it to wear quicker. For example, chemicals or high/low temperatures can reduce the cup life of NBR or polyurethane, and so silicone may offer longer life instead since it has a high chemical resistance and temperature range. The quality of material can have a tremendous influence on cup durability. Numerous suppliers manufacture the most common industry models, however, each offers different life expectancies. This is due to the quality of material, manufacturing techniques, and mold conditions.

OCTOBER 2019

A quick note about color. The color of a vacuum cup does not affect its life as it is simply a dye used in the manufacturing process. This is often misunderstood as specific materials tend to be linked to their common dye color.

COST VS DURABILITY PARADOX Everyone likes a good deal to save money. Each purchasing decision is an investment and the price tag is usually front and center. However, our obsession with getting the best deal can often cloud the big picture results. Vacuum cups, being a wearable item, gives us a new perspective and approach to its investment. Table 1 compares three different cups and their yearly financial impact. Total Yearly Cost = Cost Each x Yearly Usage Cup1 = $6.00 x 1200 = $7,200 Cup2 = $10.00 x 400 = $4,000 Cup3 = $18.00 x 300 = $5,400 Table 1 suggests that Cup2 is the best investment. Although it costs more than Cup1, it lasts longer so the overall yearly cost is lower. Cup3 offers better durability, but its increased life expectancy does not outweigh the overall yearly cost compared to Cup2. So in this closed parameter analysis, we can crown Cup2 as the winner. However, there are other effects on vacuum cups that can come into play.

DOWNTIME IMPACT All manufacturing sectors experience downtime or scheduled maintenance, and everyone has the same interest: minimize the occurrences and time frames. Depending on the industry and manufacturing process, the impact can be drastically different. A large company that runs a three shift, 24-hour operation, with each process relying on one another for productivity, would value downtime much more. Let’s first consider how to reduce downtime when physically replacing a vacuum cup. One key feature can make a significant difference. Figure 3 shows two types of vacuum cups. One

Figure 3

OCTOBER 2019

Table 1 – Comparing vacuum cup finances Model

Cost Each

Expected Life

Yearly Usage

Total Yearly Cost

Cup1

$6.00

1 month

1200pcs

$7,200

Cup2

$10.00

3 months

400pcs

$4,000

Cup3

$18.00

4 months

300pcs

$5,400

Table 2 – Factoring in yearly downtime due to cup interchanges Model

Yearly Cup Cost

Yearly Downtime Cost

Total Cost

Cup1

$7,200

$18,000

$25,200

Cup2

$4,000

$6,000

$10,000

Cup3

$5,400

$4,500

$9,900

Table 3 – Including reliability cost averaged over a five-year period Model

Yearly Cup Cost

Yearly Downtime Cost

Yearly Reliability Cost

Total Cost

Cup1

$7200

$18,000

$12,000

$37,200

Cup2

$4000

$6000

$4,000

$14,000

Cup3

$5400

$4500

$3,000

$12,900

with a loose fitting and the other with the cup molded to the fitting. The loose model offers a distinct advantage for replacing cups as it can be pulled off the fitting, then have a new one pushed back on—an easy, quick interchange. However, the molded cup assembly fitting needs to be unscrewed, and of course, the new cups need to be threaded in and tightened with a tool: a lengthier process by comparison, which can be quite time consuming when replacing multiple cups on a few tools. Pull-off-and-push-on cup assembly fittings are ideal for ease of maintenance and should be used if possible. However, molded cup assembly fittings are sometimes all that is available particularly for larger vacuum cups. There are many contributing factors, but the primary costs of downtime include production loss, labor costs, and time. Table 2 uses the same data from Table 1 to compare the three cup models. In this example, we will consider all cup models to have equal time needed for interchange, and therefore the frequency of changing out the cups determines downtime cost.

Downtime Cost = (Production Loss + Labor Cost) x Interchange Time Production Loss = $1,300 per hour Labor Cost = $200 per hour Interchange Time = 1 hour Downtime Cost = ($1,300 + $200) x 1 = $1,500 per interchange Yearly Downtime = Downtime Cost x Number of Yearly Interchanges Yearly Downtime Cup1 = $1,500 x 12 = $18,000 Yearly Downtime Cup2 = $1,500 x 4 = $6,000 Yearly Downtime Cup3 = $1,500 x 3 = $4,000 Contrary to Table 1, Table 2 suggests that Cup3 is the better financial choice. Not only that, but less frequent cup changeouts create peace of mind. The human and reliability aspects can incur their own set of costs.

THE LIABILITY OF RELIABILITY Reliability of a vacuum cup is arguably the most important feature. We discussed cup life, which over time can be very predictable, but what

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

about instances when cups fail unexpectedly? It’s a rare occurrence, but cups can fail due to external influenced damage, cracking, falling off its fitting, and other situational anomalies. In turn, it can result in damaged product, broken machines, and even worse, injured workers. These are considered “what-if” scenarios and are generally immeasurable, but should not be overlooked. For the most part, cups with higher durability are usually more reliable. But it is important to choose a cup that offers a confident seal, and ensure the machine is adjusted and designed to work effectively with the chosen cup. Table 3 includes a reliability cost associated with the points discussed above and demonstrates additional cost savings with Cup3. It also provides an understanding of the potential large gap in overall costs between Cup1 and Cup3. It is difficult to designate a specific dollar value to reliability cost as it is unpredictable and can incur larger values from a single incident. Our theory is that cups with shorter life pose greater liability and therefore will result in higher costs. The following example is a hypothetical situation for each cup model based on a five-year period. Yearly Reliability Cost = (Total Production Loss + Total Machine Repairs)/Time Time = 5 years Cup1 Total Production Loss = $48,000 Cup1 Total Machine Repair = $12,000 Cup1 Yearly Reliability Cost = ($48,000 + $12,000) / 5 = $12,000 per year average Cup2 Total Production Loss = $16,000 Cup2 Total Machine Repair = $4,000 Cup2 Yearly Reliability Cost = ($16,000 + $4,000) / 5 = $4,000 per year average Cup3 Total Production Loss = $12,000 Cup3 Total Machine Repair = $3,000 Cup3 Yearly Reliability Cost = ($12,000 + $4,000) / 5 = $3,000 per year average

We Make Valve Automation Easy!

Automated Valves from Stock Built, Tested, Shipped - Same Day

Compact On/Off Valves

High-Cycle Ball Valves

For Lower Pressure Water, Oil, Gas, and Steam OEM’s, integrators, and factories all over the world are turning to Assured Automation’s compact on/off valves and high-cycle ball valves to improve machine reliability and increase productivity.

See the complete range of valves at:

/FPJ

CIRCLE 224

Inserta

Stainless Steel Flange Type 2-Port Ball Valves NOW Available

CONCLUSION This article covered strategies to increase vacuum cup durability and how to interpret long-term cup costs. With this analysis we have found that cup model selection and price can have a greater effect on the financial impact than one would expect. Although this is a subjective recommendation, it is based on actual experiences in a production environment. To ensure you choose the right cup for your application, a professional evaluation is recommended. 

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

I F P S U P D AT E

Self-paced Online Training

Members Only $109.00

The ULTIMATE resource for hydraulic, pneumatic, and motion control professionals

EACH ONLINE COURSE delivers a broad-based understanding of the most important fluid power subject matter concepts. Courses begin with the basics: physics laws, systems basics and design, basic analysis, and basic components, then demonstrates how these systems apply to our industry and how they work and interact with each other. Each online training course features approximately 12-16 hours of trade-specific e-training filled with simulations, assessments, quizzes, tests, learning labs, and more. Completion of the online training courses does not constitute IFPS Certification; however, after completion of the course, you may be better prepared to take an IFPS certification test.

• • • • •

ONLINE COURSES OFFERED: Mobile Hydraulics Course* Industrial Hydraulics Course ** Industrial Mechanical Course * Mobile Electrical Course * Industrial Pneumatics Course *

• Industrial Electrical Course * • Electrical Theory * • AC/DC Motors and Drives * • Diesel Engines * • PLC Fundamentals +

*available in metric, ** available in metric, Spanish, and Spanish (metric), + available in Spanish

Visit Training/Resources at www.ifps.org.

Fluid Power

Reference Handbook FIRST EDITION

New Fluid Power Reference Handbook to be Released in 2020

THE IFPS IS in the process of developing a new Fluid Power Reference Handbook. The ultimate resource for hydraulic, pneumatic, and motion control professions will include: • Full-color graphics • ISO 1219 Compliant Symbology • Color-coded Table of Contents and Index • Glossary of Terms • Troubleshooting Algorithms • General Safety Guidelines

New!

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

Up to 6,000 PSI Operating Pressure—Coupled or Uncoupled Full 4:1 Safety Factor Superior Flow Characteristics—Minimal Pressure Drop RoHS Compliant Plating Multiple Port Options—Female NPTF, Female SAE O-Ring, Female BSPP, Code 61 & 62 Flange Port/Head P.O. Box 6479, Fort Worth, TX 76115 V. 817/923-1965 www.hydraulicsinc.com CIRCLE 226

OCTOBER 2019

CIRCLE 227

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

Newly Certified Professionals ELECTRONIC CONTROLS SPECIALIST (ECS)

Ken Mieding, Motion EFX Michael Frain, Walt Disney Company HYDRAULIC SPECIALIST (HS)

Kenneth McCloud, General Dynamics Land Systems Daniel Scharplaz Dennis Ball II, J.H. Fletcher Company James Whitlow, DuPont Jarrod Sheetz, Kaman Fluid Power Jordan Treharn, Parker Hannifin Corporation Jeremy Raines, J.H. Fletcher Company Michael Dagefoerde, Kaman Michael Lamothe, Motion Industries, Inc. Scott Maher, Kaman Fluid Power Donald Bucci, S.G. Morris Co. MOBILE HYDRAULIC MECHANIC (MHM)

Austin Smith Adam Wood, AEP

(July 2019)

Benjamin Skidmore, American Electric Power Co. Brad Sanekane, Altec Industries, Inc. Brent Kremer, Duke Energy Broc Denroche, Altec Industries, Inc. Chad Redman, American Electric Power Co. Henry Garza, Altec Industries, Inc. Daniel Tidwell, Altec Industries, Inc. Edgar Mendoza, Altec Industries, Inc. Ernesto De La Garza, Altec Industries, Inc. Espen Cleveland, Altec Industries, Inc. Jesse Lashmett John Dye Jonathan Williams Jimmy Alfaro, Altec Industries, Inc. Joshua Smithson, American Electric Power Co. Joseph Fisher, Altec Industries, Inc. Joshua Montgomery, Duke Energy Jacob Falabella, American Electric Power Co. Juan Loza, Altec Industries, Inc. Justin Lang, Duke Energy Jerry Billings, AEP

Kevin Sides, American Electric Power Co. Kurt Girardot, American Electric Power Co. Leonel Ochoa, Altec Industries, Inc. Martin Matthews, American Electric Power Co. Marc Canevari, Altec Industries, Inc. Matthew Studer, Duke Energy Phillip Treutlein, American Electric Power Co. Jason Poppert, Altec Industries, Inc. Mickey Paxton, Altec Industries, Inc. Shayne Schlosser, Altec Industries, Inc. Scott Goble, Duke Energy Shawn Bland, Duke Energy Olliver Baxter, Wilson Const. Shae Jordan, American Electric Power Co. Timothy Schneider, Altec Industries, Inc. Tyrel Tullis, Altec Industries, Inc. Vincent Lavaroni, Altec Industries, Inc. Zachary Haynes, American Electric Power Co. MOBILE HYDRAULIC TECHNICIAN (MHT)

Jacob Lane

THIS IS PRODUCTIVITY P2M Industrial Ethernet

Lowering Costs Easy Diagnostics Integrated Connectivity

CIRCLE 228

WWW.IFPS.ORG â&#x20AC;¢ WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

I F P S U P D AT E

Certification Testing Locations ndividuals wishing to take any IFPS written certification tests can select from 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).

TESTING DATES FOR ALL LOCATIONS: November 2019 Tuesday 11/5 • Thursday 11/21 December 2019 Tuesday 12/3 • Thursday 12/12 January 2020 Tuesday 1/7 • Thursday 1/23 February 2020 Tuesday 2/4 • Thursday 2/20 March 2020 Tuesday 3/3 • Thursday 3/26

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

OCTOBER 2019

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

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

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

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

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

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

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

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Certification Review Training In-house Review Training – an IFPS Accredited Instructor will come to your company (minimum 10 individuals) HYDRAULIC SPECIALIST (HS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details November 4-7, 2019 - Eden Prairie, MN - hydraulicstraining@eaton.com | Written test: November 8, 2019 March 23-26, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: March 26, 2020 April 20-22, 2020 - Mukwonago, WI - wanke@msoe.edu | Written test: April 23, 2020 September 14-17, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: September 17, 2020 ELECTRONIC CONTROLS (ECS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details August 10-13, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: August 13, 2020 PNEUMATIC SPECIALIST (PS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details December 3-6, 2019 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: December 6, 2019 July 13-16, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written test: July 16, 2020 CONNECTOR & CONDUCTOR (CC) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details May 18-19, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: May 20, 2020 November 16-17, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: November 18, 2020 MOBILE HYDRAULIC MECHANIC (MHM) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details Online Mobile Hydraulic Mechanic Certification Review (for written test) offered through info@cfcindustrialtraining.com. This course takes you through all chapters of the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written MHM test. Members receive 20% off. (Test fees are additional - separate registration required.) April 14-16, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: April 17, 2020 September 21-23, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: September 24, 2020 INDUSTRIAL HYDRAULIC MECHANIC (IHM) CERTIFICATION Onsite review training for small groups – contact kpollander@ifps.org for details August 3-4, 2020 - Fairfield, OH - info@cfcindustrialtraining.com | Written and JP test: August 6, 2020 INDUSTRIAL HYDRAULIC TECHNICIAN (IHT) CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio MOBILE HYDRAULIC TECHNICIAN (MHT) CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio PNEUMATIC TECHNICIAN (PT) and PNEUMATIC MECHANIC CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio JOB PERFORMANCE (JP) TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Online Job Performance Review - CFC Industrial Training offers online JP Reviews which includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members may e-mail askus@ifps.org for a 20% coupon code off the list price or get the code in our Members Only area for the entire IFPS Job Performance Review; test not included. LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details E-mail info@cfcindustrialtraining.com for information.

OCTOBER 2019

can you dig it? HIGH-PRODUCTIVITY MINE INVESTS IN HYDRAULIC DRIVES By Ashok Amin, Hägglunds, Market Segment Manager, Bosch Rexroth

The air is filled with dust, and the large, heavy rocks pound the equipment hard. Only the toughest survive at the Aitik mine. Boliden therefore takes great care in selecting suppliers for its new crushing plant. “We make sure we only use suppliers that have experience in this field. This applies to all the investments we have made in recent years, but this project has given us the best results so far,” says Jörgen Larsson, Project Manager at Boliden. 30

OCTOBER 2019

Visitors to Sweden’s biggest open-pit copper mine are greeted with an impressive sight in Gällivare. The entire Empire State Building could stand on the floor of the mine without reaching above its rim. Way below, some of the largest machines in the world are crawling about: excavators with a bucket capacity of 45 cubic meters and rock trucks capable of

carrying more than 300 tons, with wheels that are a full four meters in diameter. The ore deposits in Aitik contain a copper ore called chalcopyrite, as well as some gold and silver. The ore is refined to produce a concentrate that feeds Boliden’s own smelting works. The rock waste, or overburden, is removed from the pit and sold for road-building and concrete production, for example.

Aitik is not only the largest open-pit copper mine in Sweden, but also the most productive in the world. This is thanks to largescale production, highly efficient methods, and a high degree of automation. “We can process more low-grade ore than many other mines because of our efficiency. We actually have lower input levels than many other mines have in waste,” says Larsson.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

STRATEGIC INVESTMENTS FOR GROWTH The Aitik mine has set a long-term goal to raise production from 36 to 45 million tons of crushed ore by 2020. To achieve this growth and improve the consistency and reliability of production at the same time, Boliden has invested in a completely new crushing plant with two spindle crushers. In its annual report, the company states that this massive investment will ensure “more reliable production planning, lower maintenance costs, better predictability and better profits.” “Right now we are getting a good price for what we produce. That gives us the opportunity to invest. But one big challenge is that we are greatly increasing the area of mining, which also involves high costs. We constantly have to finetune our mining operations so that we can increase production using our existing equipment. The new crushing plant will enable us to do that,” says Larsson. Obtaining the permit to expand also placed big demands on the ecological sustainability of the Aitik mine. “We are leading the way environmentally. This will allow us to ramp up production. The measures we have taken range from electric vehicles to energy recovery and

ecological compensation areas,” shares Larsson, who stresses that the company is constantly raising its commitment to the environment.”

a plant to be proud of Larsson has a great deal of experience in the industry. He has done everything from operating mining machinery to supervising maintenance and installation. He has supervised the crushing project and been involved in commissioning. “It’s fantastic that we have been able to invest in a totally new plant, where everything is well-planned and we have plenty of access to the equipment.” Larsson is especially pleased with the completely new feed system. “We originally had inclined apron feeders. They were unreliable in every way. These are the first conveyors that are completely horizontal. And they look great!” The feed system was designed by Metso in the U.S., and is a proven design with many systems already in use around the world. Metso Minerals adapted the system to suit the particular needs of the Aitik mine. This work was done in close collaboration with Bosch Rexroth, which supplied four CBM hydraulic Hägglunds motors.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

CURIOUS ABOUT HYDRAULIC DRIVE One of the reasons why Boliden decided to invest in apron feeders with direct hydraulic drive was frequent problems with gearboxes. Another was curiosity. “We had many gearbox breakdowns over the years and wanted to improve availability. This will be a test of hydraulic technology. I have seen Hägglunds drives in various reference installations around the world, and during my investigations, I did not hear of any negative experiences. My visit to the factory in Mellansel was also incredibly interesting. I gained a new understanding of how hydraulic systems work.”

In addition to improved availability, Boliden set high demands on the performance of the equipment. Then, Metso drew up a specification of requirements based on two motors that share the load on each feed unit, with a capacity of 8,000 tons per hour, a variable speed of 0–7.46 rpm and a starting torque of around 1,000,000 Nm. The solution offered by the Hägglunds specialists at Bosch Rexroth was two CBM 2000–1400 motors per apron feeder. It was a welcome solution that easily met the requirements. “We wanted to have some power in reserve, so that’s good. It gives OCTOBER 2019

SUCCESS FACTORS FOR THE PROJECT us a maximum capacity of 9,000 tons per hour. It also gives us redundancy for all the main components, so we can drive with one motor if needed,” explains Larsson.

The new plant was commissioned in June and the Aitik mine is now running at full production capacity. “After a few weeks of testing, we went on summer vacation. I was away for five weeks and everything

worked perfectly! The plant has now processed more than six million tons of ore and there has not been a single incident. The fact that production is running so smoothly at this early stage is an excellent result. Especially when the plant was custom-built specifically for our needs.” The drive systems take up minimal space and allow fast replacement of components, thanks to the splined couplings. Larsson reckons they make installation incredibly easy. “The main benefits are that we have improved availability while reducing maintenance costs. The hydraulic drives provide better access from the sides and make the plant easier to maintain. The way things are looking now, we won’t need to work on them, but

if we do have to replace anything we have really good access. Another big advantage is that we can reverse the hydraulic drives during maintenance.” All that remains to do now is a few small adjustments and performance tests. Boliden will take both crushers and drive systems up to maximum load and check that they produce the tonnage required. A big part of the performance testing is to ensure that the plant can meet availability targets over the course of a month. “It all looks good so far. If this turns out well and gives us improved reliability, we will probably use hydraulic drive technology elsewhere. For our big conveyor systems in particular, the Hägglunds drives are definite contenders,” says Larsson with satisfaction. 

Suction Cups for Packaging & Robotics

Since 2006, VacMotion has become North America’s “in stock” source for suction cups. We offer direct replacements to many brands on the market as well as custom designs you won′t find anywhere else - all at very competitive prices.

Visit us today at www.vacmotion.com or call 866-554-2877 Located in “America’s Hometown” Plymouth, Massachusetts CIRCLE 229

OCTOBER 2019

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

FIGURE IT OUT

New Problem:

Noisy Pump Causing Foam to Escape Through the Filler Breather

olution to the previous problem: Ink Mixing Machine Speed Problems

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

The source of the problem of adjusting the speed of one mixer blade and how it affects the speed of other blades turned out to be the compensator setting on the pump. It was set at 1,000 PSI and just needed to be set an additional 100 PSI to resolve the issue. Apparently, due to the lack of good documentation, when the pump was replaced, the team set the speeds and pump pressure to what worked for the normal consistency inks and not for the occasional thicker mixtures.

I WAS CALLED to troubleshoot a foaming problem on a system that had the pump-motor unit mounted on top of the tank. When I got there, I was surprised that a root beer-like foam indeed was oozing from the filler breather cap and the pump was very noisy. Closer inspection showed that the foaming was worse when the pump was unloaded back to tank. I felt the pump noise was caused from the foaming problem, and the pump shaft seal showed a slight leaking problem when the unit was turned off. Any idea what’s the cause of the problem?

If you have any questions about the details, please contact Robert Sheaf at rjsheaf@cfc-solar.com. Visit www.fluidpowerjournal.com to view previous problems.

CIRCLE 230

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2019

2019

In an effort to combat the skills gap in fluid power and other industries, Fluid Power Journal, in collaboration with the International Fluid Power Society (IFPS), established an online salary survey in order to create a baseline resource for professionals. Thank you to the participants! Here are the results.

SALARY

SURVEY How old are you?

11%

24 or younger 2.6% 25-29 10.5% 30-39 34.2% 40-49 21.1% 50-59 22.4% 60 or older 9.2%

33%

6.6%

2-4

6.6% 18.4%

5-7 8-10

13.0%

11-15

13.2%

16-20

11.9%

21-25

OCTOBER 2019

Which of the following best describe your job?

11%

I do not live in the U.S.

14%

Engineer 25.0% Mechanic 2.6% Specialist 11.9% Sales 38.2% Technician 11.8% Other 10.5%

WHERE DO YOU LIVE?

5.3%

More than 25 years

93%

14%

How many years have you worked in the fluid power industry? Less than 2 years

What is your gender?

25.0%

% hold an IFPS certification WWW.FLUIDPOWERJOURNAL.COM â&#x20AC;˘ WWW.IFPS.ORG

% local

% regional

% national

% international

How long have you worked for your current employer?

0-4 years 40.8% 5-7 years 17.0% 8-10 years 10.5% 11-15 years 14.5% 16-20 years 5.3% 21-25 years 5.3% More than 25 years 6.6%

DESCRIBE YOUR COMPANY OPERATIONS

think they are fairly compensated.

How many employees work at your company? 17.0%

1-24 25-49

15.8%

50-99

14.5%

100-299

18.4%

300-499

5.3%

500-999

4.0%

1,000 or more

25.0%

Which IFPS certifications have you earned? HS: Hydraulic Specialist 42.1% PS: Pneumatic Specialist 18.4% E: Engineer 1.3% MHM: Mobile Hydraulic Mechanic 6.6% CC: Connector and Conductor 6.6% PT: Pneumatic Technician 1.3% MHT: Mobile Hydraulic Technician 4.0% IHT: Industrial Hydraulic Technician 4.0% IHM: Industrial Hydraulic Mechanic 7.9% PM: Pneumatic Mechanic 2.6% SD: System Designer 1.3% I'm not certified 40.8%

How many employees report to you? None 59.2% 1-5 18.4% 6-10 7.9% 11-25 10.5% 26-49 2.6% 50-99 1.4%

Very satisfied

22.3%

Satisfied

50.0%

Somewhat satisfied

23.7%

Dissatisfied

4.0%

ARE YOU SATISFIED WITH YOUR JOB? What is the highest formal education you have received?

High school or equivalent 11.8% Some college 21.0% Associate's degree 18.4% Bachelor's degree 31.6% Advanced degree 17.2%

think their job is secure. OCTOBER 2019

2.6%

34.2% What percentage raise did you receive, or do you expect to receive, this year? 27.6%

No raise

$200,000+

17.1%

$100,000+

13.2%

$90,000-$99,999

6.6%

$80,000-$89,999

6.6%

$70,000-$79,999

7.9%

$60,000-$69,999 13.2%

1-2 percent

27.6%

2-3 percent 14.5%

3-4 percent 4-5 percent

9.2%

5 percent+

7.9%

Which of these benefits does your company offer?

401K 80.3% Profit sharing 23.7% Bonus 55.3% Commission 32.9% Paid overtime 30.3% Paid maternity/paternity/ adoption leave 18.4% Paid holidays 82.9% Paid vacation and sick days 82.9% Medical insurance 81.6% Flexible work scheduling 35.5% Educational assistance 34.2% None of the above 3.9%

represented by a union. 36

OCTOBER 2019

6.6%

$50,000-$59,999

2.6%

$40,000-$49,999

2.6%

$30,000-$39,999

Less than $30,000

WHAT IS YOUR CURRENT SALARY?

14.5

39.5

feel that IFPS certifications impact their salary and/or job position. What is your company's primary business in the fluid power industry? Manufacturing 38.2% Distribution 31.7% Education 2.6% OEM 11.8% Consumer 3.9% Other 11.8%

% received additional compensation

after receiving an IFPS certification.

What is the average salary at each level of education?

High school or equivalent $ 50,000-$59,999 Some college $90,000-$99,999 Associate's degree $80,000-$89,999 Bachelor's degree $100,000-$199,999 Advanced degree $100,000-$199,999

The average salary of those who have an IFPS certification is

higher than those who don't.

On average, how many hours of overtime do you work per week? None 22.4% 8 hours or fewer 16 hours or fewer 24 hours or fewer 24 hours or more

52.6% 19.7% 2.6% 2.7%

WWW.FLUIDPOWERJOURNAL.COM â&#x20AC;˘ WWW.IFPS.ORG

M E D N A T L AIR/OI H P M E L O R A CONT

N O I T U L O A S IZ E D S er, PHD, Inc. ation Engine

lic aynes, App By Travis H

As automation expands across a variety of industries, the performance required of actuators becomes more diverse in terms of loading and speed. In some situations, it can be difficult to determine whether pneumatic or hydraulic actuators are the optimal choice. Air/oil tandem actuators are a compromise that can provide characteristics of both pneumatic and hydraulic operation. In cases where lighter payload capacity or force output is needed, pneumatics may be preferred due to low operational costs. Pneumatic actuators may also be able to cycle faster than hydraulic units. However, the compressible nature of air limits how well the speed of pneumatic actuators can be controlled. Additions such as flow controls can help through metering the exhausting air, but erratic motion can still result from operating pneumatic actuators at low speeds. Since liquids are virtually incompressible, hydraulic actuators can be operated reliably at lower speeds with smooth motion. This controlled operation lends itself to better energy handling. Hydraulic actuators can also be supplied with greater pressures, producing more force than pneumatic counterparts. In most cases, however, hydraulic operation requires greater initial and operational costs than pneumatic options.

WWW.IFPS.ORG

Some applications require a combination of pneumatic and hydraulic benefits, pointing to air/ oil tandem units as the ideal option. These tandem units are pneumatically operated, providing modest force output at an efficient cost. The inclusion of oil results in motion resembling that of a hydraulic unit, allowing greater speed adjustability and controlled motion. By incorporating both air and oil, tandem units eliminate disadvantages that come from using purely pneumatic or hydraulic options. For linear motion, an air/oil tandem cylinder would be used. The construction resembles two cylinders that are joined head-tocap with a common piston rod. The bore of one cylinder is pneumatically

driven to extend and retract the piston rod. The head and cap of the other cylinder are plumbed together, and the bore is filled with oil. As the rod extends or retracts, the oil flows from one side of the piston to the other. This results in consistent linear speed and evenly applied force through the entire stroke. An air/oil tandem cylinder can be useful in vertical stroke applications where gravity could cause excessive acceleration of a load being lowered and eliminate the need for an external stopping method. Rotational motion can also benefit from the inclusion of oil. The construction of an air/oil tandem rotary actuator is a double-rack rotary with a cap that connects the two bores on one side of the pinion. This configuration only achieves the torque of a single-rack Cylinder Air-Oil Tandem

Rotary Air-Oil Tandem

rotary as one side of each rack is used for oil communication. As a rack is pressurized, the oil flows from one bore to the other via the shared cap. The torque is applied evenly through the rotation, resulting in consistent rotational speed. This smooth motion is ideal for rotations in the vertical plane in which the loadâ&#x20AC;&#x2122;s center of gravity passes over the pinion. An air-only rotary used in this case could experience compression of the exhausting air when the mass descends, resulting in undesirable acceleration of the load and a high-energy impact. The introduction of oil avoids the compressibility issue and is a viable alternative to using a rotational counterweight. Integrated flow controls and check valves provide the ability to set the speed in each direction of travel of an air/oil tandem unit. An oil reservoir is used to ensure a constant supply of oil to the actuator. Retaining a pressure head to the oil reservoir prevents improper displacement of oil and retains the oil within the tandem unit. The oil portion of the actuator must be properly bled before use as air trapped within the oil could result in the sporadic motion that an air/ oil tandem unit is used to avoid. The addition of oil into a pneumatically driven unit is a cost-effective option to eliminate issues that may arise from the compressible nature of air. Air/oil tandem actuators are ideal when pneumatic operation and force output must meet the speed control and steadiness of hydraulics. ď Ź OCTOBER 2019

CL ASSIFIEDS

HYDRAULIC FLANGES and COMPONENTS THE “SPECIAL” YOU WANT IS PROBABLY ON OUR SHELVES MAIN Mfg. Products, Inc. 800.521.7918 fax 810.953.1385 www.MAINMFG.com/fpj

FOR SALE Profitable Fluid Power Training Business • • • • •

(owner retiring) Sale Price $160,000 Manufacture Hydraulic Training Equipment Provide Training & Component Sales Could be operated from any geographical location $100,000 inventory, $200,000 Annual GP

Inquiries: fluidpower12345@gmail.com Website: FluidPowerTraining.com

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

almomanifold.com

• Single DIN blocks • Active Valves • Monitored Poppets

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

Correct answers to the Test Your Skills on page 7 are 1.e, 2.c.

ADVERTISER INDEX Company......................................................... Page.......Circle Aignep USA.................................................................. 33........... 230 Aignep USA.................................................................. 20........... 243 Assured Automation.................................................. 25........... 224 Assured Automation.................................................. 21............247 BellowsTech, an MW Industries company................17........... 222 BellowsTech, an MW Industries company............... 21............250 Clippard Instrument Lab Inc....................... Back Cover............231 Clippard Instrument Lab Inc.......................................18............236 Emerson..........................................................................9............216 Festo Corp....................................................Inside Back........... 233 Festo Corp....................................................................19............241 Flange Lock....................................................................6............214 Flange Lock................................................................. 22............251 Flow Ezy Filters Inc......................................................14............219 Fluidyne Fluid Power.....................................................5............213 Hydrapulse Inc.............................................................15........... 220 Hydrapulse Inc.............................................................19........... 238 Hydraulics, Inc............................................................. 26............226 Hydraulics, Inc..............................................................18........... 234 IFPE 2020..................................................... Inside Front........... 232 Inserta Products......................................................... 25............225

OCTOBER 2019

Inserta Products......................................................... 20........... 244 J/T Hydraulics & Service Co...................................... 21............249 La-Man Corp.................................................................16............221 Main Manufacturing Products Inc............................ 22............252 MOCAP INC..................................................................14............218 MOCAP INC..................................................................18............235 Parker Hannifin Corp. - Pneumatic Div..................... 27........... 228 Parker Hannifin Corp. - Pneumatic Div..................... 21........... 248 PHD, Inc........................................................................ 22........... 223 PHD, Inc.........................................................................18............237 Quaker Chemical Corp..................................................3............212 Vac-Cubes................................................................... 26........... 227 Vac-Cubes....................................................................19........... 239 VacMotion................................................................... 32........... 229 VacMotion....................................................................19............242 VIAIR Corporation........................................................11............217 VIAIR Corporation....................................................... 20........... 246 Wilkes & McLean Ltd.....................................................7............215 Wilkes & McLean Ltd...................................................19........... 240 Yates Industries Inc.......................................................1............211 Yates Industries Inc.................................................... 20........... 245 Ad • Product Spotlight

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Please circle numbers for additional information from our advertisers. 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

READER SERVICE FORM

For complimentary information, mail or fax completed form to: c/o iPacesetters P.O. Box 413050 • Naples, FL 34101-6795 Fax: 888-847-6035 TYPE OR PRINT ONLY: Name Title Company Company Address City

State

Phone

Zip Code Fax

Web Address E-Mail Address

129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157

158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186

187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215

216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244

1. Do you specify, select, or influence the purchase of components & systems on new or existing machinery? If yes, in which technologies? (check all that apply) 05  Hydraulic 06  Pneumatic 07  Vacuum 2. What is your primary job title? (check all that apply)

10  Administration 13  Technical

11  Plant Operations 14  Mechanical

3. Which of the following best describes your market focus? A  Aerospace I  Forestry B  Agricultural Machinery J  Furnaces C  Automotive K  Gas & Oilfield Machinery D  Civil Engineering L  Heavy Construction E  Cranes & Equipment F  Drills & Drilling Equipment M  Military Vehicles G  Flame Cutting/Welding N  Construction & Utility Equipment Equipment O  Machine Tools H  Food Machinery P  Government Related 4. Number of employees at this location?

A  1-19

B  20-49

245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273

274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302

D  100-249

5. What is the primary business activity at this location? In the Fluid Power Industry: 56  Manufacturer 57  Distributor Outside the Fluid Power Industry: 59  Original Equipment Manufacturer (OEM) 6. In which region does your company do business? (check all that apply) 61  East 62  Midwest 63  Southeast 64  Southwest

332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360

361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389

03  Yes 04  No 08  Electronic Controls

12  Engineering 15  Purchasing

A  Marine & Offshore Equipment B  Material Handling Equipment C  Mining Machinery D  Packaging Machinery E  Plastic Machinery F  Presses & Foundry G  Railroad Machinery H  Road Construction/ Maintenance Equipment

C  50-99

303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331

E  250-499

390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418

419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447

448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476

477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505

09  None of these

16  Other

I  Simulators & Test Equipment J  Snow Vehicles, Ski Lifts K  Steel Plants & Rolling Mills L  Truck & Bus Industry M  Textile Machinery N  Woodworking Machines O  Other (specify) P  Fluid Power Industry F  500-999

G  1000+

58  Education 60  End User of Fluid Power Products 65  West

66  National

67  International

7. My Company should be advertising in or submit an article to the Fluid Power Journal. Please contact this person: Name: ___________________________________ Title: _________________________________ Phone: _______________________________________ 8. I wish to receive a free subscription to Fluid Power Journal:

01  Yes

02  No

_________________________________________________________________________________________________________________________________ Signature Date 9. I would like more information on the following products: (Please check all that apply) 800  Accumulators 805  Filters 808  Hose & Tubing 801  Accessories 806  Gauges & Sensors 809  Hydraulic Fluids 802  Electronic Controls 807  Heat Exchangers, 810  Motors 803  Couplings & Fittings Heaters, Aftercoolers, 811  Pumps 804  Cylinders Dryers 812  Seals & Packing 10. I plan on purchasing the above products in the next: 68  0-3 months 69  3-6 months

70  6-9 months

Please send information about the International Fluid Power Society (check all that apply) 897  Membership 898  Certification 899  Training/Education

71  12+ months

813  Vacuum 814  Valves 815  Software

REQUEST FREE

product information online at fluidpowerjournal.com

ISSUE: October 2019 EXPIRES: November 30, 2019

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

Title (required)

Date (required)

Telephone

Fax

E-mail

02  NO. Not interested. /

Please Type or Print Clearly: First Name

Middle Initial

Last Name

Company

Division

Web Address

Address

Mail Stop

City

State

Zip Code

 Check here if you would like to keep your name, address, phone and fax numbers confidential, and not released to third parties The address above is my:  Home Address  Business Address Which edition would you like to receive?  Print  Digital  Both (View a sample of our PAPERLESS digital edition at www.fluidpowerjournal.com) 1. Do you specify, select or influence the purchase of components & systems, on new or existing machinery? If yes, which technologies? (check all that apply) 05  Hydraulic 06  Pneumatic 07  Vacuum 08  Electronic Controls

03  Yes

04  No.

09  None of These

2. What is your primary job title? (check only one) 10  Administration: Chairman, President, V.P., Secretary, Treasury, General Manager, Owner, Business Manager, Director, etc. 11  Plant Operations: VP of Manufacturing/ Operation/ Production, Plant Management/ Director/ Manager/ Supervisor/ Superintendent/ Foreman/ Safety Director, etc. 12  Engineering: V.P. Eng., Eng., Design Eng., Director of Eng., Staff Specialist, Chief Eng., Senior Eng., Maintenance/Production Eng., etc. 13  Technical: Chief Tech., Fluid Power Tech., etc. 14  Mechanical: Chief Master Mech., Master Mech., Fluid Power Mech., etc. 15  Purchasing: VP/Director of Purch., Procurement Manager, Buyer, Purch., etc. 16  Other: (please specify)_________________________________________________________________________________________________ 3. Number of employees at this location? A  1-19 B  20-49 C  50-99

D  100-249

E  250-499

F  500-999

4. What is the primary business activity at this location? In the Fluid Power Industry, Outside the Fluid Power Industry 56  Manufacturer 57  Distributor 58  Education 59  Original Equipment Manufacturer (OEM) 61  Other: (please specify)__________________________________________ 5. Which of the following best describes your market focus? A  Aerospace A  Marine & Offshore Equipment B  Agricultural Machinery B  Material Handling Equipment C  Automotive C  Mining Machinery D  Civil Engineering D  Packaging Machinery E  Cranes E  Plastic Machinery F  Drills & Drilling Equip. F  Presses & Foundry G  Flame Cutting/Welding Equip. G  Railroad Machinery H  Food Machinery H  Road Construct/Maint. Equip. I  Forestry I  Simulators & Test Equipment J  Furnaces J  Snow Vehicles, Ski Lifts K  Gas & Oilfield Machinery K  Steel Plants & Rolling Mills L  Heavy Construction & Equip. L  Truck & Bus Industry M  Military Vehicles M  Textile Machinery N  Construction & Utility Equip. N  Woodworking Machines O  Machine Tools O  Other (specify)_____________ P  Government Related P  Fluid Power Industry

G  1000+

60  End User of Fluid Power Products

MY COMPANY SHOULD BE ADVERTISING IN OR SUBMIT AN ARTICLE TO THE FLUID POWER JOURNAL. PLEASE CONTACT THIS PERSON: NAME:_ _____________________________________ TITLE:_______________________________________

SCAN HERE

PHONE:_____________________________________

Always get a star performance every time Whether youâ&#x20AC;&#x2122;re designing control systems or programming PLCs, you need to know the core products are going to perform like stars. Festoâ&#x20AC;&#x2122;s Stars of Automation offers you a one-stop solution for products, with over 4,000 quality-engineered, high-performance components.

Fast Shipping Guaranteed! 24 hours

5 days or less

For great value, look to the stars. Choose Festo.

Discover all the Stars that will brighten your automation process at Festo.us/stars CIRCLE 233

ALL NEW Electronic Pressure Controls!

Miniature Solutions for Today’s Engineering Challenges

Air Cylinders • Pressure Controls • Electronic Valves • FRLs • Control Valves • Custom Assemblies A leader in miniature pneumatics, Clippard provides quality products

CINCINNATI • BRUSSELS • SHANGHAI

and complete design solutions

877-245-6247

for today’s engineering challenges!