Stamp of Approval: Testing Fluid Power Seals

By Chuck White, Director of Sales and Marketing, Hallite Seals Americas

Seals play a vital role in fluid power because they allow for the containment of pressurized fluid, which produces the energy for various pieces of equipment. The premise of fluid power is based on creating this energy and involves managing or controlling it for maximum effectiveness in a wide range of applications. Therefore, understanding the demands of each application is essential to offering the best sealing solutions to keep equipment operating efficiently for as long as possible.

Seal experts make recommendations based on where the seals will be used and their knowledge of overall field performance (both good and bad) with specific seal packages. Because of the wide range of applications and ways equipment might be used, replicating field operating conditions in a test environment is complex. Though some of these conditions may be simulated, the challenge is rapidly changing the conditions during the test cycle. Having test equipment capable of making these changes is possible, but the cost of the advanced control systems and fixturing to handle millions of testing cycles is significant. Nevertheless, advances in control system technology combined with the use of some creative test fixture designs make performing these tests a reality. So why is the testing of seals so important? Understanding how seals perform in a wide range of conditions allows the seal manufacturer to make and recommend better seals based on performance data. Five inputs determine how a seal will perform: size, temperature, application, media, pressure, and speed, often referred to as STAMPS (see figure 1).

By focusing on these inputs, tests can be designed to understand a seal’s capability. For example, such testing may reveal that a seal performs well at higher pressure limits only when the speed is maintained at a slower velocity. It may also find that a seal performs well at a higher temperature when the appropriate viscosity fluid is used to assure proper lubricity at the sealing lip. All this data provides a clearer picture of the strengths and weaknesses of a seal, making the selection of a seal package much easier and the life expectancy of that package much clearer.

Hallite has invested in expanding its test capabilities at the company’s Hampton, U.K., facility and in partnership with the Milwaukee School of Engineering and OEMs. As a result, durable test equipment has been designed to replicate application conditions consistently. We will consider findings from three critical areas: surface finish, oil viscosity, and seal lip temperature using infrared technology.

Surface finish. Testing revealed how exposure to various conditions impacts a seal's performance and overall life. An example is the dynamic hardware's surface finish impact on seal function and life. Testing confirms that all surface finish factors must be considered to ensure the best seal life and performance.

Ra was considered the essential factor in the past, with little or no consideration given to Rz or RMR (see figure 2). Extensive testing has shown that having an Ra that is considered acceptable with an Rz that is above the recommended level will impact overall seal performance. Running seals on surfaces with a low Ra (too smooth) will cause the seal not to perform as expected. Smoother surface finishes would have both a low Ra and low Rz, which, in theory, should enhance seal life as the surface is not rough and causes micro tearing at the sealing lip. However, having a dynamic surface that is too smooth does not allow proper boundary lubrication to get to the sealing lip, causing it to overheat, resulting in premature wear. Testing has quantified how both conditions (e.g., surface finish too rough or too smooth) impact the seal's performance.

Oil viscosity. Hallite testing has also revealed that using the proper viscosity oil may significantly impact seal life. Most of the seal testing (piston and rod seals) occurs at either 185°F or 212°F (85°C or 100°C) fluid temperature using an ISO 46 oil. A set of tests revealed that a seal performed well at 185°F (85°C) but less effectively at 212°F (100°C). As an experiment, the oil was changed to an ISO 220, which maintains a much higher viscosity level at higher temperatures. The test revealed that the seals that did not perform well previously at 212°F (100°C) were now able to seal effectively at this temperature. It was concluded that the media or fluid provided proper lubricity, which kept the sealing lip from overheating during the test (see figure 3).

Seal lip temperature. Understanding the effectiveness of media in providing proper lubrication led to other questions on mapping temperatures of the seal in operation. Both rod and piston seals have a minimal

FIGURE 1

S

Size Understanding of the size of the dynamic hardware that needs to be sealed and the length or “L1” of the groove available for the seal – Ratio to assure proper “squeeze” and seal placement in the system.

Temperature Understanding of both the media and environmental temperatures the seal will be exposed to in the application. This includes both the highest and lowest potential temperatures.

T A M P S

Application

Application where the seal will be used or any specific differences as compared to what might be seen in these applications (e.g., higher the anticipated operating conditions).

Media

Understanding the media that is being sealed is key to making sure the proper material is used in the design. Media also plays a part in determining the proper seal material to ensure long seal life.

Pressure

Understanding both maximum operating pressure and potential pressure spikes is key to choosing the proper seal configuration. Knowledge of low-pressure sealing requirements is also important to establish the operating range.

Speed

Speed of travel is key to ensure excess seal friction is avoided resulting in premature failure. Consideration of slower speeds is also important as slow and long stroke applications offer additional challenges to sealing.

FIGURE 2

contact point to the dynamic surface that is referred to as the sealing lip. Because this area is so small, the testing team postulated there would be a noticeable temperature difference compared to the temperature of the media, but they had no idea what that would be. Rotary fluid power seals typically present a difference of 80-90°F (27-32°C), which can be measured as the shaft rotates.

Since the test focused on hydraulic cylinder seals, the team had to find a way to install sensing equipment on or near the sealing lip, which was difficult. Working with MSOE, a state-of-theart test method was developed using infrared technology to measure sealing lip temperature. Using a rod seal, the test methodology mapped out temperatures of the media, rod, and sealing lip of the rod seal to assess the frictional heat generated at that location. As a result, the industry now has a platform to understand better how oil viscosity impacts sealing lip temperature, providing the expertise to recommend the optimum seal solution, minimizing heat and frictional wear. •

FIGURE 3

FALL

LITERATURE REVIEW

HITACHI FLANGELOCKTM AND CAP KITS AVAILABLE

Part number Part description Applicable machines Number of parts

SWINGFLGLCK2062 Swing hose FlangeLockTM kit EX3600, EX5600, EX8000 16 x 2062U - red FlangeLockTM

SWINGCAP2062HITACHI FLANGELOCKTM Swing circuit cap kit EX3600, EX5600, EX8000 16 x 2062 - cap TRAVELFLGLCK2462 TRAVELCAP2462 AND CAP KITS AVAILABLE Travel hose FlangeLockTM Travel circuit cap kit kit EX3600, EX5600, EX8000 EX3600, EX5600, EX8000 16 x 2462U - purple FlangeLockTM 16 x 2462 - cap Weight (kg)

6.7

4.5

7.7

6.4

Part description FRONTATTFLGLCK326162 Applicable machines Front attachment FlangeLockTM kit Number of parts EX3600, EX5600, EX8000 Weight (kg) 14 x 3262U - black FlangeLockTM 4 x 3261U - black & silver FlangeLockTM

SWINGFLGLCK2062 Swing hose FlangeLockTM kit FRONTATTCAP326162 EX3600, EX5600, EX8000 Front attachment cap kit 16 x 2062U - red FlangeLockTM EX3600, EX5600, EX8000 6.7 14 x 3262 - cap 4 x 3261 - cap 8.9

9.5

TRAVELFLGLCK2462 Swing circuit cap kit Travel hose FlangeLockTM kit BOOMARCHFLGLCK3262 BOOMARCHCAP3262 EX3600, EX5600, EX8000 EX3600, EX5600, EX8000 Boom arch hose FlangeLockTM kit Boom arch hose cap kit 16 x 2062 - cap 16 x 2462U - purple FlangeLockTM EX3600, EX5600, EX8000 EX3600, EX5600, EX8000 4.5 7.7 Stop the Mess 20 x 3262U - black FlangeLockTM 9.9 20 x 3262 - cap 11.3

TRAVELCAP2462 Travel circuit cap kit EX3600, EX5600, EX8000 16 x 2462 - cap 6.4

FRONTATTFLGLCK326162 FRONTATTCAP326162 BOOMARCHFLGLCK3262 BOOMARCHCAP3262 Front attachment FlangeLockTM kit Front attachment cap kit Boom arch hose FlangeLockTM kit Boom arch hose cap kit FlangeLockTM Stops Leaking Hydraulic Lines. • No Tools Required • No Expensive Hardware Needed CONTAMINATION CONTROL Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is sometimes overlooked when performing maintenance due to incorrect practices being used. THE FLANGELOCK™ TOOL AND CIRCUIT BLANKING CAPS The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection. Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps EX3600, EX5600, EX8000 14 x 3262U - black FlangeLockTM 4 x 3261U - black & silver FlangeLockTM 8.9 EX3600, EX5600, EX8000 14 x 3262 - cap 4 x 3261 - cap 9.5 EX3600, EX5600, EX8000 20 x 3262U - black FlangeLockTM 9.9 EX3600, EX5600, EX8000 20 x 3262 - cap 11.3 THE ULTIMATE CONTAMINATION CONTROL TOOL CONTAMINATION CONTROL stop the mess. HITACHI MAKING CONTAMINATION CONTROL EASY Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system • No more Rags stuffed into hoses Hitachi have packaged FlangeLock™ tool and caps specifically for Hitachi mining excavators. The Hitachi customised to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is sometimes • No more messy Plastic Capskits make sure no matter which component routine maintenance is being performed on, you will always have the exact number of FlangeLocks™* and caps to help reduce contamination. overlooked when performing maintenance due to incorrect practices being used. THE FLANGELOCK™ TOOL AND CIRCUIT BLANKING CAPS *Note: FlangeLocks™ are not to be used under pressureThe FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection. • The Ultimate Contamination Control Tool Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps stop the mess. • One hand Installation HITACHI MAKING CONTAMINATION CONTROL EASY Hitachi have packaged FlangeLock™ tool and caps specifically for Hitachi mining excavators. The Hitachi customised kits make sure no matter which component routine maintenance is being performed on, you will always have the exact • Eliminate Hydraulic Oil Spills & Clean up number of FlangeLocks™* and caps to help reduce contamination. *Note: FlangeLocks™ are not to be used under pressure • Quick Installation & Ease of Usage • Industry Acclaimed • Safe for Personnel & EnvironmentCall you local Hitachi Muswellbrook representative or the branch on 02 6541 6300 • 50% Reduction of Labor Costs for more information. • 100% Made in USA

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

FlangeLock

203.861.9400 • sales@flangelock.com www.flangelock.com Hengst Filtration offers a wide range of high-quality hydraulic filters, elements and accessories to meet the most stringent industry standards and requirements. With innovative glass fiber, multi-layered elements and filters handling flow rates exceeding 500 gpm and pressures of 6500 psi, our products are designed to handle demanding high, low or suction return pressures found in most hydraulic systems and processes. Contact Hengst North America for more information at sales-hydraulics@hengst.com

Hengst of North America, Inc.

www.hengst.com

Compressed Air Filtration

Brochure offers a comprehensive overview of the company’s complete line of compressed air filtration products. Highlighted is the patented family of Extractor/Dryers. These two-stage, point of use filters remove contaminates to a 5-micron rating with flow ranges of 15 to 2,000 scfm. Additional products available include the SuperStar Membrane Dryer, .01 Micron Filter, Refrigerated Extractor/ Dryer, and much more.

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Hydraulic Flanges and Components

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

MAIN Manufacturing Products, Inc.

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

Hydraulic Live Swivels Catalog

Inline and 90° hydraulic live swivels. Available in sizes from 1/8" to 2-1/2", rated to 10,000 PSI, heat treated, superior quality alloy steel, chrome or stainless steel ball bearings, withstands heavy side loads, burnished (micro smooth) barrel bores, Viton® , Aflas® , or Teflon® encapsulated seals, zinc or nickel plated, available in 304 and 440 stainless steel, full flow - low pressure drop, rebuilding kits available.

Super Swivels

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Our Repair Services Brochure covers the types of components (pumps, motors, final drives, valves, control cards, amplifiers and cylinders) we VERTICALLY INTEGRATED MANUFACTURING AND VALUE ADDED CAPABILITY For nearly 60 years, OTTO has been designing and manufacturing precision switches and operator controls for the most demanding applications. OTTO has a broad can repair, why we’re an excellent range of standard and custom products including traditional snap action switches, Hall effect technology and grips. OTTO excels in providing all levels of value added services to meet our customers’ needs by managing every phase of the project from conceptual design to finished product. On site capabilities include product engineering, 3D printing, injection molding, stamping, milling, machining and full choice for your repair needs, and also quality testing. Our expertise allows us to offer complete custom interfaces incorporating various control products plus LED indicators, keypads/touchpads, cable assemblies and additional electronic circuitry. From a simple basic switch to a sophisticated panel assembly integrating many components, the array of possibilities are endless. how the repair process works. View or www.otto-controls.com

Corporate Headquarters

download it by visiting our website at 2 East Main Street Carpentersville, IL 60110 847-428-7171 info@ottoexcellence.com www.ottoexcellence.com www.hydraulex.com. © Copyright 2020 OTTO Engineering, Inc.® OTTO and the OTTO Expect Excellence logo are registered trademarks of OTTO Engineering, Inc. All rights reserved. MKT0020-02

Hydraulex

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CONSTRUCTION & AGRICULTURE

OTTO’s Construction and Agriculture catalog offers an overview of products designed and used in these markets. The catalog includes grips, joysticks, Hall effect, electromechanical switches and CANbus solutions.

Products can be customized to solve customer’s unique needs. All products are engineered and built for the most demanding applications. For detailed specifications, see our Full Line Catalog, website or contact us.

OTTO Engineering

2 East Main Street Carpentersville, IL 60110 info@ottoexcellence.com (847) 428-7171 www.otto-controls.com

New Problem

Extractor Motor Reverse Speed Rises to an Unexpected Creep

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

»A HYDRAULIC SYSTEM drives a vertical ball screw that slowly lowers product into a vat. The company found it was important that the force of lowering the part be limited in case the new part encounters a previous part that had not moved out of the way. They installed a pressure-reducing valve to control the lowering force, and it worked well.

They experienced a leak coming from one of the swash-plate bearing covers and replaced the pump with a new one they had in stock. They primed the pump and set the pressure, ran several cycles, and turned the machine over to production.

Production called maintenance back to the machine complaining about a problem with the reversing speed of the hydraulic motor. Every two or three cycles, the motor would act like it had a flow control adjusted to low speed when the motor reversed. After inspecting for a contaminate in the lines and inspecting the pressure reducer and directional valve, they could not find the problem.

What could be the issue?

Solution to the August 2022 problem:

Deep Pan Forming Press Loses Operating Pressure

The 200-ton press pressure problem was a hard one to solve. It was determined that the lack of filtration had introduced scarring on the solenoid #6 directional control valve spool, increasing its leakage to tank when pressure is present. The only oil flow leaving the X port (sometimes referred to as the vent) of the start-up/safety relief was determined by a small control orifice in the relief valve. The oil flow through this orifice was exceedingly small and completely leaked past the directional valve spool back to tank at 600 psi. Replacing the directional valve solved the problem.

FIGURE IT OUT

WANTED SURPLUS

Pumps · Motors · Valves · Servo/Proportional

Email, call or fax with a list of your Surplus. We’ll provide you with a price offer!

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

The correct answers to Test Your Skills on page 24 are 1-d and 2-e.

HIGH FLOW PROPORTIONAL FLOW CONTROL

• 16MM to 50mm • Standard ISO 7368 and

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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

ADVERTISER INDEX

Company.................................................................. Page ........................................................ Phone...............................................................................Web

AEM ................................................... Inside Front Cover ...................................................................................................................................www.IFPE.com AKG Of America Inc .................................................. 30 ....................................... (919) 563 - 4286................................................www.akg-america.com Almo Manifold............................................................. 31 .......1-989-984-0800, 1-800-ALMO-NOW.......................................................almomanifold.com Assured Automation ............................................ 13, 23 .........................................1-800-899-0553....................................www.assuredautomation.com Camozzi Automation, Inc........................................... 20 .........................................1 972-548-8885............................................... www.camozzi-usa.com CFC-Solar ..................................................................... 12 ............................................513-874-3225.......................www.CFCINDUSTRIALTRAINING.com COXREELS ............................................................. 14, 23 ............................................800-269-7335.......................................................www.coxreels.com Flange Lock ........................................................... 25, 28 ............................................203-861-9400....................................................www.flangelock.com Fluid Design Products, Inc. ..........................................5 .........................................1-800-774-7500.............................................fluiddesignproducts.com Fluidyne Fluid Power ............................................ 27, 31 .........................................1-586-296-7200...................................................www.FluidyneFP.com Gemels spa .................................22, Inside Back Cover ..............................................................................................................................www.gemels.com Hallite Seals ................................................................ 11 ................................................................................................................................ www.hallite.com Heinrichs.........................................................................5 ............................................859-371-4999........................................................ heinrichs-usa.com Hengst of North America, Inc. ............................ 19, 28 ......................................... (803) 432-5992..........................................................www.hengst.com Hunger Hydraulics ...................25, Outside Back Cover .........................................1-800-248-9232................................................ hunger-hydraulics.com Hydraulex......................................................15,23,29,31 .........................................1-800-323-8416.....................................................www.hydraulex.com Hydraulics, Inc. ...................................................... 23, 30 ............................................817-923-1965...............................................www.hydraulicsinc.com J/T Hydraulics & Service Co. ..................................... 23 .........................................1-800-591-8280..................................................www.jthydraulics.com La-Man Corp.......................................................... 12, 28 ............................................800-348-2463...........................................................www.laman.com Lubrication Engineers, Inc..........22, Inside Back Cover ...........................................800-537-7683.................................................. www.lelubricants.com Main Manufacturing Products ............................ 28, 31 .........................................1-800-521-7918......................................................www.mainmfg.com MOCAP INC ................................................................. 30 .........................................1-800-633-6775........................................................ www.MOCAP.com MP Filtri USA Inc ........................................................ 20 ............................................215-529-1300............................................. www.MPFILTRIUSA.com Ohio Fabricators Co.......................................................9 ............................................888-354-0291............................................................www.ohfab.com Otto Controls .......................................................... 3, 29 ............................................847-428-7171............................................... www.otto-controls.com Super Swivels ............................................................. 28 .........................................1-763-784-5531...............................................www.superswivels.com Tele Radio LLC ...............................................................3 ........................................... 866-629-0780..............................................www.tele-radio.com/us/ Tubes N' Hoses .......................................................... 11 ............................................972-923-0766...............................................www.tubesnhoses.com Yates, Inc.................................................................. 1, 22 .........................................1-586-778-7860.......................................................www.yatesind.com

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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)_________________________________________________________________________________________________

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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

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