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March 2011
iVT Industrial Vehicle Technology International
Encouraging new drivetrain concepts EAJH
March 2011
Bobcatâ&#x20AC;&#x2122;s biggest loaders Interview: Jim Mccullough, cNh Cat 374D & 390D excavators Electrohydraulics
Vol 19 No. 1 www.iVTinternational.com Published by UKIP Media & Events ltd
www.iVTinternational.com
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eview
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Pub: IVT International
March 2011 215 mm x 275 mm
CONTENTS
p26
COVER STORY p44 DESIGN CHALLENGE Design a new kind of hybrid drive concept p36
REGULARS 6 9 11
CASE STUDIES & SPECIAL FEATURES
NEWS
119 BULLETIN BOARD
CONSTRUCTION FOCUS BY JIM MANFREDI
Blowing the whistle on sharp practice in the construction industry – do you know Colin?
AGRICULTURE FOCUS BY PETER HILL
14
TALKING HEADS DEBBIE MELLOR, KEIGHLEY LABS
16
ASSOCIATION VIEW DAVID ELLISON, FLTA
EVERY CLOUD… Jim McCullough, CNH Construction president, is in an upbeat mood as he discusses how the economic downturn has left his organisation in better shape than ever to handle the recovery
120 THE INSIDER
MATERIALS HANDLING FOCUS BY MICHAEL LEU
12
18
26
PASS-TIME PARADISE With Cat’s latest large hydraulic excavators finely tuned to load dump trucks more productively than ever, quarry managers will be in seventh heaven
36
HERDING CATS If there’s one thing more tricky than expanding a market-leading product range, it’s trying to do justice to the many new Bobcats in a single article
“This is the first time I’ve ever seen – as a result of severe problems – an incredible opportunity” p18
50
CONTROL ALT DELETE Is it time to start all over again as far as your vehicle’s hydraulic system is concerned? There are few hydraulic components that cannot be improved with the addition of electronic controls
62
DATES IN THE DESERT Our in-depth preview will ensure your fruitful visit to ConExpo, held from 22-26 March in Las Vegas, Nevada
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March 2011
iVT Industrial Vehicle Technology International
Encouraging new drivetrain concepts
Edito Richard Carr Editor r.carr@ukipme.com
EAJH
March 2011
Bobcat’s biggest loaders Interview: Jim Mccullough, cNh Cat 374D & 390D excavators Electrohydraulics
Vol 19 No. 1 www.iVTinternational.com Published by UKIP Media & Events ltd
www.iVTinternational.com
Vol 19 No 1
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eview
Chief Sub-Edito Sub-Editor Alex Bradley Sub-Edito Sub-Editor William Baker Proofreaders Aubrey Jacobs-Tyson, Frank Millard Art Director Craig Marshall Design Louise Adams, Andy Bass, Anna Davie, James Sutcliffe, Nicola Turner, Julie Welby, Ben White Production Manager Ian Donovan Production Team Carole Doran, Lewis Hopkins, Cassie Inns, Robyn Skalsky
International Advertising Coordinators Kevin Barrett k.barrett@ukipme.com Michael Briant m.briant@ukipme.com Subscriptions Manager Suzie Matthews s.matthews@ukipme.com Circulation Adam Frost a.frost@ukipme.com
Managing Director Graham Johnson Chairman and CEO Tony Robinson
The views expressed in the articles and technical papers are those of the authors and are not endorsed by the publishers. While every care has been taken during production, the publisher does not accept any liability for errors that may have occurred. iVT International, ISSN 1471115X, published four times per year by UKIP Media & Events Ltd, Abinger House, Church Street, Dorking, Surrey, RH4 1DF, UK. Distributed by US mail agent, Clevett Worldwide Mailers LLC, 7 Sherwood Ct, Randolph, NJ 07869.
Annual subscription US$102/£57 Periodicals postage paid at Dover, NJ 07801. POSTMASTER: Please send address changes to: IVT International, 19 Route 10 East, Bldg 2 Unit 24, Succasunna, NJ 07876, USA. This publication is protected by copyright ©2011 Average net circulation per issue for the period 1 January-31 December 2009 was 9,988
UKIP Media & Events Ltd, Abinger House, Church Street, Dorking, Surrey RH4 1DF, UK Tel: +44 1306 743744 Fax: +44 1306 742525 Editorial fax: +44 1306 887546
Printed by: Nuffield Press, Member of the Audit 21 Nuffield Way, Abingdon, Bureau of Circulations Oxfordshire, OX14 1RL, UK
iVTInternational.com March 2011
1
CONTENTS PRODUCTS & SERVICES 82 evolution solutions
95 big brother is watched
107 screen saviours
ZF’s latest power transmission developments
97 join forces
84 rapid response
Horton’s variable-speed fan control
86 waste not, want not
New braking products from Carlisle
90 plus points
Sauer-Danfoss PLUS+1 products
92 less is more
100 lighten up
Clever locking solutions from TriMark
foreword
p107
If there’s one thing I get a kick out of, it’s being able to get a bit of free energy. By which, I’m not referring to the dodgy wiring job running from the lamppost across the street to my kettle, but making use of something that would otherwise have been wasted and lost forever. Maybe it’s the by-product of many miles of effortless cycling, from being sucked along in the slipstream of lorries and buses; perhaps it’s just nice to see the greedy oil companies lose out on a few gallons in potential sales; or, more likely, it’s just the sheer thrill of seeing a simple idea implemented that can make a huge difference to fuel economy and the environment. We’ve really got the lot in this issue, featuring currently available solutions such as Parker’s RunWise system, which has cut some fuel bills by almost half, Deutz-Fahr’s cab-rooftop solar panels for some light airconditioning work, and Cat’s electric regeneration valve that enables gravity to do most of the work. Then we’ve got a few futuristic solutions in our Design Challenge, including the novel one on our cover, which I like to think of as FOPS (Falling Object Perfection System). And on the topic of saving energy, I’d also like to take this opportunity to send out a polite ‘Thanks, but no thanks’ response to the invitations to 07:00 press conferences at the imminent ConExpo. Come on, people – seriously! As if attending trade shows isn’t
Coming up in the June issue of iVT
iVTInternational.com March 2011
Hella’s LED worklamps
105 entry-level technology?
Epec EPC-i10 heavy-duty HMI display
115 thrills without spills
102 led reckoning
Finnradiator’s CuproBraze heat exchangers
113 Essential nervous system
Xenon lights from Nordic
Ethernet cables and connectors from Molex
111 hot property
M-Series sensors from MTS
Parker’s RunWise system
p89
2
Flat-face couplings from Faster
98 safely mobile
Fairfield’s Torque-Hub solutions
89 coefficients of friction
Wachendorff’s Opus A6 display
Ace Pump centrifugal wet seal pumps
117 the hot topic
HCT fan drive controller from Custom Fluid Products
p115
tiring enough, you expect us poor journalists to get up with the lark – usually after having attended a long and, er, sociable, formal dinner the night before? And then start the press conference – which on occasion has been nothing more than the précis of a company report, rather than anything newsworthy – before I’m barely halfway through my second slice of melon? But anyway, in honour of ConExpo – a show I love in a city I detest – we’ve really got into the spirit of things, featuring an exclusive interview with CNH Construction president and new incumbent of the AEM chair, Jim McCullough, as well as case studies of construction machinery from two iconic US brands. Oh yeah… and we’ve devoted approximately one-third of the magazine to previewing the latest component highlights that will be on show. We’ll be there with a booth (S-14209), too – feel free to drop by, although we’ll be more likely to be found traipsing around the rest of the exhibits. Oh, and one final thing. You might want to pay more attention than usual to this edition’s Association View on page 16. I can’t really say too much more at the moment as this issue will probably be going live on our website just before the FLTA’s annual bash takes place, but there’s a real twist in the tale this year… Richard Carr, editor, iVT International
• Design Challenge • Traction technology • Hands-free operation • Schuitemaker Innovado automatic feeder • Powertrain • Look out for Advanced Lift-Truck Technology soon!
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STRETCH T RACINE, WI, USA – New Holland has wheeled out the big guns with the launch of its T8 and T9 tractor series to meet Tier 4i. Its flagship T8 series is built around the ‘compact long wheelbase’ concept, coupling the transport stability and greater traction of a long wheelbase design with the manoeuvrability of traditional row crop tractors to create a truly universal machine. At 3,450mm, the wheelbase is up to 445mm longer than competing models, yet lends itself better to front linkage operations, as this is located nearer to the front wheels, offering exceptional balance and providing unimpeded visibility to the implement. “The range is much more than the old T8000 models with Tier 4 engines,” Andrew Watson, business director, was keen to stress.
Completely new from the transmission forwards, the most notable change is the engine, following the switch from an external supplier to sister company FPT’s Cursor 9 SCR model. Now running at 2,000rpm rated speed (a 200rpm reduction), its use of SCR and doubled (600 hour) service intervals could result in a 17% reduction in operating costs. The five-model range delivers between 235-339hp rated power, and 273-389hp with maximum Engine Power Management (EPM), which continuously adjusts output to match working conditions via intelligent sensing of loads on the PTO, hydraulics and transmission. Cursor 9 and 13 SCR engines are used on the T9 machines, providing EPM horsepowers of 390-669 with up to 40% torque rise.
Not just a pretty face The newly developed single-piece hood design – a result of computer modelling, lab testing and field testing – isn’t just for aesthetic purposes. One major reason is airflow through the engine – the design has reduced velocity through the grilles by up to 40% over the T8000, reducing the risk of blockages from debris. Air is also now deflected away from the cab, helping to reduce noise and heat levels at the windscreen area. The nomenclature on the hood has been changed to make the performance more immediately obvious. The T8.390’s designation, for instance, therefore indicates its range, followed by the maximum EPM horsepower.
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iVTInternational.com March 2011
Longer and stronger New Holland’s largest range, the T9, has undergone a complete upgrade and redesign. With increased strength and rigidity, the chassis is totally new, and produces a wheelbase up to 18in longer than competitive models. There are two heavy-duty chassis and four narrowframed (36in wide, down from the previous 44in) models, of which there is no Case equivalent at the higher horsepowers. This enables it to run on RCI 50 tyres, providing a footprint closer to that of tracks. Reliability of the chassis was also an area for concern, with the articulation pivot undergoing testing in highly abrasive Arizona sand for over 10,000 hours. Yet the manoeuvrability has not been compromised, with the 42° angle producing a reduced turning circle equivalent to that of the T7000 – with no scuffing. The maximum permissible weight of the range has been increased to 25 tonnes, enabling the heaviest loads and implements to be handled and there is an extensive range of ballasting options.
WHAT’S NEW
H THE RULES Slimmed down for agility We’ve become accustomed to hearing about OEM concerns surrounding the squeezing of hefty Tier 4 aftertreatment paraphernalia under the hood, but the addition of SCR has actually managed to reduce bulk in the T8 tractors. Because the engine cooling requirements have been reduced, so has the cooling package. The front axle is placed right beneath it, enabling the wheels to swing right around it and deliver a 10m turning circle equivalent to that of the T7000 – something that would not have been possible if using EGR. This sculpted tombstone, which integrates the new cast front linkage and bonnet provides an unmatched 55° turning angle; ideal for tight turns on headlands.
Comfort ride cab suspension ensures stability on uneven terrain, while the new Terraglide front axle suspension system provides 100mm extra travel, as well as improved manoeuvrability advantages in tight spaces.
iVTInternational.com March 2011
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WHAT’S NEW
CONSTRUCTION FOCUS JIM MANFREDI, MACHINERY OUTLOOK
EAST TREATS WEST HITACHI CITY, JAPAN – Hitachi’s third large-capacity rigid dump truck, the EH 4000 ACII, is now available in Europe. Drawing on some of the technology developed for the company’s bullet trains and automation systems for large production plants, this is the only rigid truck range to use a drive system designed and built entirely in-house. Maximising transference of the power from a Cummins QSKTA60-CE engine, the AC drive provides superior rimpull due to the elimination of heavy rotating parts such as the transmission and torque converter. Combined with
the load-responsive InsulatedGate Bipolar Transistors (IGBTs), this enables smooth operation, reduced fuel consumption and greater speed control. Retarding capabilities are particularly improved, slowing the truck to inching speeds while reducing brake wear. To come to a complete standstill, the service-brake blending feature automatically kicks in to add extra stopping power, meaning only one pedal is needed to achieve a smooth braking action all the way down to zero ground speed. A hill-hold brake feature is also included as part of the service-brake blending.
Using the Euclid-pioneered front trailing-arm and NeoconETM suspension system, frame stress has been minimised while improving handling and reducing tyre wear. Its turning diameter is 30.2m. The perfect match for Hitachi’s EX-series large excavators, the truck’s 222ton nominal capacity body features a sloping floor and tail chute for reduced spillage and smoother shedding of the payload. The ISO 3471/ISO 3449compliant cab features a new air-ride seat with a threepoint rubber ISO mount to reduce operator fatigue.
MAGNIFICENT 7 HIT VEGAS SAVANNAH, GA, USA – The first fruits of JCB’s joint venture with Volvo CE will be on show at ConExpo, with the launch of the seven-model (soon to be 18) Eco skid-steer range that will almost double JCB’s market coverage in the sector. The four wheeled and three tracked models are all vertical lift, with minimum rated operating capacities of 2,600 lb. Many of the improvements are centred around the cab, which is 17% larger and – with noise levels at 76dB(A) – 85% quieter than before. This has enabled a larger leftside access door, and greater visibility has been afforded by the replacement of the mesh screen around the cab with laminated glass. New features inside the cab include multifunction
joysticks with an attachment control harness and a heated air-suspension seat with adjustable armrests. The cab tilts for service access to the hydraulics and powertrain, and
a rear service door enables easy daily checks and work on the engine. O-ring face seal hydraulic fittings and a simplified design have resulted in 38% fewer parts, making servicing even easier.
CAT NAB Caterpillar is to purchase Bucyrus International Inc (BII) for US$8.6bn. BII will have 2010 revenues of about US$3.75bn; Cat’s estimated 2010 miningrelated revenues are US$3.9bn. With only one product category overlap (trucks), a combined annual US$7.65bn in mining equipment sales is likely, making up over 18% of Cat’s revenues and making it the world’s largest mining equipment manufacturer. BII will benefit from Cat’s massive distribution network for sales and product support, financing solutions and sales advantages from customers wanting a fullline supplier. It would also have access to Caterpillar Production System expertise as well as its purchasing power, especially for steel and components – including Cat’s own diesel engines and drivetrain assemblies. Caterpillar will gain an installed base of products with an estimated US$40bn replacement value, and improve aftersales support. The deal will enable Cat to make more credible mine planning recommendations – both underground and surface – through offering all the alternatives. It hopes to trim about US$400m of expenses from the combined business, and plans to move its mining equipment HQ to BII’s Wisconsin HQ. GETTING TOGETHER Mergers have also been on the crane industry’s mind, with Konecranes confirming it had approached Demag Cranes to discuss a buyout. Demag responded that it had no interest in engaging in any such dialogue. Terex had also been mentioned as a potential buyer of Demag.
Instead, Konecranes is to acquire WMI Cranes Ltd, a leading Indian manufacturer of heavy-duty cranes. WMI’s sales in its last FY were about US$39.3m, and it has an order book of more than US$65.5m. Konecranes will acquire 51% of WMI for US$36.7m. One year later, it will buy the remaining 49% of the shares at a price linked in part to performance, with the total maximum price for 100% of the shares in WMI possibly totalling US$79.6m. Terex Corp has also announced the acquisition of 33% of Recom Srl and a long-term agreement to acquire the rest. Based in Belluno, Italy, Recom designs and manufactures luffing-jib tower cranes, which are distributed exclusively by Terex. BUYS IN BRAZIL Volvo CE will invest US$9.5m in a plant for excavators and related key welded structures in its facility in Pederneiras, Brazil; an action in line with its strategic objective of becoming one of the top three OEMs in BRIC. The project consists of localising assembly and components to achieve 50% local content on its four most important models in the Latin American market. The building in the facility will be extended by 8,500m2, and there will be specific investments in welding, machining and assembly equipment. The first Pederneiras-built excavators are expected to be delivered to customers in March 2011. Localising production of excavators will greatly reduce the amount of inventory being shipped from Korea and dramatically cut import taxes and currency exposure.
Subscribe online at www.machineryoutlook.com
iVTInternational.com March 2011
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The Drive to Build Our customers are passionate about the machines they build! That’s why they rely on Fairfield’s proven expertise for their drive requirements. We deliver excellence in Application Engineering, Product Design and Precision Manufacturing. If your company’s mission is to build equipment that will out perform, out last and out sell the competition, call Fairfield: +1.765.772.4000 or visit www.fairfieldmfg.com We’ll make a great team.
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WHAT’S NEW
SLIM PICKINGS TIPTON, UK – Flexi Narrow Aisle has added the Flexi HiLoad to its range of articulated counterbalance trucks. Designed to handle heavy loads in very narrow aisle (VNA) storage systems, the truck is particularly aimed at companies operating in the manufacturing, building materials, engineering and food ingredients sectors, where high pallet weights are particularly common. The Flexi HiLoad can lift loads of 2.5 tonnes to 9.5m with the aid of its heavy-duty Vision tilting mast design, and is available in a choice of 1,250mm or 1,350mm chassis widths. Requiring minimum manoeuvring in the aisles, the machine’s maximum ‘over-rotation’ and smooth digital encoder steering ensure that one turn is all that is required to place or retrieve a pallet, resulting in the fastest possible throughput and efficiency. Using the latest AC technology to minimise maintenance costs and deliver optimum efficiency from the high-capacity battery, the time between recharges can be maximised to provide high levels of
performance throughout a full shift. The HiLoad can also be used outside the warehouse, giving it the ability to load and unload lorries and deliver pallets to the racking in a
BEST IN SHOW BIRMINGHAM, UK – Described as ‘the world’s smallest, most powerful counterbalance truck’, Wilmat’s Bulldog was designed with SolidWorks CAD to provide superior manoeuvrability and impressive lifting power in the tightest of spaces. The five-model range reaches 850kg in capacity. At 1,933mm long, the smallest model provides 300kg lifting capacity and a lift height of up to 3,300mm with a triplex mast.
HANDLING FOCUS single operation. It thereby increases efficiency and productivity, abolishing double handling and the costs invariably associated with operating a bigger truck fleet than is necessary.
MICHAEL LEU, FORKLIFTACTION.COM
GOING UP Forklift OEMs have begun 2011 by raising prices. Christian Baerwolff, Still’s VP of marketing, said its prices had increased by up to 2.5% on 1 January. “Our own production sites and also our suppliers are faced with increased raw material prices. The supplier also demands higher prices due to good plant utilisation.” Linde MH has increased prices by an average of 2.5% since 15 December 2010 because of the escalating prices of steel and other raw materials. This applies to all its products in all global markets. Manitou’s Maxime Deroch said that its price increase “was initially intended to prepare our customers for the cost increase that will come with the Stage IIIB/ Stage IV implementation, and is barely enough to limit the impact of the higher raw materials cost”. TMHE has not yet revealed increases but is monitoring raw material prices. “These increases come at a time when the cost of hire and maintenance has been held artificially low for [some] years and there is no way that these new increases can be absorbed,” said UK Fork Lift Truck Association chief executive David Ellison. “The cost of fuel has risen and so have oils, lubricants, parts, etc. Higher steel costs affect the prices of new trucks as well as chains, forks, batteries, etc, and overheads are also rising.” CHOICE OF WARES MCFA has added three new Jungheinrich-branded warehouse products to its line. “The addition of the new Jungheinrich products [models of a 4,400-5,500 lb multidirectional reach truck, 2,200-3,000 lb order picker
and 15,400 lb tow tractor] enables us to provide our customers with further equipment choices for the warehousing industry,” said Jeff Rufener, VP marketing. Under an agreement effective from 1 Jan 2010, MCFA serves as the exclusive distributor of Jungheinrichbranded warehouse products via its North American dealer network. TREAD CONFIDENTLY Trelleborg Wheel Systems’ acquisition of Watts Tyre Group is set to strengthen its market position in industrial tyres through geographic expansion in Asia, and boost its aftermarket presence. Watts, with a sales presence in 60 countries, has annual sales of about US$43.5m. TWS business area president Maurizio Vischi said that the transaction will enable future growth and create synergies, mainly through greater use of Watts’ plant in Sri Lanka: “We … will have access to an advanced service concept that is marketed under the name Interfit.” STREAMLINING PLANS Linde plans to soon disclose how its North American organisation will absorb responsibilities for the sale and distribution of heavy truck products. “We made the overall decision and now have to finalise the organisational structure,” said Detlef Sieverdingbeck, head of corporate communications at the German HQ. “Until then, the Heavy Truck Division will continue to run the business.” Francesco Chinaglia, MD of the Heavy Truck Division, said its goals are to “improve our market presence in North America, increase our heavy truck business, and be closer to the growing markets”.
Global materials handling online: www.forkliftaction.com
iVTInternational.com March 2011
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WHAT’S NEW
AGRICULTURAL FOCUS FRANCE FLOURISHING? French tractor registrations began to rise towards the end of 2010, indicating that the farm equipment market may be recovering. France, the EU’s biggest tractor market with about 40,000 vehicles licensed in 2009, saw a 3.6% increase in registrations in November 2010, the first year-on-year increase in 2010. Recent data from Germany showed a 58% jump in licenses in October 2010. In both countries, the improvement was led by registrations of tractors below 100hp, which rose by 7.2% in France and by 62% in Germany, the European Union’s secondranked tractor market. Some of the increases could be attributed to prebuy, due to the impact of stricter emissions standards coming into force on 1 January 2011. However, higher grain pricing and improving confidence in the market could have led some farmers to be more willing to invest in new machinery. (MOE) WIND SALE Deere & Company recently announced the completion of the sale of John Deere Renewables LLC, its wind energy business, to Exelon Generation Company. A definitive agreement for the transaction was signed in August 2010. Deere said it sold the wind energy business as part of its increased focus on investing its resources to grow the core equipment businesses worldwide. SWEET DEAL Deere’s above-mentioned focus on core equipment no doubt includes its recent investment of US$35m to expand its factory in Brazil’s state of Goiás and increase production capacity over the next four years.
12
Brazil’s agricultural machinery segment has seen a strong recovery, with a series of government loans and high commodity prices helping to spur domestic sales. Deere, which has two other factories in the state of Rio Grande do Sul, also intends to produce a new range of sugarcane pulverising machinery. (MOE) GOOD YEAR FOR TITAN The Goodyear Tire & Rubber Company has entered into agreements with Titan Tire Corporation to sell its European and Latin American farm tyre businesses, including a US$130m licensing agreement that will allow Titan to manufacture and sell Goodyear-brand farm tyres in Europe, Latin America and North America. The European portion of the transaction is subject to the exercise of a put option by Goodyear following completion of a social plan related to the previously announced discontinuation of consumer tyre production at its facility in Amiens, France. Upon completion of this action, and subject to the usual closing conditions and regulatory approvals, the transaction will include the Amiens North plant, property, equipment and inventories. The Latin American portion of the transaction includes Goodyear’s manufacturing plant, property, equipment and inventories in São Paulo, Brazil. Subject to customary closing conditions and regulatory approvals, that portion of the transaction is expected to close in the first half of 2011. Goodyear sold its North American agricultural tyre business, including a plant in Freeport, Illinois, USA, to Titan in 2005. (MOE)
iVTInternational.com March 2011
SUSPENDED ANIMATION
HORST, THE NETHERLANDS – John Deere has begun production of an enhanced version of the self-propelled 5430i, with a variety of developments in terms of spray boom suspension and application rate control. As the sprayer is switched on and accelerates away, the Boom Charge control system automatically increases the pressure in the spraying system to optimise the
application rate accordingly. This improves overall spray accuracy and minimises under-application, especially in areas where forward speed is changing rapidly. A brand new boom centre frame and suspension now incorporates revised geometry for the folding cylinders, hinge points and anti-yaw system – an arrangement that increases preloading on the anti-yaw
dampers and simultaneously reduces boom yaw travel. Working with this new suspension geometry, new software for the BoomTrac automatic boom-levelling and height-control system further boosts boom ride performance and enables minimum height over the crop to be constantly maintained – even with wider booms and at speeds of up to 20km/h.
CATCH A FEW RAYS LAUINGEN, GERMANY – Deutz-Fahr’s first Tier 4icompliant tractor, the 260hp TTV 7.260, was shown at Eima – with an interesting twist. In addition to the Deutz TCD 6.1 L06 six-cylinder turbo-diesel engine with intercooling, four-valve technology, common-rail injection system and SCR catalytic converter, power can be drawn from a flexible
solar-cell panel in the cab roof. Covering an area of 0.6m², the solar cells produce enough electrical energy to run the cab fan when the tractor is parked in the sun – a welcome feature in the southern parts of Europe where heat accumulation in tractor cabs is a problem. The internal cab temperature therefore remains at least at outside temperature, so the
air-conditioning can then cool down the cab more quickly once the engine has been restarted. As Deutz-Fahr’s largest CVT tractor, each of its four operating ranges enable up to 100% of the driving power to be mechanically transmitted, thereby removing hydraulic losses, even in low speed ranges, for improved fuel consumption.
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TALKING HEADS
FAIL TO PREPARE… …PREPARE TO FAIL, SAYS DEBBIE MELLOR, MD OF KEIGHLEY LABORATORIES. SO HOW DO YOU MINIMISE THE RISK OF COMPONENT FAILURE? “Critical component failures often make the headlines, whether at sea, underground or in mid-air. Faulty pipes, valves, shafts, gears, couplings and other engineered components give rise to safety, environmental, productivity and financial issues, some catastrophic. These failures might result from design, manufacturing and assembly errors, inadequate quality assurance or unforeseen operating conditions, but sometimes they relate just to substandard materials and improper processing treatments. With growing volumes of steel, alloys and components being sourced in the Far East from comparatively unknown suppliers, and manufacturers ultimately responsible for component failures, there is now a pressing need to reinspect, or overcheck, material certifications. In support of this view, a recent US study found that 133 out of 220 samples of imported steel rod were rated as failures by a certified test laboratory – an astonishing 60% failure rate. If you have specified imported material to a particular grade or heat treatment process, then overchecking is the best way to ensure you are getting what you paid for. Often the raw material is not as specified, even with the correct certification, potentially creating problems down the line. The cost of a simple chemical or mechanical overcheck or a full in-depth metallurgical analysis might be hundreds of Euros, but if that item is safety-critical or forms part of a product worth hundreds of thousands, then it’s a relatively small price to pay. Given the legal implications of a failure in the field, it’s a question of either verifying incoming material or possibly putting your own business at risk. A certified test laboratory should be able to provide independent chemical analysis, employing state-of-the-art spectroscopy or classical wet methods, microscopic sample examination using metallography techniques, and mechanical testing for impact resistance, hardness, ductility, tensile strength and durability. These specialist techniques are also used in the allied fields of reverse engineering and failure investigation. Customers often ask us to re-engineer specific low-volume, high-value components and we apply reverse engineering techniques to such projects as part of the process, usually introducing design and material upgrades to improve it to better than original spec. Reverse engineering can also be invaluable for remanufacturing a vital replacement part, where the original manufacturer no longer exists or drawings have been lost. It is also useful for reclassifying mixed stock, where materials have been mishandled in storage and certification is missing. On mixed batches like this, we can test the hardness profiles, looking at depth and quality of case and the microhardness then the surface hardness, to determine which material is actually fit for purpose and which has been wrongly classified. A good lab will also handle problem and failure investigation, employing forensic analysis techniques to find out why specific components have failed in the field and suggest from what material the component should be made and how it should be processed. It’s just another useful weapon in the fight against critical component failure.” iVT
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iVTInternational.com March 2011
SPOILT FOR CHOICE BURLINGTON, IA, USA – With the launch of four Case Construction King T-Series backhoe loaders offering the choice of Powershuttle or Powershift transmissions, pilot or mechanical backhoe controls and two- or four-wheel steer, operators can now specify the model that is exactly right for their operation. Load-sensing hydraulics have contributed to a 10%
reduction in fuel consumption, so the larger fuel tank will now typically allow two days’ operation between refills. Productivity has also been boosted, with all models now featuring a 1.2m3 bucket – 20% larger than before – for faster truck loading. Transport height has been reduced by 30cm due to the overlapping backhoe boom cylinders. These also improve
visibility, due to the boom’s slimmer profile. Fully adjustable control lever towers provide an ergonomic working position, along with the suspension seat and its adjustable lumbar support. Internal noise levels are just 77dB(A) and all four windows can be opened for improved ventilation, with the rear screen tilting for a clear view of the working area.
LEVEL BEST
LINZ, AUSTRIA – Wacker Neuson has received an EDGE Innovation Award for its Vertical Digging System (VDS) in the sub-5-ton mini excavator segment. VDS enables digging operations to be carried out more precisely – i.e. in an upright position – by enabling the excavator
operator to continually tilt the superstructure by up to 15° at the push of a button, compensating for slopes of up to 27°. This speeding up of excavation and filling work can result in notable time and material savings of up to 25% on uneven terrain, while making it easier and more
comfortable for operators to carry out the work. Increased stability and control is another benefit, creating a much safer working environment on the construction site. VDS is available on seven Wacker Neuson models and, depending on the model, is controlled either mechanically or electrohydraulically.
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NEWS FROM THE EAST
…GOOD DESIGN, WHICH SHOULD ALWAYS BE RECOGNISED, SAYS DAVID ELLISON, CHIEF EXECUTIVE OF THE UK’S FORK LIFT TRUCK ASSOCIATION “When the FLTA conceived its Annual Awards for Excellence 17 years ago, it was an exceptional and pioneering initiative. The concept was simple: to encourage – and acknowledge – examples of excellence throughout the forklift truck industry and beyond. Importantly, this has remained our guiding principle, even as the spread and scale of the Awards has grown to reach an ever-wider audience and encompass important new categories. Indeed, we believe it is this integrity of purpose that has enabled the Awards to flourish – as well as the field of forklift truck design. As if to prove a point, this year’s Awards attracted a record number of finalists in each of the key product categories of safety, ergonomics, innovation and protecting the environment. Responding to the types of real issues facing users, every finalist represents a considerable advancement in the field of forklift truck design. At Linde, for example, designers have addressed the problem of noise pollution with their futuristic-looking CiTi Truck. Inspired by the growth of deliveries in the inner city, this model features a specially designed large rubber-tyred drive wheel and two pivot-mounted rear load wheels. Together, these enable this hand/powered pallet crossover to traverse obstacles of up to 70mm with minimal noise. Improving safety is central to the FLTA’s mission, and that of more than one-third of its finalists this year. Canadian firm Flexco addressed the important issue of forklift tip-over accidents with its Flex-1500 safety system. Using Flexco’s patented technology, it measures the lever effect – or the load’s effect on the forklift truck based on its position on the forks and the forks’ height level – to alert drivers to a truck reaching its limit. The Design Achievement Award, established by the FLTA in 2004, encourages innovation within the materials handling industry and rewards those companies and individuals who think ‘outside the box’. It recognises those few who have made an important contribution to promoting the ongoing improvement of the forklift truck. Continental Tyres, for example, developed a special adaptor that fits between a tyre and its rim, eliminating the need for a conventional mounting press. Last year, Product Design Technology graduate Luke Elmer received the award for his Vibralert design. His wristband and transmitter system has the making of an efficient and cost-effective method of warning pedestrians about the close proximity of a forklift truck. Other recipients of this prestigious honour include manufacturers of lift-truck and ancillary equipment, such as Narrow Aisle in 2004 for the ingenious design of the Flexi Generation 3 articulated counterbalance truck, Combilift in 2005 for its innovative ‘three in one’ truck design concept, Linde in 2006 for ergonomic developments in the X-range of reach trucks, and Jungheinrich for its rotating cab on the EFG D30 in 2007. The 2011 winner will be announced on 12 February 2011 – watch this space!” iVT More information at:
www.fork-truck.org.uk
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iVTInternational.com March 2011
Tamil Nadu, India – Kobelco Construction Machinery will open a 17-acre, US$10m hydraulic excavator site in 2011. It expects to initially produce 1,200 units per year; but depending on demand, capacity may increase to 3,000 units. Fabrication components will be sourced from India, but engines and hydraulics will be imported. Kobelco said it would add one or two more dealers to serve the northeastern states of Jammu and Kashmir. (MOE) Hong Kong, China – Cargotec is intent on expanding its load-handling solutions in the Chinese market. Deputy CEO Pekka Vauramo relocated to Hong Kong in January to drive the company’s development initiatives in the APAC region. He says China is a “very attractive market” for many Cargotec products. “For example, over 50% of new ship orders are currently being awarded to Chinese shipyards. Cargotec is well positioned in China to supply its MacGregor solutions, such as hatch covers and ship cranes to these vessels.” Cargotec intends to set up new plants in China as the market for its goods expands. (Forkliftaction)
Dalian, China – Liebherr has announced plans to start manufacturing small numbers of wheeled loaders in China. The first model available will be its 140kW L 556 II. The machines will be produced at Liebherr’s excavator factory,
and are expected to be available by April 2011. Dr Stefan Gilch, MD of Liebherr Machinery Service (Shanghai), said, “The new L 556 II has been specifically developed to satisfy the needs of the Chinese market. At the same time, as it is engineered by Liebherr, it complies with our globally high standards.” (MOE) Tianjin, China – Oshkosh has officially opened its plant to build JLG access equipment for China and other Asian markets. Construction was completed in early 2010, since when JLG has gradually introduced additional product models into the plant for local fabrication and assembly. The facility uses the latest in manufacturing, subassembly, fabrication and paint technologies. (MOE)
Beijing, China – Komatsu (China) Ltd established wholly owned subsidiary Komatsu China Mining Limited (KCML) on 1 October 2010 to engage in sales and product support of mining equipment and parts exclusively for large-scale mining customers. KCML operates a total of seven on-site offices in Shanxi Province, Inner Mongolia and Jiangxi Province, and a rebuild centre in Shuozhou, Shanxi Province. (MOE) Pune, India – JCB is reported to be transforming its Indian operation into a global manufacturing hub for the South Asian and Middle Eastern markets. The company has begun exporting excavators to Indonesia and plans to export its complete product line, including backhoe loaders, shovels, handlers and compactors, to the entire Asian region. (MOE)
Wuxi, China – Caterpillar Investment Co and AVIC Liyuan Hydraulics Co have signed a JV agreement to establish a company in Jiangsu Province to design and manufacture mediumand heavy-duty hydraulic pumps and motors for use in Caterpillar products as well as third-party equipment. Hans Haefeli, Caterpillar VP who has responsibility for Advanced Components & Systems, said, “This strategic alignment will also enhance Caterpillar’s supply base and key component capacity in support of Caterpillar’s machine capacity expansion plans in China.” Once the deal is approved by the applicable regulatory authority, it will be the first key components JV for Caterpillar in China. (MOE) Gunsan, S. Korea – Doosan Infracore recently opened its new production plant in Jeonbuk province, with a capacity of 4,000 machines per year. The plant will manufacture larger construction machines, including six excavator models and four types of wheeled loaders. Doosan said it has invested approximately US$98.8m since 2007 into the 610,000m2 plant. As a result of the completion of the Gunsan plant, Doosan Infracore said it now has a global production capability of approximately 45,000 wheeled loaders and excavators per year. The Incheon plant produces 13,000 machines, the Yantai plant manufactures 25,500 machines, and the Belgium plant builds 2,500 machines per year. (MOE)
Know-How in Motion®
Solutions for Tier IV and Stage IV Challenges Sacrifice shouldn’t have to be an option New lower emission Tier IV and Stage IV engines will have significant impact on future generations of offroad machines. In order to meet the required emission regulations, a number of engine characteristics will be affected. For starters, net engine power levels and torque characteristics will change. Along with this, the heat rejected from the engine installation will increase significantly. Even the engine operating speeds and installation space will change. These changes will have an impact on nearly every aspect of the OEM manufacturer’s business. Our industry is facing the most compelling event of our time, and time itself is running out.
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richard carr, iVT International
EVERY
CLOUD…
…has a silver lining, they say – and this is even the case with the recent economic downturn. Jim Mccullough, president of cnh construction, tells ivt why he’s optimistic for the future
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OEM INTERVIEW
“It’s a very different world from two years ago,” reflects CNH Construction Equipment president Jim McCullough, when I enquire about the changes he’s implemented since switching from overseeing Case alone to adding the New Holland and Kobelco brands to his portfolio too. Back in July 2009, the worldwide construction equipment market was at its nadir, and Jim’s goal of streamlining operations and reducing the costs of managing brand networks had never been more important. “All of a sudden, our couple of months’ worth of inventories had become equivalent to a year’s supply, but we made our way through all that.” The Chinese word for ‘crisis’ containing the ‘opportunity’ symbol may be one of the more popular misconceptions of late – yet this is exactly what has proved to be the case for CNH Construction. “This is the first time I’ve ever seen – as a result of severe problems – an incredible opportunity,” Jim enthuses. “I spent 18 months focusing on moving out the old inventory so that when we got into the recovery, we were in a position to start with fresh iron and sync it with our scheduled product launches. If we can keep the discipline in the process, even if we have to reengineer a little bit, it would make sense to do so. We’ve got two-thirds less inventory available than normal, and I’d like to keep those inventories very lean. I’m desirous of a three-time turn for light
equipment – or four-time in an ideal world. That’s harder to do with larger machines, and my gut says 2.75, but in the past it’s been more like 1.8, with most manufacturers having eight to twelve months’ supply of excavators. That’s a lot of money to have sitting in your yard.” CNH is blessed to own a division focusing on the agricultural market, he points out, which, being relatively buoyant during what was a horrific period for purely construction equipment manufacturers, enabled the whole organisation to perform respectably (more market comment in Predicting the future on p23). It also helped that Fiat Group CEO Sergio Marchionne takes a pragmatic view of downturns – i.e. they are normal and temporary – so R&D spend was maintained and work continued on an entirely new product line, with more launches than ever before.
Different strokes
BELOW AND BOTTOM: As part of a group of companies including Iveco and New Holland Agriculture, CNH Construction has been able to leverage technological and financial benefits
So what about that streamlining then – has maximum component commonality been implemented yet, and is there much technological crossover between the group’s Ag and CE divisions? “We strive for differentiated units in our CE brands,” Jim stresses. “Take the Case and New Holland skid steers, for example – although some of the guts underneath are the same, the geometry is different, the styling is different, and the cabs and the layout of the instrument clusters are different. But we are able to use common suppliers who still give us the opportunity to leverage volume purchases. “Are we as far as could be? No. Although we’ve been able to swap quite a lot of technology back and forth with the Ag division, we haven’t used many of its suppliers, other than the logical ones such as
“THIS IS THE FIRST TIME I’VE EVER SEEN – AS A RESULT OF SEVERE PROBLEMS – AN INCREDIBLE OPPORTUNITY” iVTInternational.com March 2011
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OEM INTERVIEW
ABOVE AND LEFT: Maximising brand appeal worldwide, with New Holland and Kobelco
tyre suppliers. We’d like to – not quite get the exact same component – but be able to double up the ones we need and have one built as a CE design and one as an Ag design. “But as we go forward, there are lots of things we can bundle in – we also have the opportunity to go to any of the other Fiat companies, so we’ve tried to give someone proprietary responsibility for the two purchasing groups, also with trucks where possible, to leverage everything we can.” During a 2009 press conference, Jim suggested there could be a supply opportunity for Magneti Marelli, the Group’s automotive electronics division. Has that happened yet? “We’ve put things like wiring harnesses out for them to look at, but there’s no installation that I know of yet in CE. But Ag and CE have a Group Executive Committee made
“WE’VE RETURNED TO A VERTICAL INTEGRATION PHILOSOPHY IN AREAS THAT ARE IMPORTANT FOR US TO CONTROL FROM QUALITY AND DELIVERY STANDPOINTS” up of our CEO Harold Boyanovsky, and execs from the other companies. Each of the major projects we’re planning are shared and reviewed, so opportunities can arise there. “We’ve also returned to a vertical integration philosophy in areas that are very important for us to control from quality and delivery standpoints. We’ve tried to identify those areas where we believe we need to be able to control it ourselves, because when the market is booming it puts you at risk of production bottlenecks and drops in quality. But, we don’t want to do it all!”
Class act Quality is obviously high on Jim’s agenda, as he proudly highlights his 21-ton excavator with a mere 0.4% warranty failure. “I’d love to do that for every single product we offer – you often hear about ‘customer delight’ – well, that’s the definition!” To that end, the CNH design and development processes have been recently overhauled, and machine prototypes are sent to customers with the ‘worst’ applications. Jim also highlights how the modern buyer is changing: loading variables into software packages and basing their decision on which machine the computer says is best, rather than on strength of brand. “Customers see us as a partner, someone who can help them be more competitive against a guy running competitors’ machines, so we really have to focus on operating performance, uptime, lifecycle costs and residuals. So in terms of Tier 4, our message to the customer is: ‘We realise it’s driven by government, but we’ve tried to make this cleaner burning so that it also meets your requirements, burning more iVTInternational.com March 2011
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CASE STUDY
efficiently, more reliably, and with some added enhancements.’ No one wants to pay more under the word ‘compliance’, especially when they’re not the guilty party.”
Fast forward When I enquire about long-term industry trends or predictions, he whets my appetite by admitting to greenlighting some radical concepts, but is unwilling to expand further. So with that, I ask about progress with CNH’s hybrid vehicles, of which five were under development by ConExpo 2008, even though demand was not thought to be high. “Some of the answers I’d give to your questions are not the same as I would have given two or three years ago,” he admits. “Then, electric cars were back on the shelf; now they’re launching all over the place. But I think there will be a lot of changes in the car and truck business that may start changing customer perceptions about what’s possible, practical and cost-effective. “But I’ve got technology that will enable us to go in a lot of different directions – we’ve done a lot of work to understand what technologies we can employ, even if they’re a bit more radical, and how they’d fit in with global manufacturing and service, etc. “Anyhow, both hybrid excavators are working. Kobelco’s SK80 is in use
MAIN IMAGE: A host of potentially exciting concepts could be on the cards at Case – this was the Jobsite of the Future display at ConExpo 2005 INSET: O&K was one of the acquired brands that made CNH the strong contender it is today
PREDICTING THE FUTURE
CNH’s Jim McCullough is increasingly bullish about the prospects for the construction equipment market, pointing to a recent seasonally adjusted sales forecast of 115,000120,000 earthmoving vehicles for western Europe – up from a predicted 98,000 since November. “Okay, so those figures are still way down on 2007, but the USA has a GDP forecast of around 3.2, and normally when we hit 2.5, construction equipment starts moving, so I think it could turn out to be a much bigger industry than figures suggest. So North
America will improve, as will Europe – but what I don’t know is how our competitors are positioned. Do they have a lot of old inventory? “There are suggestions that China may come down – but if you get behind the data, it could be 35-40% up on the same time last year! So I believe Asia-Pacific will be stable, and Latin America will be stable to strong.” These latter two markets certainly played a strong role in helping CNH Construction through the downturn. “AsiaPacific stayed very strong, and although Latin America may not be as big as the North American and European markets when they’re functioning properly, the amount of profit opportunity in vehicle sales and our high market share really helped us come through to this recovery period.”
in Japan although take-up rates have not been astonishing. The USA may not be knocking on the door, but we’ve told Japan we want to have availability of them and we’ll let the customers decide when they want it. “I think we’ll eventually see a ‘hybrid hybrid’, where much more technology will be combined. The next piece, and it’s already begun, is the motor in conjunction with the hydraulics, transmission, axles, etc, because it’s a combination of things that are influenced if you’re after the optimisation of the motor.”
From fantasy to reality Talking of concepts, whatever became of that prototype tracked backhoe loader shown at ConExpo 2008? “That’s not been scrapped – in fact, I can see there’ll be a growing application for it, as compact tracked loaders have taken a big chunk of the skid-steer business. More and more ag tractors are switching to tracks, too, as they do a lot more iVTInternational.com March 2011
23
OEM INTERVIEW
Spread the word MAIN IMAGE: Reducing the amount of stock standing idle is now high on Jim McCullough’s agenda INSET: Fruitful partnerships are benefiting the organisation enormously
“IT’S AFFECTED OUR GLOBAL COMPETITIVENESS – WE’RE BUILDING TENNIS COURTS WHILE IN ASIA THEY’RE BUILDING AIRPORTS!” moving around in the dirt than we do, where it’s sit-and-move. “But there are a few reality problems – mainly that tracks are for soft dirt. If you bought it for use on slate and rock, the only work you’re going to do is replacing the tracks. Initially we had 500 customers who showed interest in a demo and we try to stay in touch with them. Both Case and New Holland are in the process of launching new loader backhoes, and as part of that process we asked if there was any interest in tracks, but most of them said, ‘Not the way I use them!’ However, potential markets would be in the soft dirt regions, such as mid-west USA and southern England.” That ConExpo was one of the most enjoyable shows I’ve visited for years, due to the announcements of 24
iVTInternational.com March 2011
a handful of other new, very exciting concepts, such as Deere’s High-Speed Dozer and Manitowoc’s giant Model 31000. What’s the outlook for the next one? “I open ConExpo this year as chairman of AEM (see Spread the word box, p24) so I’m very excited to see the different solutions that have been brought forward. However, I would bet that it’s more likely to be a hypothetical version of Tier 4 Final, rather than something that’s extremely aggressive in newness. “But, when all’s said and done, hopefully the pain of the past few years is over, and as they say in California, ‘Surf’s up!’ So I’m optimistic that as CNH arrives at ConExpo with our most exciting product line ever, we can catch a few good waves!” iVT
Jim McCullough kicked off 2011 by taking over the chair at the AEM and has lofty ambitions for the organisation and its role in policymaking. He also has some scathing criticisms about what US government should be doing for the industry – not to mention for the country. “I served for two years as chair of global public policy, which sought a louder voice for the construction, agriculture and their associated service industries. We’ve tried to understand what we had to do despite the stimulus money not showing up very effectively. It turns out some of it was used to rebuild a boardwalk near Washington DC – somehow they managed to tap into stimulus money! – so we started lobbying Washington to let them know that extending the Highway Bill by 30, 60 or 90 days is meaningless. No contractor will make a decision based on such a short period. “Infrastructure creation is historically what’s led us out of recession, but the reality is that we – and Europe – have neglected investing in it for so long that it’s affected our global competitiveness. We’re building tennis courts while in Asia they’re building airports! In November 2009, there was a blip in China. They quickly realised a stimulus package was
needed, it was implemented in January, and by February the business was back to where it had been. That’s a lesson about what can happen when you have a less political climate. So I’ll spend the next year singing the message to anyone who will listen that we’re on a slippery slope – and at some point we’ll slip and not return.” Jim is also keen on increasing AEM’s worldwide coverage, working closely with other national and international bodies to create continental associations that operate independently but can join together on global issues. “I’d like to expand membership [from the current 800 or so] to 2,000 servicing the Ag and CE industries to increase the voice we have when it comes to emissions legislation, for example, and facilitate competitiveness and prosperity on a global basis. “AEM doesn’t perceive itself as American – we, along with machinery manufacturers, have to think global and act local or we’re out of business. So I’d like to standardise the retail reporting – manufacturers, especially the big ones, really appreciate how much the data drives everything. It all starts with a forecast, and then you can put things in place to better manage the inventories.”
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richard carr, iVT International
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CASE STUDY
PASs-time
paradise
with the launch of cat’s latest large excavators, truck loading has never been so productive. And with greater uptime, safety and reduced operating costs, quarry managers will be in seventh heaven If there’s one thing that we off-highway journalists have become accustomed to over the last decade or so, it’s that a new tractor or digger launch will inevitably focus – sometimes disproportionately so – on the topic of engine emissions, and the steps taken to comply with the latest stage of legislation. So it came as something of a surprise when a presentation of Caterpillar’s two latest large hydraulic excavators – the 374D and 390D – at its facility in Gosselies, Belgium, instead concentrated on a bunch of relatively simple technology improvements, such as the bucket and stick. The reason for this, quite simply, is that
With no engine emissions requirements to worry about, Cat’s engineers were able to busy themselves in creating a variety of performance improvements on the 374D (pictured) and 390D
iVTInternational.com March 2011
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CASE STUDY
these machines have retained the Stage IIIA engines used on their predecessors, the 365C and 385C, taking advantage of a combination of strategies to stay within EU regulatory requirements. These include using up existing machine inventory, using engine inventory that was built before the compliance deadline, and taking advantage of the ‘flex laws’ that enable the equivalent of 20% of the average production in that engine class over the previous five years to be exempted. “We’re using those three strategies to stay in production with these two models until late 2013,” says Zack Kauk, EAME HEX product manager. “They will actually skip a generation, so we anticipate these will be some of the first Cat machines to go to Stage IV. The higher-volume products are the ones that we try to move to the next stage of emissions first. That makes a higher impact from an environmental perspective while giving us the advantage of using the flex on our lower-volume products.” “Engineering resources are finite, and making modifications in the engine bay would have restricted the opportunity to modify other areas of the machines where more dramatic improvements were required,” adds Ken Gray, Large HEX global product
manager. “We wanted to focus on uptime, performance, owning and operating costs and safety – so that’s where I put my investment dollars in this product line.”
More bang for your buck That is not to say that there have been no improvements in terms of power output or fuel efficiency on these new models. Most notably, the 374D was deliberately designed to outperform its predecessor in terms of productivity, starting with an 18% power increase that takes the same Cat C15 ACERT engine up to an
main: All parts of the truck loading cycle have been improved on the 374D left: Electric regeneration valve uses gravity to help reduce fuel costs centre: Calling in reinforcements – the stick is now much more resistant to damage from rocks right: Tougher hoses and permanent couplings reduce downtime
impressive 476hp. To reap the benefits of this, implement pump flow was boosted by 10%, and the swing torque modified, to provide faster cycle times and a 20% productivity increase. “Many of these machines work in benchloading operations where the full cycle of dig, swing, dirt in the truck and return may take 20-22 seconds,” explains Jerome Claret, HEX product specialist. “The whole swing operation, back and forth, may take eight seconds, so optimising that area can have a huge impact on the overall cycle time.” As you may have guessed, digging performance, which may require eight seconds in loose material or 13 seconds in compacted material, has also been improved – on both models. “To optimise the digging cycle time and greatly improve the fill iVTInternational.com March 2011
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We will be attending the IFPE/Conexpo-Conagg show See us on booth no. 16043, South Hall
CASE STUDY
MAIN IMAGE: Optional HID lighting improves working visibility and safety ABOVE: Time Delay Light ensures safe egress from the cab
factor in the bucket, the best way is to provide more force,” adds Claret. “Digging force is provided by the cylinder and to increase that force, you’ve basically got two solutions. On the 374D we adopted them both – we’ve increased the hydraulic pressure by 9% and modified the stick cylinder diameter by 5%, which gives you a digging force increase of 19%. For the reach excavation configuration, we’ve increased the bucket digging force by 20%. We’re also using a new, much stronger material for the rod and a new sealing design which reduces the clearance between gland and barrel inner diameter.” The case for the new 390D to outperform the 385C was not as compelling, as the older machine was already performing well in its main task of loading 55-tonne trucks in four to six passes. Any major leap in productivity would merely leave the excavator operator twiddling his thumbs while a new truck got itself into position. Instead, the target was a slight performance improvement to enable more efficient partnership with 65-tonne trucks such as Cat’s 775 – even if it is still not quite the ideal pass match. Operator efficiency was pinpointed, via a 9% boost in hydraulic pressure that delivers a similar improvement in crowding-in force and productivity.
The next logical step was to provide a dedicated bucket that could handle all this improvement. “In terms of compatibility, you could still assemble the bucket of the 365C on the 374D,” claims Claret. “But we do not recommend it. That bucket would be killed – it was not designed to work with such high digging forces.” Therefore, among the upgrades to the new worldwide design are optimised loading characteristics and the bucket:payload weight ratio – more details can be found in the sidebar to the right.
Reinforcement theory With all these improvements in performance, it’s no surprise that the business end of the machines had to be reinforced to cope. But first, the machine stability to cope with the increased digging force had to be ensured, so 800kg was added to the counterweight – on the larger model, this was also moved back slightly to increase the control level. Being positioned above the 365C, the 374D was also given a wider track gauge, which has increased overall machine width by 5% and improved stability to the sides. Yet when the track frame is in the retracted position, the width is the same as its predecessor, and therefore has no negative impact on transportability.
BUCKET LIST Produced at Caterpillar’s Work Tools facility in Den Bosch, The Netherlands, the buckets were specifically designed to fit the specifications of the D-Series machines. As well as increased durability through optimum combinations of material specifications and thicknesses, the structures have been made stronger to guarantee increased uptime, such as the reinforced top-box design and upsized GET (teeth). The sidebar angle has been lowered, concentrating the power of the machine across a smaller surface and producing less resistance to material flow in and around the bucket, which has also increased in capacity (by 5% and 10% on GD and HD models for the 374D; 5% on the GD for the 390D). Moving the tip-forward position towards the operator has opened up the mouth of the bucket and lengthened the floor, improving material flow and visibility into the bucket, which provides operators with visual clues for faster loading. A new, more clearly defined, naming convention has been employed, with General Duty (GD), Heavy Duty (HD), Severe Duty (SD) and Extreme Duty (XD) replacing the previous Excavation (X), Extreme Excavation (EX), Rock (R) and Heavy Duty Rock (HDR) bucket categories.
“YOU COULD STILL ASSEMBLE THE BUCKET OF THE 365C ON THE 374D, BUT WE DO NOT RECOMMEND IT. THAT BUCKET WOULD BE KILLED” iVTInternational.com March 2011
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CASE STUDY
But that extra counterweight is not the whole story for the 5% increase in operating weight of the two excavators. More uptime – or in other words, durability – was one of the four critical areas that customers highlighted as being of particular importance, so extra iron has been added to several key areas. Stiffness of the reach and mass excavation sticks has been increased with extra baffle plates, and reinforcement bars have also been added to the latter. “When you’re loading rocks on a bench, best practice is usually to start at the bottom, but rocks can fall down from the top and damage the stick,” explains Claret. “With the reinforced bars, the structure of the stick is not affected, so this is a key feature in quarrying applications.”
The boom-foot mounting in the upper frame has also been completely redesigned with thicker plates to handle the increased weight, as have the 374D’s swing guide to cope with the higher swing torque, while the carbody has been fabricated with thicker reinforcing plates at critical locations and extra bolts added at the track-frame interface. Thicker reinforcing plates in the rails and bottom pan compensate for the stresses the heavier counterweight adds to the back of the frame. An improved welding process has also strengthened the arms of the machine. Runoff tabs are tacked at each end of the seam between plates to be joined; the weld begins on the first tab, continues across the seam and ends on the second tab. The
MAIN IMAGE: A smaller performance upgrade makes the 390D a better pass match for 65-tonne trucks such as the 775 ABOVE LEFT: Like father, like son – the 374D is an ideal replacement for the 365C ABOVE: Now 110mm wider, the 0.5m walkway greatly improves safety for service personnel
tabs are then removed, leaving a consistent weld bead across the seam, with no craters that can introduce stress. Once completely fabricated, the boom and stick are placed in a heat-treat oven to relieve any welding-induced stress. As well as structural considerations, the hydraulic system also came in for scrutiny in terms of durability. “We’ve designed new hoses, using a new material type and altering the way we layer the steel wire. We also now use a permanentdesign coupling instead of a reusable design coupling – both of these improvements enable us to work with much higher pressure than before,” Claret points out. “This also results in greatly improved hose and coupling life over the previous generation, even at the higher pressures.”
Costcutters Reducing fuel costs, particularly with such big machines, is also an area of prime concern to quarry managers. Of course, the 5% and 11% efficiency increases in the 374D and 390D respectively play a useful role here, but according to Claret, the biggest reason for the greater iVTInternational.com March 2011
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CASE STUDY On the Web See them in action, with testimonials, at: www.iVTinternational.com
economy of the new machines is the electric regeneration valves on the boom and stick cylinders – soon to be applied across the forthcoming E-Series range of excavators. “The principle is to take the benefit of the energy created by gravity when the boom and stick contract, pushing the whole of the cylinder down so that the oil inside is under pressure,” says Claret. “To give you an idea of how much energy you can retrieve with this system, when the 374D is in the maximum boom position you may have up to 200 litres of oil in each cylinder, so with the bucket loaded, you can get 200 bar for free. The only reason we are burning fuel is to provide energy to the pump, the only goal of which is to take oil from the tank and increase the pressure provided to the cylinder. “Without a regeneration valve in a boom-down operation, the weight would create huge pressure but, once you open the other side of the cylinder, that oil goes to tank and the energy is just lost as heat in the main valve – then you have to provide the flow to the other side again. Our system means you do not need so much flow from the pump, and therefore 2-6% less fuel from the engine, which can be lowered by 100rpm during this phase.” 34
iVTInternational.com March 2011
Main iMAge: The spacious cab is big on visibility too, especially with rearview monitors (below) to promote safety. A fuel consumption display (bottom) is also provided
It’s the operator, however, that typically has the biggest impact on fuel consumption – in fact, just completing one of Caterpillar’s Eco Drive training courses can often lead to a 10% efficiency improvement. So a real-time fuel consumption monitor in the cab helps them stay aware of the issue, while the Visual Link satellite interface enables the office to stay on top of individual machine or operator performance in this key area. Three power mode settings are also provided, enabling fuel to be saved when the highest productivity is not required, with the two lower settings slowing engine rpm to reduce consumption (and equally, productivity) by 15% and 25%. Yet even when the 374D is being used in the standard operating mode, it has still been shown to be more productive than the 365C.
Safe mode Safety was the final main customer requirement, so the addition of extra monitors and cameras has greatly reduced blind spots. Even someone standing right behind the counterweight can be clearly seen in the in-cab monitor via the rearview camera (standard in Europe), while the Work Area Vision System (WAVS) overcomes the large right-hand side
blind spot by mounting one camera on the toolbox and another on the boom – which can also provide a better view to the attachment, if used in demolition applications. New optional High Intensity Discharge (HID) worklamps provide twice as much – and ‘whiter’ – light than the previous halogen models, meaning that an object 30m away from the cab can be clearly seen; no mean feat when maximum reach of the boom does not exceed 15m. But increased safety depends on much more than merely improving working visibility: a relatively high proportion of injuries actually occur when these machines are switched off and at a complete standstill. So the walkway has been increased in width to 0.5m, allowing service and maintenance personnel to move around more safely, while exiting the cab in hours of darkness has been made much easier through the incorporation of a Time Delay Light. Factory-set at 30 seconds, although adjustable to individual preference, this stays on to illuminate the steps after the engine is switched off and the operator leaves the cab. Although, by getting so much more out of their working day due to all that extra productivity and uptime, maybe operators won’t have to work quite so late in future? iVT
Caterpillar has the solution for your most demanding applications. Our integrated power units are designed to meet applicable emissions regulations. Our experience puts us generations ahead – from drop-in installation through world-class product support, Cat® industrial power units deliver maximum value. Cat industrial engines – Powering you for generations. To learn more, call your local Cat dealer or visit www.cat-industrial.com. See us at ConExpo, South Hall Booth S16329A.
POWERFUL PACKAGE C9.3 ACERT™ 224-261 bkW (300-350 bhp) 1800-2200 rpm Tier 4 Interim/Stage IIIB
©2011 Caterpillar. All rights reserved. CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
NICK JOHNSON, IVT INTERNATIONAL
IT’S ALWAYS TRICKY TO UPDATE AND EXPAND A MARKET-LEADING PRODUCT RANGE, ESPECIALLY WHEN SO MANY VARIATIONS ARE INVOLVED. NEITHER IS IT EASY TO DO THEM ALL JUSTICE IN A SINGLE ARTICLE – BUT LET’S ATTEMPT TO GET UNDER THE MANY NEW SKINS OF THE TRADITIONALLY SOLITARY BOBCAT
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CASE STUDY
When your company name has become synonymous with a particular type of machine, updating that product to enhance a very prominent market position can be daunting. That was the challenge facing Bobcat’s engineers as they set about developing a range of newgeneration skid-steer and compact tracked loaders. The first results of this extensive development work were revealed in the USA in September 2009, and subsequently the M-Series S630 and S650 skid-steers and T650 tracked loader had their world launch at Bauma last April. Towards the end of the year, Bobcat introduced its new, biggest-yet compact loaders – the flagship M-Series S850 and T870 models. Now the company is scheduled to March’s ConExpo in Las Vegas as the official launch pad for its M-Series T770. MAIN IMAGE: The ConExpoCon/Agg 2011 exhibition in March will provide the launch pad for the next new-generation Bobcat loader – this tracked T770
Vertical-lift newcomer for Las Vegas The next new-generation Bobcat loader will be the tracked T770 (pictured), which will be launched at ConExpo-Con/Agg 2011 in Las Vegas in March. Sporting a powerful 68.6kW (92.3hp) Kubota V3800-DI-T-E3 Stage IIIA diesel engine, the vertical-lift newcomer will have a high-rated operating capacity of 1,611kg when shod with metal tracks. A standard hydraulic flow of 87.1 l/min enhances attachment performance. Bobcat states that the T770’s high-flow hydraulic power has been optimised by ensuring that peak flow occurs close to the rated engine load, providing better fuel efficiency and engine cooling. Bobcat’s ConExpo display of new-generation M-Series loaders will include not only the T770 but also the S630 and S850 skid-steer loaders and the tracked T650 and T870.
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CASE STUDY
These M-Series Bobcats are the latest in a long line of skid-steer loaders designed and produced in Gwinner, North Dakota, USA. It was here in 1960 that Louis and Cyril Keller, together with Cliff Melroe, developed the original M-400, claimed to be the world’s first true compact skid-steer loader. It replaced the M200, which had two front driving wheels and a rear castor wheel. The innovative trio produced an effective skid-steer loader concept by selecting a combination of weight balance and wheelbase to enhance traction and turn-on-the-spot manoeuvrability. They discovered that a 70:30 front:rear wheel loading ratio (which reverses from front to back between laden and unladen) was best for their M-400. An improved version, called the M-440, was released in 1962 under the Bobcat brand name. This prairie animal was selected because its dictionary description was ‘tough, quick and agile’ – attributes that advertising manager Syl Melroe considered very appropriate for the skid-steer loader. Over subsequent years, continuous product development
has helped Bobcat to build up and retain its very strong market position despite an increasingly formidable array of prominent competitors. That invaluable R&D investment has been maintained by Doosan Infracore, which purchased the business in 2007 when the MSeries development programme was already well advanced.
Customer feedback Bobcat says that the development of the new-generation wheeled skidsteers and the increasingly popular compact tracked loaders is based on feedback from customers. Its designers were given the brief to improve the visibility, enhance performance and upgrade operator comfort, serviceability and durability. And according to Rod Koch, Bobcat’s loaders engineering manager, based in North Dakota, these objectives have been met. An important part of meeting this challenge was the positioning of the new Premium cab on the latestgeneration loaders. By moving the cab further forwards, access has become easier while forward vision has been enhanced.
MAIN IMAGE: An important feature of the latest Bobcat skid-steer and compact tracked loaders is the lower and more forwardmounted Premium cab that greatly enhances visibility to the front INSET: The back-end protection provided by the new rear bumper can clearly be seen on this S650 skid-steer ABOVE: On the newgeneration Bobcats the quick-connect auxiliary circuit hose couplings are now neatly integrated into the nearside loader arm
Bobcat has retained its longestablished twin loader arm design, so entry and exit to the operator’s seat continues to be through the front doorway. Providing a lower threshold aids this, while enabling a better view down to a bucket or other attachment when it is being used at, or below, ground level. Once seated inside the Premium cab of the new S630, S650 and T650 models, the 10% increase in internal space over their predecessors should be immediately apparent to most operators. The reduction in internal noise levels is also welcome – Bobcat claims a 5dB(A) improvement in what is known as a less-than-quiet machine type. The view from the seat has certainly improved compared with earlier Bobcat skid-steer models. The overall height of the rear loader arm support towers has been reduced (for both the radial- and verticallift versions), while the glazed area of the door on the new-generation machines is 45% larger than on the previous models. Koch highlights the improved rear visibility of the Premium cab. Overall visibility is said to be 30% iVTInternational.com March 2011
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CHINA - FASTER HYDRAULICS Co, Ltd. 200233 SHANGHAI, P.R. China n° 1289, Yishan Road, Caohejing Hi-tech Park (+86) 021-6082 3060 - Fax (+86) 021-6082 3080 info@fasterchina.com.cn INDIA - FASTER HYDRAULICS Pvt. Ltd. 410501 DISTRICT PUNE, MAHARASTRA, India Plot n° 10, Gate n° 108 Ambethan, Taluka Khed (+91) 21 356 7800 info@fasterindia.com
HEADQUARTERS: ITALY - FASTER S.p.A. I-26027 RIVOLTA D’ADDA (CR) Italy Via Ludovico Ariosto, 7 (+39) 0363.377211 Fax (+39) 0363.377333 info@faster.it
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USA - FASTER Inc. MAUMEE, OH 43537-9505 6560 Weatherfield, Ct. (+1) 419-868-8197 - (+1) 800-231-2501 - Fax (+1) 419-868-8360 info@fasterinc.com BRAZIL - FASTER BRASIL EQUIPAMENTOS HIDRÁULICOS Ltda SP, 12421-010 PINDAMONHANGABA, Brasil Avenida Nossa Senhora do Soccorro, 2100, Bairro Soccorro (+55) 12 3648 1226 - Fax (+55) 12 3648 1226 info@fasterbrasil.com
CASE STUDY
better, aided by a larger rear window (and sloping surface of the engine compartment), 16% larger side windows and a 34% bigger roof window. Sensibly, the windows are mounted on the outside of the rollover protection structure (ROPS) to make cleaning easier and to provide more elbow space inside the cab. To take advantage of the more spacious cab, the adjustable seat now has 50mm more longitudinal adjustment. Control options include the traditional Bobcat hand levers and foot pedals, AHC (hand levers only), ACS (choice of hand levers and foot pedals or just hand levers) and selectable joystick controls (SJC), where the joystick mounts can be adjusted independently of the seat. Providing all these alternatives maximises the ability to satisfy individual customer preferences â&#x20AC;&#x201C; but it does also highlight the lack of standardisation in the industry. The optional pressurised cab features a new one-piece seal that goes all the way around the door, fitting into a special curved pocket, aiding climate control and minimising the amount of dirt and dust that can enter the cab. The performance of the optional heating and air-conditioning system has been increased by 35% and the controls are fully illuminated so the
temperature settings can be chosen in low light conditions. All the new-generation loaders are designed for field installation of a radio, with placeholders for the radio and speakers. There is also a 12V power accessory for charging a mobile phone, iPod or other devices.
Radial- and vertical-lift arms The new-generation S630 is a radialarm skid-steer loader with a rated operating capacity of 989kg. The
Main image: The new top-of-the-range Bobcat T870 compact tracked loader has maximum lift height of 3,557mm that aids the loading of high-sided trucks above: The flagship S850 and T870 loaders are intended to run powerful attachments such as wheel saws, planers and forestry cutters
1,220kg capacity S650 and the tracked T650 (with 1,166kg capacity) are vertical lift path machines whose geometry provides greater forward reach at maximum lift height. To power its S630, S650 and the T650, Bobcat selected the fuelefficient Kubota V3307-DI-T-E3 turbocharged diesel engine rated at 55.4kW (74.3hp). This Stage IIIAcompliant model is transversely mounted on three (rather than the previous four) mounts to improve balance and reduce vibrations. The size of the fuel tank in the two skidsteers has been increased by 18%. The Bosch Rexroth hydrostatic transmission on these new skid-steer loaders is claimed to provide a 20% increase in tractive effort that provides better digging performance and pushing force. New hydraulic circuits provide more pressure and flow, which contributes to faster dump/roll-back cycle times. The machines have been fitted with two 10Âľm filters for much better hydraulic filtration. To increase reliability, the number of hydraulic connections has been reduced and there are fewer angled fittings.
Integrated auxiliary couplers Skid-steer and compact tracked loaders are effectively mobile power sources that can be equipped with a iVTInternational.com March 2011
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CASE STUDY variety of different attachments (many hydraulically powered) to increase their operational versatility. A neat improvement on the new-generation Bobcats is that the quick-connect auxiliary hydraulic circuit hose couplings are now properly integrated into the nearside loader arm. The cooling for the hydraulics is now carried out on the charge oil rather than the implement oil, providing much better efficiency. The flow rate through the oil cooler is much steadier as it is not affected by the operation of the cylinders or attachments. The oil cooler, which is now made of aluminium, swings up to make it easier to clean the area between it and the radiator. Serviceability is aided by having the tailgate open from the offside of the machine, an arrangement that enables better accessibility for refuelling when the machine is transported on a trailer. There is enhanced access to the battery, and the hydraulic filter is now better placed at a higher level. Also on the offside, there is now a see-through hydraulic oil sight level gauge. Another noticeable feature is the lower frame that extends out beyond the rear tailgate to better protect the back of the machine from site damage. The latest loaders also benefit from simple, easy-to-reach tie-down points so that they can be quickly secured during transportation.
Largest loaders The arrival of the new-generation S850 and T870 last year marked the introduction of the largest skid-steer and compact tracked loaders ever manufactured by Bobcat. They are both vertical-lift path machines that provide a maximum lift height (to bucket hinge pin) of 3,557mm. Suitable for powering heavy-duty attachments such as road saws and forestry cutters, and doing arduous jobs such as ship trimming, their maximum operating capacities are 1,850kg and 1,584kg respectively. Each of these top-of-the-range Bobcat loaders have a Kubota V3800 DI-T-E3 engine that is Stage IIIA emissions compliant. The wheeled model has a power rating of 68.6kW (92hp) and its tracked counterpart gets 74kW (99.2hp) – so both are 8% more powerful than the previous 42
iVTInternational.com March 2011
hydraulic flow is 90 l/min, with an optional high flow of 142 l/min. The S850 and T870 can also be supplied with an optional deluxe instrumentation panel that intelligently monitors key loader functions, and has a keyless start feature designed to prevent theft. The panel incorporates a new 127mm, full-colour LCD screen designed to be more interactive and easier to read. It features virtual sweep gauges to enable the operator to quickly read and understand the machine’s performance. The SJC controls for both the S850 and T870 models can move up and down with the seat to reduce arm movement and operator fatigue. The joystick mounts are able to slide forwards and backwards to adjust to the preference of the individual operator.
Substantial axles above: The new Premium cab is quieter and more spacious and it can be equipped with the optional full-colour deluxe instrument panel (top right) Right: The hinged rear door provides good service access, and the oil cooler hinges up to facilitate easier cleaning
Bobcat S330 and T320 flagships. Koch says that structure of these machines is ready for the future fitment of Stage IV engines.
High flow capability The hydraulic systems of these big machines have been engineered for higher standard flow and pressure to provide more power for work with attachments. The standard auxiliary hydraulic flow on the S850 is 87 l/min at 241 bar and the optional highflow feature delivers 140 l/min for greater attachment performance. On the T870, the standard auxiliary
Koch says that these big, longer wheelbase loaders have been specifically designed to reflect their heavier weights and greater payloads. The skid-steer loader has more substantial axles, axle bearings and tubes with metal thickness being some 15% greater than on the next largest Bobcat. The S850 makes use of heavy-duty Tsubaki drive chains that have been well proven in the machines from Gwinner. The T870 comes with Bobcat’s roller suspension tracks as standard. This undercarriage has steel-reinforced rubber tracks and permanently sealed bottom rollers carried on leaf springs to provide a smoother ride. iVT
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Front dump bed support mounted on vertical sliding frame Pneumatic pistons Air lines connecting pneumatic pistons to pressurised air storage tanks
Pressurised air storage tanks
Pneumatic-powered generator
Hoist cylinder set on float Battery banks Swing arm mounts for independent rear suspension instead of solid axles give room for load energy recovery system Gas-assisted struts hold up empty dump bed Dump bed hinge mounted on a vertical sliding frame
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DESIGN CHALLENGE
load energy recovery system Pope Design Jon Pope has designed heavy equipment for 13 years. He has worked for a variety of offhighway OEMs, whether as an independent design consultant or employed by Teague In just one pass, large front shovels can drop more than 80 tonnes of dirt and rock into huge heavy haul-truck dump beds. The Load Energy Recovery System is a way to recover this potentially huge source of wasted energy. It works by the payload compressing air in 14 large separate pneumatic pistons mounted directly under the dump body. This compressed air is piped to two holding tanks. Once the pneumatic pistons have been completely compressed, the pressurised air stored in the tanks is released through two turbines to generate electricity. This is then stored in a series of batteries to be fed to the traction motors when the truck needs extra power during heavy acceleration or when climbing a steep grade. After the load is dumped, the hinge mount and front dump body support that brace the front of the dump body are raised up by large gas struts. Guides keep them from racking or getting hung up. A frame that ties all the spring-loaded pneumatic pistons together is pushed up flush to the bottom of the dump body. The hoist cylinders are set to â&#x20AC;&#x2DC;floatâ&#x20AC;&#x2122; and allow the empty dump body to raise 12in above the chassis. The heavy haul truck is now ready to accept another load and recover some more wasted load energy. I used a pneumatic system because it is a much more simple system, with fewer moving parts and components, than a hydraulic system. Plus if there is a failure, you donâ&#x20AC;&#x2122;t have large amounts of hydraulic fluid spraying all over the machine and leaking on the ground, creating a HazMat situation. The pneumatic pistons also help lessen the shock loads on the truck chassis. This could help prolong the lifespan of the truck suspension system and the dump body. jpope@pope-design.net / www.pope-design.net iVTInternational.com March 2011
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DESIGN CHALLENGE
Folding solar panels along the boom
motion capture Amos Boaz Amos Boaz is a specialist in the industrial design and styling of high-performance vehicles. He also lectures in the Bezalel Academy of Art and Design, Jerusalem, Israel Self-propelled sprayers have to be durable and resist chemical corrosion. This leads to the widespread use of polymers and composite materials, which are very friendly with regards to form; hence my decision to design a crop sprayer for this challenge. The Orpela Leaf concept’s main goal is to capture and store energy. The self-propelled sprayer moves with a hub motor at each of the four wheels, providing more efficiency than a single engine. Steering is by wire for each wheel. Each motor has a kinetic energy recovery system (KERS), which converts the braking energy into electricity and stores it in the batteries. The main frame is solid and is positioned beneath the aerodynamic carbon shell. The arms are also under the shell to improve the Orpela’s aerodynamics when travelling fast on the road. The secondary frame acts as a cradle, supporting the generator, the batteries, the 500-litre cleaning tank and the main tank. This cradle is connected to the main frame with a suspension that enables it to move as the working machine vibrates. This movement is converted by KERS into electricity and stored in the batteries. The main tank contains a special ‘leaf’ or paddle, which moves with the fluid in the tank during work mode, and this movement is also converted into electricity to charge the batteries. A KERS also exists in the machine’s suspension, in the boom system and in the driversuspended seat, generating and storing electricity in the batteries. On the carbon body and on the large area of the boom there are solar panels that open during work, using solar power to generate electricity. A ‘nanodynamo’ wheel system enables energy from the tyre’s elastic movement to be transported in nano tubes in the tyre, to pass into the rim and rotate a disk. Heat from the friction between tyre and road can also be channelled in this way. The concept uses innovative materials and systems to capture energy and be ultra-efficient. Its unique shape emphasises its difference and makes it desirable. www.amosboaz.com/amosboaz@netvision.net.il
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DESIGN CHALLENGE
Dynamos replace shock absorbers Suspension (flow frame) Suspension springs Main tank Boom and suspension dynamo Boom suspension
Water circulation system
Leaf moves with liquid to produce electricity
Lift for driver to safely enter cab
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DESIGN CHALLENGE
Full hybrid vehicle Piston
1. Accumulator 2. Tank 3. Torque converter 4. Hydraulic group
Electricity
hydraulic/ electric hybrid Visionengineering Joeri de Vriesere has worked as a designer for European OEMs since 1999. He founded his independent design and engineering office, specialising in industrial vehicles, in 2005 A hybrid is a result of crossing two different species. That’s what we have done. We started with a classic telehandler that is able to place various loads, often very high up, and then combined it with a mobile platform, enabling numerous functions in high places. The result is a vehicle able to work high up, using various tools, over a wide area. As soon as the vehicle is stabilised on the ground, it is capable of a wide spectrum of functions. If necessary, the vehicle is able to rotate 360°, due to the peculiar geometry of its wheels. The same architecture enables the vehicle to remain stable on the ground, to move using crab steer, or use the front or the rear wheels to go in the required direction. But hybridisation doesn’t stop there. We used it for the drivetrain too, choosing to go electric and employing a battery to provide electricity to the four wheel motors, combined with a hydraulic system to operate the cylinders. Via accumulators and a torque converter, the movement of the hydraulic cylinders is converted into electricity as shown in the diagram above, which is then used to help power the vehicle when the need arises. The outcome of this design is an asymmetric vehicle with improved stability and weight distribution, organised around the telescopic arm. The hybrid telehandler’s front and rear chassis sections are designed to provide a lot of space so that the wheels can turn freely. joeri@vision-eng.be/www.vision-eng.be
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DESIGN CHALLENGE
Outstanding manoeuvrability and flexibility of use
â&#x20AC;&#x2122;s Next issue e: alleng Design Ch
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gerald scheffels, iVT International
CONTROL ALT
DELETE is it time to start all over again as far as your hydraulic system is concerned? There are few hydraulic components that cannot be improved with the addition of electronic controls
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MOBILE HYDRAULICS
High power in a compact envelope and long life – even under rough conditions – are the typical advantages of hydraulic drives in mobile machinery. But vehicle operators and owners need a little bit more than power and reliability: they want efficiency, adaptability and intelligence. And for this, they need electronics. The main manufacturers in the hydraulics business are, of course, well prepared to meet these new demands. They frequently use electronic controls in their systems and solutions – and what’s more, they have also begun to offer their electronic devices independent of the hydraulic muscles.
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Professionals in motion
B&PImmagine
GG CONEXPO-CON/A17029 d South 2 Indoor - Stan
Bondioli & Pavesi has nurtured one passion from the beginning: the transmission of power. The results are a complete and integrated line of products designed and manufactured to satisfy the requirements of our customers.
www.bondioli-pavesi.com
MOBILE HYDRAULICS FIGURE 1 (LEFT): The Linc 2 system from Linde Hydraulics offers an even wider range of functions than the previously presented Linc 1
Linde Hydraulics, for instance, has started by offering the electronic control Linc 1. This device has been specifically designed for the control of hydrostatic propel drives, and it can be individually matched to the requirements of the application. This initial step was followed by a system with the name – easy to guess – Linc 2 (Figure 1, above) which offers a wider scope of functions. It enables the machine manufacturer to map the complete control of the hydraulic system in an excavator or similar machine, and it is also able to control a vast array of electric motors using Linde’s own power modules. The compact module is suitable for control functions in open and closed loops as well as for combined systems. A function controller and a safety controller in 16-bit technology together with a further 16-bit controller – which has the sole purpose of controlling all the numerous PWM outputs – are the core components of this control. A total of 32 proportional solenoid valves can be controlled. The high number of inputs and outputs – 126 pins can be assigned altogether – creates the conditions for the realisation of complex drive and work functions. Besides the electrohydraulic drives, components such as joysticks, travel and brake pedals, as well as the combustion engine, can be integrated in the control concept. Linc 2 thereby supplements the modular product programme of Linde Hydraulics, from which the adaptability of the control reaches far beyond its own components. Via flexible interfaces, the new control
device can be integrated into almost any machine periphery.
Safety included As systems integration proceeds, OEMs and integrators desire as few components as possible. With this aim in mind, Parker has designed the latest member of the IQAN controller family. One of the main features of the new IQAN-MC3 (Figure 2, below) is the ability to control both safety and operational functions with a single module. This enables system design and build times and costs to be cut, while improving machine performance, safety and productivity. The OEM is able to have the systems function certified to accepted functional safety standards, such as EN ISO 13849-1 or IEC 61508. With the help of Parker’s dedicated IQAN Studio Software Tools, the engineer programs both operational and safety functions, which are controlled and monitored through a single controller. This helps machine builders minimise the number of components required and thereby reduce overall system complexity and cost.
FIGURE 2 (BELOW): With the new member of the IQAN family, both operational and safety functions can be controlled according to the highest safety standards FIGURE 3 (RIGHT): High loop speed for mobile machines: a main feature of Eaton’s SFX controllers
To make this possible, IQANMC3 has been designed to conform with IEC 61508 (with certification pending) and effectively enables the operation and performance level of all safety functions to be proven as part of an SIL 2 (safety integrity level) methodology, or to be used as part of a PLd subsystem within EN ISO 138489-1. The new module can either be used as a standalone controller, with local I/O, or be integrated into larger systems using four CANbuses. Each module possesses 16 digital inputs and 16 analogue inputs, all of which can be set for safety-related signals. There are also four proportional current outputs designed to drive proportional hydraulic valves, with each output controlling one bi-directional valve section, as well as five digital outputs for driving on and off solenoids.
High-performance controllers With the SFX 1000 and SFX 2000 (Figure 3, above), Eaton offers highperformance controllers which have been specifically designed for offhighway machines such as forestry equipment, excavators, telehandlers, agricultural machinery and paving equipment. In these applications, control loop times are critical. This is why the new control generation offers higher operating speeds than the EFX controllers. Because they have been equipped with an internal Freescale HC 908 ‘watchdog CPU’ and monitoring software, they comply with the IEC 61508 safety standard. When used as standalone controllers they meet SIL 2 requirements for off-highway vehicle applications. The SFX 2000 model has an additional TTP (timetriggered protocol) controller that enables deterministic network bus communications. By combining two controllers in an electrohydraulic iVTInternational.com March 2011
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Together we can manage better access at every level. Even to the tightest corners.
The Parker Universal Push to Connect push-in system for tube and hose connections is particularly simple and safe to apply. The tube or hose end is introduced into the system nut, pushed in – and that’s it! This leak-free system design is based on the universally recognised ISO 8434-1 (DIN 24° cone connection) and ISO 8434-3 (SAE face-mounted O-ring seal) market standards. Reduced idle and installation times are possible even in tight access conditions. During maintenance, the hose connector can be replaced by a commercially available sealing cone. For tube servicing, replacements can be made with the famous EO-Plus or EO2-Plus connectors. The product diversity of this system, which is compatible with the globally available Parker product programme, delivers greater assembly flexibility and cost savings.
00800 2727 5374 www.parker.com
See us at CONEXPO on S-14457
Hannover Fair 2011 04.04. - 08.04.2011 Hall 23, Stand A50
MOBILE HYDRAULICS
application, a SIL 3 certification can be achieved. This is, so Eaton says, important because new technologies that have a higher degree of risk, such as steer-by-wire, will want to achieve this compliance. Hawe Hydraulik has developed a programmable logic valve control which enables comfortable access to complex hydraulic systems in cranes, crane installations, complex lifting and hoisting installations, forestry machines, construction machinery, and other mobile applications. The user of the control called PLVC 8x2 (Figure 4, below) can program not only pressure, velocity and acceleration processes, but also complex control and actuation tasks with short cycle times for the hydro consumers. The device has a total of 16 proportional outputs, which can be used, among other purposes, to actuate eight twin solenoids for eight functions using the PSL proportional directional spool valves (Figure 5, above). The PLVCâ&#x20AC;&#x2122;s basic configuration furthermore includes six digital frequency inputs, as well as 11 analogue inputs that switch between
0-5V, 0-10V, and 4-20mA with the help of software. An extension board can be activated if additional inputs and outputs or a second CANbus interface are required. Further delivery options include a real-time watch and a remnant memory for data logging that can record measured values or error events for example. The ESX-3XM is the latest freely programmable electronic control unit to come from Sensor-Technik Wiedemann. It has been conceived specifically for typical applications in modern off-highway vehicles and SIL 2 safety-relevant applications. As the second ESX family member after the ESX-3XL, it is built around a 32-
Those who have brains also have memory and, in line with that motto, electronics do offer the capability of recording operating data and their treatment
high-side outputs are equipped with precise current feedback for current controlled devices and low-loss freewheel circuits. All outputs can be switched off via a second path. For customer-specific adaptation, up to three expansion boards can be added, with each accessing 14 pins on the connector, where each pin can be independently assigned a functionality. Several expansion boards are already available, for example for RS232/RS485, RTC, data memory, incremental inputs and PVG/digital/PWM outputs. Development of new expansion boards and also customer-specific boards with special functionality, can be completed quickly and simply.
Recording faults and operations Those who have brains also have memory and, in line with that motto, electronics do offer the capability of recording operating data and their treatment. This is what the remote service module ESX-TC3 from Sensor-Technik
FIGURE 4 (BELOW): Valve controls can perform complex tasks FIGURE 5 (ABOVE): The PSL proportional directional spool valves can be controlled with Haweâ&#x20AC;&#x2122;s new electronic valve control FIGURE 6 (RIGHT): Recording data on an open source platform, the ESX-3XM comes with GPS, Bluetooth and Linux technology
bit processor. Although it only requires around half the space of the 3XL, it still offers up to 66 input/output channels. The 32-bit microcontroller is said to be one of the most powerful freely programmable control units on the market. One highlight of the ESX-3XM is its extreme flexibility and scalability. For example, the base configuration is extremely configurable through software, and up to three expansion boards can be added in any combination. All inputs and outputs in the base version are configurable. For example, the 15 multifunction inputs can, depending on function call, be used as current, voltage, digital or RPM inputs. The eight
Wiedemann does (Figure 6, above). Apart from the internal data, it is able to record GPS information and has a GSM/GPRS/EDGE module and a Bluetooth module of the latest generation. All data can therefore be transmitted wirelessly. The module is available with a board support package, which includes all the necessary drivers and software interfaces that are required for an embedded software application. It is based completely on open source and allows the programmer to develop suitable software for the desired application. Because the controllers integrate and match a variety of hydraulic components, the advantages can easily be found at the level of the iVTInternational.com March 2011
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Visit us at 22-26 26 March 2011 Stand S-15450 Las Vegas - USA
High volumetric efficiency Wide speed range High starting torque Freewheeling resistance High power density
www.saispa.com The Complete Line of Centrifugal Pumps for Mobile Applications • Hydraulic Driven • PTO Belt Driven • Magnetic Clutch Driven • Frame Mounted • Gasoline Engine Driven • 3/4” x 1” thru 21/2” x 2” • Pressure up to 11 bar (160 psi) Applications Include: • Milling Machines • Slip Form Pavers • Volumetric Mixers • Fire Trucks • Concrete Trucks • Roadside Spraying • Street Sweepers • Liquid Deicing • And More...
Call or visit us online today for more information!
800-843-2293
www.AcePumps.com
MOBILE HYDRAULICS
The H1 AC is customisable via the PLUS+1 Service Tool between four operator-selectable system modes that can be programmed according to three main propel methods or mode types which are suitable for machines such as, for instance, wheeled loaders and site dumpers (automotive mode) or sweepers and mowers (nonautomotive mode). Further features include engine anti-stall and protection against engine over-speed, extreme high and low hydraulic oil temperature conditions, and hydraulic motor over-speed. Variations in hydraulic oil viscosity that affect control performance are compensated for automatically. The result is, so SauerDanfoss claims, a predictable vehicle complete drive system. This is what Sauer-Danfoss has put forward when launching the new AC (automotive control) solution (Figure 7, above). This control is the prerequisite for the presentation of a SIL 2-certified transmission system. The Plus+1-compliant system incorporates an H1 variable piston pump with embedded electronic control, H1 bent-axis variable piston motor, sensors and associated human-machine interface (HMI) devices. Combined with intelligent software, the system provides an automotive-style automatic transmission that enables operators to adjust hydrostatic transmission characteristics to suit their specific operating requirements. The H1 embedded controller (H1 AC), features robust electronics mounted directly on the H1 pump and an additional ‘watchdog’ circuitry which provides real-time fault monitoring of the electronic hardware. Combined with optional software to monitor redundant HMI input channels, H1 AC provides single fault tolerance for AC vehicle transmission systems, SIL 2 certified by TÜV. The software, which can be easily configured to the vehicle manufacturer’s requirements, is also designed to comply with SIL 2 IEC 61508 standards.
FIGURE 7: Sauer-Danfoss offers an architecture for electrohydraulic drive systems, including pumps and motors
The system provides an automotive-style transmission that enables operators to adjust hydrostatic characteristics to suit their specific requirements
Components need connectivity Being the brains of mobile hydraulic drives, the controllers from Eaton, Hawe, Linde, Parker and SauerDanfoss need nerves and muscles. This means that the ‘hardware’ of hydraulics must be able to exchange information with the electronic controls. For this reason, Hawe is now offering the well-approved proportional spool valves, type PSL (Figure 5, previous page), complete with direct CANbus interface. This valve type is used in mobile hydraulics to control the direction of movements and the load-independent and continuously adjustable control of movement velocities of hydro consumers. It is characterised by
simplified wiring, supporting speedier and safer installation. The electrical connection complies with ingress protection rating IP67, making it suitable for a broad range of deployment, particularly in rougher environmental conditions. The integrated signal relay ensures the automatic optimisation of the valve’s reactive behaviour. This is particularly helpful for reducing the hysteresis, as this considerably simplifies the precision of repetitions, not to mention the integration into automatic sequences. The selfteaching functions of parameters also reduce the set-up work, for example, for the entry current.
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Reduce fuel consumption by 10-20% Achieve ROI in a matter of months for a complete electro-hydraulic system with a HCT fan drive controller
The HCT fan controller suits virtually any style or type of cooling application and enables increased productivity by utilising available engine horse power for work not cooling. This results in a fuel consumption saving of 10-20% for your mobile or industrial application. It operates with all OEM electro-hydraulic equipment and is suitable for new OEM build or repower/retro-fit/upgrade applications. Suitable applications include buses, emergency vehicles, above ground mining equipment and agricultural machinery. Custom Fluidpower is the Australian distributor of the HCT product range and can offer complete electro-hydraulic system solutions.
+61 7 3307 8200 | 1300 781 178 | www.custom.com.au Adelaide | Brisbane | Emerald | Mackay | Melbourne | Naval Base | Newcastle | Perth | AUSTRALIA
速
MOBILE HYDRAULICS performance, irrespective of the operating temperature. Additional benefits include the ability to further customise hydraulic pump and motor displacement control profile and ramp times, provide constant speed drive functionality, interface to vehicle systems via CAN, and easy-to-use diagnostics.
Sensors for control Sensors are an important part of control circuits. Pressure and position are parameters that have to be considered. OEMs, as well as the operators, want them to be integrated without restricting the availability and serviceability of the machine. To fulfil this aim, MTS now offers the Temposonics connector system in protection class IP69K for the whole M-Series of positioning sensors (Figure 8, top right) – including the compact MS and the redundant MT series. All of these sensors can be embedded completely inside a hydraulic cylinder, while click-on mounting without the need of any tools saves valuable mounting time and increases the safety of the sensor installation. The sensor is installed and connected electrically within seconds. Time-consuming connection of the cable conductors, polarity errors or ‘dry’ solder joints become a thing of the past. The connector system is in compliance with the most exacting protection requirements according to DIN EN 60529. With protection type IP69K, the robust metal housing is not only absolutely dustproof, but penetration of water inside the cylinder is also prevented. It is able to withstand even extremely hard cleaning conditions using highpressure equipment. During installation of the cylinder unit into the vehicle, the M-Series sensors can be connected at different angles using a universal M12x1 connector. The minimised installation height of the connector system ensures successful cylinder mounting even under limited space conditions. The market success of these sensors can be seen from the fact that MTS has recently established an ‘Integration Partner Programme’ with the aim of combining positionsensing technology and expertise with best-in-class hydraulic cylinder
oems and operators want sensors to be integrated without restricting the machine’s serviceability and availability FIGURE 8 (ABOVE): Eyes of automation – all M-Series position sensors can be equipped with a new, rugged connector system in protection class IP69K FIGURE 9 (LEFT): Joystick replaces levers – one more advantage of electrohydraulics
knowledge, enabling cost- and performance-optimised smart cylinder designs. Among the team partners are several leading companies in the field of cylinders for mobile applications: Büter, Burnside, Hyco, Hydroline, Ognibene, Pacoma, Serta and Wipro.
Joysticks instead of levers The use of electrohydraulics also has an impact on the layout of the instrument panel. Levers can easily be replaced by new kinds of manmachine interface, such as finger-tip controls and joysticks. Parker has especially designed a new co-ordinate joystick for mobile and off-highway equipment. The new IQAN-LC5 (Figure 9, left) is rugged, flexible, ergonomic, and has been developed for load-handling and positioning applications both in-cab and on external vehicle surfaces that are exposed to the weather. The new joystick is simple to install, configure and operate. All moving parts have been tested to ensure an operating life of over five million full stroke cycles. There are versions using either analogue voltage or CAN connections, with the latter having additional I/O to allow the IQAN-LC5 to be used as an iVTInternational.com March 2011
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MOBILE HYDRAULICS
FIGURE 10 (RIGHT): Electronics inside: JCB wheeled loaders use the innovative electrohydraulic flywheel system FIGURE 11 (BELOW): Pure mechatronics: Poclain’s AddiDrive electrohydraulic system for better control of trailers
input module for controlling ancillary devices. The CAN version is suitable for use with Parker’s IQAN Studio Software Tools, enabling electronic systems to be programmed, configured, and remotely managed.
Electronification of hydraulics There is not much doubt that the electronification of hydraulics will proceed further. Modern, highly efficient hydraulic systems, such as hybrid regenerating drives or the intelligent Hydraulic Flywheel from Bosch Rexroth (Figure 10, above) would not be able to work without the help of electronics. When it comes to integration of different
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iVTInternational.com March 2011
when it comes to integration of different drive systems, electronic data are the media to build the integration
drive systems, such as working and drives functions or combustion engine and hydraulic drives, electronic data are the media to build the integration. One of many examples of the benefits of electronics controlling hydraulics is Poclain Hydraulics’ AddiDrive system (Figure 11, below). This assistance system delivers driveability to the wheels of trailers used in agriculture, construction and public works. It consists of hydraulic motors integrated into the wheels, valves and a hydraulic pump, all controlled by a computer and electronic sensors. The operator easily controls the assistance from the cabin using a joystick and visualises the state of the system in real time via a display unit. The system won a Mechatronics Award in 2010. Another example is the HLB high-performance brake from Bosch Rexroth. An additional function for vehicles with hydrostatic drives, it offers the capability of hydrostatic braking while protecting the combustion against overspeed. The system also includes ABS and ASR functions. The brains of the HLB system are the control units SRC 1410 and SRC 9-34 which have already been described in iVT. iVT
Visit us at the
CONEXPO/IFPE Booth 15929
System Solutions for Mobile Machines ~ ATSdRTS Qh_Pbb _aTbbdaT ^UUTaX]V P] X\_a^eTS T]TaVh balance ~ >] Q^PaS T[TRca^]XRb X]R[dST X]cTVaPcTS _aTbbdaT bT]b^ab ~ CWT ^_cX\P[ bhbcT\ b^[dcX^] U^a h^da P__[XRPcX^] ~ F^a[SfXST bTaeXRT Inlet pressure max: 350 bar Nominal flow rate max: 260 l/min
Proportional Directional Valve LVS info@bucherhydraulics.com 路 www.bucherhydraulics.com
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richard carr, iVT International
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iVTInternational.com March 2011
CONEXPO PREVIEW
DATES IN THE
DESERT
When the industry’s finest hit las vegas in march, you’re sure to find something to appeal. Here’s a sneak preview of some of the highlights, as well as all the information you need to ensure the most fruitful visit
ConExpo-Con/Agg and IFPE 2011 will be the off-highway industry’s global gathering place in 2011. The co-located shows will be held 22-26 March, at the Las Vegas Convention Center in Nevada, USA. Industry customers say key reasons for attending are for the first glimpses of new products and access to industry experts – and they’ll find both at these shows, with leading US and global OEMs exhibiting and more targeted industry education and training opportunities on-site. Attendees and exhibitors will all benefit from the shows’ commitment to provide maximum value and a positive show experience for all participants.
Get in there! One registration provides entrance to all exhibits. Go online to register and receive the latest show details – www.conexpoconagg.com and www. ifpe.com. Attendees must first register for the shows to obtain a hotel reservation in the official show room block. Advance registration ends 21 February 2011. A comprehensive education programme is scheduled during the five-day exposition with sessions emphasising industry issues and trends, management and applied technology. More than 125 sessions are scheduled, to be presented by industry experts, with education divided into the nine programme tracks to help attendees locate topics of most interest to them: aggregates,
asphalt, concrete, earthmoving and site development, equipment asset management, management best practices, recycling and sustainability, safety and workforce development/competitive edge. New for 2011 is the co-located Crane and Rigging Conference by Maximum Capacity Media to strengthen the presence of the crane and rigging industry at the event. A Green Roads Summit will also provide attendees with a look at what green-road initiatives are all about, plus how these programmes may grow and develop in the future.
Fluid thinking At IFPE 2011, the 52nd National Conference on Fluid Power is the cornerstone of expanded education. The conference focus is on new technologies and methodologies within the fluid power industry related to improved analysis, design, manufacture and performance of fluid power components and systems for mobile and industrial markets. Proceedings will be published and available at the conference. The conference includes new sessions from the Center for Compact and Efficient Fluid Power, while additional education sessions are being provided by the Society of Tribologists and Lubrication Engineers. IFPE 2011 will also feature an Innovations Theater on the show floor, where experts in the field will present real-world solutions for current and future design
applications. Additionally, the Center for Compact and Efficient Fluid Power is also co-locating its annual meeting with IFPE 2011. ‘Product concentration areas’ will make it easier for show visitors to locate the specific products and exhibitors of most interest to them. IFPE 2011 will also feature exhibit pavilions from the American Gear Manufacturers Association and the Power Transmission Distributors Association, not to mention an exhibit pavilion which will serve to highlight the expanded presence of sensors suppliers at this year’s show. Prior to the shows, attendees can pre-plan their visit online using an interactive show planner, which includes show maps searchable by hall/lot location, booth number, company name and type of product. Attendees can assemble a personalised list of companies and products they most want to see as well as education sessions and meetings, thereby maximising their time on-site. They can edit and update their personalised schedule preshow and on-site. For additional convenience, the show planner will also be available as a free smartphone mobile application. International visitors can go to the show websites to find more information about the US visa application process, official show delegations and official letters of invitation. Selected show information will be available in a variety of languages. iVT iVTInternational.com March 2011
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Right technology. Right now.
The right choice for Interim Tier 4 engines Experience counts. Especially when it comes to making the right choice for meeting Interim Tier 4/Stage III B nonroad emissions regulations. Our off-highway engine experience tells us to continue offering equipment manufacturers a simple, single-uid solution. It’s why we continue to use proven cooled EGR and VGT technologies, and introduced an integrated exhaust lter for our new John Deere PowerTech engines.
John Deere Power Systems Ph: +33 2 38 82 61 19 Fax: +33 2 38 84 62 66 E-mail: jdengine@johndeere.com www.johndeere.co.uk
X_7550_1_E_215x275.indd 1
Our Distributor in the U.K. E.P. Barrus Ph: +44 1 869 363 636 Fax: +44 1 869 363 667 E-mail: john.day@barrus.co.uk www.barrus.co.uk
X 7550.1 E
The result – environmentally friendly engines that don’t compromise on performance, fuel economy, reliability, or ease of operation.
05.02.2010 10:23:35 Uhr
CONEXPO PREVIEW
ENGINES Cummins will highlight the Tier 4 Interim QSB3.3 engine at Booth S-16615, with a power increase taking the top rating to a new high of 120bhp. This improved power curve will further add to the premium performance associated with the fourcylinder, 3.3-litre engine and enable enhanced productivity for compact offhighway equipment. The QSB3.3’s power increase was made possible due to more efficient combustion realised by the aftertreatment simplicity of the Cummins Compact Catalyst. The catalyst removes PM by oxidation with simple, exhaust flow-through operation. The remarkably small size of the QSB3.3 catalyst, less than 500mm (20in) long, provides a major installation benefit. The 120bhp Tier 4 rating is one of the highest in the industry for an engine of this size, representing an impressive 11% increase in power output above the current Tier 3 engine and offering the space-saving benefits and fuel efficiency of a 3.3-litre installation. “For Tier 4 Interim, the Cummins QSB3.3 moves even further ahead of other similar displacement engines, with the benefit of a fit-and-forget catalyst,” says Cummins QSB3.3 product manager, Chris Calas. “The small catalyst will make a big difference for compact excavators, skidsteers, telehandlers, small cranes, air compressors and many others types of equipment typically used in rental fleets.” The Cummins compact catalyst is matched in design simplicity with a cooled exhaust gas recirculation system that has been incorporated on the QSB3.3 to reduce oxides of nitrogen (NOx). The EGR system has been specifically scaled down from Cummins’ six-cylinder platform to the compact four-cylinder and driven by a single variable-flow turbocharger. The variable-flow turbocharger improves boost across a wider engine speed than a wastegate turbo, and avoids the complexity of dual turbochargers. The combination of cleaner EGR combustion and a more responsive turbocharger enables fuel
Left: Cummins Compact Catalyst right: MTU Series 2000 below: JDPS PowerTech PSX 6.8L
efficiency to improve by up to 5% for Tier 4 Interim, depending on duty cycle. John Deere Power Systems’ line-up of Interim Tier 4/Stage IIIB off-highway diesel engines, on show at Booth S-16317, meets stringent emissions regulations without sacrificing performance, reliability, durability or operator convenience. Engine models and ratings include: • PowerTech PWX 4.5L: 85-122bhp; • PowerTech PVX 4.5L: 125-173bhp; • PowerTech PVX 6.8L: 140-173bhp; • PowerTech PVX 6.8L: 185-250bhp; • PowerTech PSX 6.8L: 225-300bhp; • PowerTech PVX 9.0L: 250-300bhp; • PowerTech PSX 9.0L: 325-425bhp; • PowerTech PSX 13.5L: 400-600bhp. The PowerTech PVX 9.0L, PowerTech PSX 9.0L, PowerTech PVX 6.8L above 130bkW (174bhp) and PowerTech PSX
6.8L models have been certified as compliant with Interim Tier 4 and Stage IIIB emissions regulations. John Deere met the challenge by starting with its proven PowerTech Plus Tier 3/Stage IIIA engine platform, which includes cooled EGR for NOx control and adds an exhaust filter for reducing PM. These engines include full-authority electronic controls, a four-valve cylinder head, a high-pressure fuel system, turbocharging and an air-to-air aftercooling system. In choosing a solution, JDPS elected not to use SCR – its cooled EGR and exhaust filter approach provides a proven solution with the best total fluid economy. Tognum subsidiary MTU Friedrichshafen (S-17607) will be showcasing its new generation of Series 2000 engines for the newly implemented EPA Tier 4 interim emissions legislation. The company has already presented its solutions for up to 730bkW for EPA Tier 4i and EPA Tier 4f – now the Series 2000 covers a power range from 561-1,163bkW and is used, for example, in harbour and mobile cranes, excavators, underground and open-cast mining vehicles such as haul trucks and wheeled loaders, as well as for drilling equipment and pumps. It sets the standard for reliability, economy and performance. Despite the considerable reduction in emissions limits, the new engines use up to 8% less fuel than their predecessors. In addition, they deliver constant power up to an altitude of 3,100m, which makes them the first in their class with this benefit to come onto the market. Lifecycle costs are
iVTInternational.com March 2011
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CONEXPO PREVIEW
had to be resolved when transferring the well-proven on-road solution into the offhighway sector.
also even lower than their predecessors, due to reduced fuel consumption and also to the long time-between-overhaul (TBO) intervals which can be up to 18,000 hours, depending on load profile. From mid-2011, in stages, 12- and 16cylinder versions of the engines will be introduced onto the market. Volvo Penta’s (Booth S-16557) new Tier 4i engines went into serial production in 2010. Selecting SCR technology for 2011 has already proved to be a wise choice. It has been easy to install, cost-effective and provides low fuel and DEF consumption. It has been summed up nicely by one OEM who stated that fitting the new engine was, “Just another engine installation”. Solutions for Tier 4 Final are currently under development within Volvo Penta, with the target to develop a system that continues to offer compact installation and low operational costs. It will continue the path with SCR and minimise the use of EGR to avoid additional cooling needs. The fuel consumption will be kept at a low level by optimising the combustion, while fan-noise reduction will be accomplished via low cooling demands, unlike some other technologies in the market. SCR systems used in Tier 4i are mature and far less complex than massive EGR and DP filters used by some OEMs. However, it doesn’t necessarily mean that it has been easy. Numerous technical obstacles have
Perkins’ new 854 Series on show at S16329b will offer customers greater power density and compactness to suit precise requirements, whatever the application. The 854E completes the company’s product range of cleaner, compact diesel engines which meet Tier 4i requirements. Offering more power and torque from a smaller package, customers now are able to move seamlessly through the power bands as the 854E produces 45bkW (60bhp) up to 86bkW (115bhp). The 854E range benefits from a common-rail fuel-injection system, smart wastegated turbocharger and aftercooler, all regulated by full-authority electronic controls to ensure world-class performance and fuel consumption. The engine, which develops a peak torque of up to 420Nm, is available in the 2,200-2,500rpm speed range. This optimised engine, which meets Perkins’ specifications, is being developed in a recent partnership with Fiat Powertrain Technologies (FPT). It deploys state-of-theart emissions control and aftertreatment. This strategic partnership ensures Perkins’ customers benefit from a classleading offering, delivered through
top Left: Volvo Penta Tier 4i engine with SCR above: SPAL SBL300 brushless technology below: Perkins 854EE34TA Tier 4i engine
complementary abilities in engine design and a global product application and support network, providing them with access to a complete suite of product solutions. As with all Perkins engines, flexibility and options availability for engine and aftertreatment ensures easy packaging for customers. SPAL Automotive (S-17529) strives to provide advanced airflow solutions that meet its customers’ demands and help guide them to future growth. Analysing today’s trends, manufacturers are investing in components and technology that will improve a machine’s efficiency over the long term. Arriving at the best fuel efficiency possible obviously requires the most efficient technology, which in SPAL’s case means its advanced brushless motor technology. This technology delivers a 35% reduction in motor density, plus a reduction in moving parts, which means more efficient airflow yielding less heat under the hood of a comprehensive range of off-highway vehicles. Featuring a completely IP68 and IP6K9K sealed brushless motor, the state-of-the-art
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Working hard on TIER 4 emissions?
SPAL IS READY TO GIVE YOU A HAND BRUSHLESS MOTOR FANS & BLOWERS
SAFE & SEALED Brushless
Sealed, High Performance, Heavy Duty SPAL is ready to provide customers with an extensive range of high performance DC and advanced safe and sealed Brushless fans and blowers specifically designed to respond to the new demands in vehicle ventilation and cooling. SPAL offers unique codesign capabilities to realise products which can meet the most challenging customer requirements.
Solutions for ever growing cooling needs •
Powertrain cooling
•
Heating Ventilation Air Conditioning
•
Battery thermal management systems
•
On-Board Electronics Cooling
Advanced Products feature: •
High efficiency and Low Power Consumption
•
Low Noise, Vibration and Harshness (NVH)
•
Electronic Controls with on-board Diagnostics
•
Motor with Integrated Electronic
No Worries!
No Worries: •
Patented internal and external design guarantees
•
Fully sealed and fireproof motor and internal electronics
•
IP68 and IP6K9K protection
•
High resistance to vibration and mechanical stress
•
Very long life under all operating conditions (over 30.000 hrs)
a 100% active and passive safety protection
OUTSTANDING TEC H N O LO G Y SPAL AUTOMOTIVE Via Per Carpi, 26/B • 42015 Correggio • Italy info@spalautomotive.com • www.spalautomotive.com
CONEXPO PREVIEW
brushless SBL300 technology is available in both axial fan and centrifugal blower configurations to suit a variety of air movement needs. When developing its new brushless SBL300 technology, SPAL focused on all aspects of design from performance characteristics to weight reduction to safety features. The brushless motor is 25-40% more efficient than an equivalent DC brush motor. The highly efficient and reliable design with advanced protection features exceeds 30,000 hours in most applications, while fully integrated motor control electronics yield increased reliability and reduced system complexity. The rugged design potential can exceed 10g+ requirements. Today, much of the machinery used in the off-highway industry has a lifecycle that extends beyond 10 years. Adding advanced components such as brushless technology into fleets today can save owners a huge amount of money in the future and thereby ensure a more environmental solution – which is definitely a growing requirement. The second generation of Donaldson’s PowerCore Filtration Technology for engine air-intake systems will be on display at Booth S-16029. Donaldson PowerCore G2 delivers longer life and less restriction in one-third less space than the original PowerCore.
PowerTRAIN
PowerCore filtration technology has been protecting engines and equipment for over a decade, with millions of units installed worldwide. PowerCore G2 filtration technology offers reduced size and the geometric flexibility to overcome tight space constraints resulting from today’s complex emissions systems. For given filter life and efficiency targets, the PowerCore G2 configurations can result in a 30% reduction in size from previous axial flow filters and a 60% reduction in size from cylindrical filters. Donaldson’s famous Duramax filters are the highest-rated medium-pressure filters available in a spin-on configuration. Duramax filters are reliable, sturdy, longlived and easy to install. Most often used as return-line filters, they are designed for working pressures up to 1,000psi/69 bar and static pressures up to 2,000psi/138 bar. Donaldson offers a full line of lowpressure, medium-pressure and highpressure hydraulic filters for the protection of machinery and components used in hundreds of heavy-duty mobile equipment applications. Wherever hydraulic filter assemblies, filter heads, replacement spinons and cartridges or hydraulic accessories are needed, Donaldson delivers!
Carraro will exhibit three examples of modular steering axles TLB2 (TC Full PS), TLB1SPS (TC Servo Synchro) and TB172-2 speed-shift for hydrostatic drivetrains at Booth S-16529. For these axles, the configuration flexibility is present in the braking system (service - service + mechanical parking or SAHR brakes), in the choice of differential locking (ECU option), as well as in electronic control capability such as steering and traction. The range of Drive Tech CE steering axles is designed to fit the needs of several applications from telehandlers to trenchers, from aerial platforms to other off-highway applications.
above: Carraro Drive Tech TB172-2 speed shift LEFT: Donaldson PowerCore filtration technology
All are controlled by a Trax proprietary ECU, which communicates via a CANbus with the other ECUs in the vehicle (engine and dashboard) to optimise performances of the entire powertrain. The Trax enables the control parameters to be widely customised and is fitted with an auto-diagnostic loop. It is designed to provide two control strategies: semi-auto and auto. Due to its performance, it can also extend its control across the entire drivetrain (for example, including electronic control of traction and steering). It was therefore designed to be the real brain of the Carraro Drivetrain. The TB172-2 speed-shift is a hydrostatic gearbox with two speed ranges (shift on the go), specifically designed to combine excellent comfort and fast shifting with the lowest power losses: by up to one third compared with many other gearboxes of similar performance. All Carraro Drive Tech drives have been developed with the specific aim of reducing consumption as much as possible while maximising comfort and the productivity of the entire vehicle drivetrain.
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TOTAL CONFIGURATION
SIMPLE. POWERFUL. EFFICIENT.
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P.O. Box 470248 Tulsa, OK 74147 Phone: 1.918.317.2616
http://www.fwmurphy.com/pv450-IVT 1010644-PV450-IVT
CONEXPO PREVIEW
The new E&Go system will also be on show. This was designed for hybrid or electrical propulsion, and is made up of a robotised two-speed drivetrain and an inverter for traction control – another example of solid skills in the field of sustainable mobility for the near future! From utility trucks to emergency vehicles, Tuthill Drive Systems’ EZ Trac (Booth S-14906) is designed to provide the driveability and confidence needed to get the job done off-highway. EZ Trac allows OEMs to cost-efficiently upgrade to ondemand all-wheel drive without the need to add drive lines, transfer cases or raise chassis height. EZ Trac is claimed to be the first commercially available, steerable hydraulic drive-assist system to simplify and overcome traction and mobility issues without sacrificing ride quality, fuel economy, safety and control. It has the novel and unparalleled ability to engage and disengage on the go at speeds less than 20mph, so that with the flip of a cabmounted switch, the driver has the control and traction to go from on-highway to offhighway – and back. Unlike conventional front-wheel drive systems, EZ Trac maintains factory turning radius, ride quality, ground clearance, overall height and allows for a lower centre of gravity, making the vehicle less likely to overturn and easier to handle. And, because it is 800-1,200 lb lighter than conventional drive systems and experiences no windage loss in freewheel mode, EZ Trac means that the vehicle consumes less fuel – and less of the operator’s bottom line.
LEFT: Tuthill EZ Trac RIGHT: Sauer-Danfoss H1 Automatic Control
The vehicle’s front axle is replaced with a fully dressed and assembled EZ Trac axle, maintaining the vehicle’s existing suspension, ride height, ride quality and steering geometry. EZ Trac axles are available in 12,000-20,000 lb weight ratings. A PTO is mounted to the transmission to power the heavy-duty hydrostatic pump (rated at 6,000psi). A hydraulic package including a hydraulic reservoir, oil filtration, electric cooling fan, hydraulic control valve and ECU, can be mounted anywhere on the vehicle chassis. The off-highway industry is currently facing two major compelling events – new emissions regulations and revised safety legislation – that will have an impact on nearly every aspect of vehicle design and development. Sauer-Danfoss (Booth S13428) will reveal technologies and solutions that will enable OEMs to meet these challenges. New engine emissions regulations require highly efficient systems to compensate for changes in power levels, torque characteristics and an increase in heat rejected from engines, while new safety standards demand a more comprehensive process of system development and qualification. With the goal of helping to reduce costs, improve overall system efficiency, increase productivity, and ultimately bring vehicles to market faster, Sauer-Danfoss will highlight:
BELOW: Sauer-Danfoss OSPE steering unit
• The new H1 Automotive Control, SIL 2certified, to help reduce vehicle development and qualification time; • A complete range of fan drive solutions that provide cooling on demand and recover up to 50% of the engine power loss of emission-compliant engines; • The new OSPE electrohydraulic steering unit, which features a direct electric interface for use with GPS, row or laser auto-steering; • The latest additions to its H1 pump and motor family, designed to improve overall vehicle efficiency and increase productivity; • An impressive range of PLUS+1 hardware and software, including new software application blocks that ensures intelligent system management, reducing energy consumption and lowering emissions.
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CONEXPO PREVIEW
MICO will introduce its hydraulic-over-air relay valves at Booth S-13653. The valves are designed to convert hydraulic modulated input pressure to a proportional output air pressure. The new relay valves are ideal for various on- and off-highway applications, such as controlling an airbraked trailer with a hydraulically braked towing vehicle that has an air power source. The system originates with a hydraulic vehicle component, such as a master cylinder or hydraulic control valve, which delivers a given hydraulic input pressure. This input pressure sends a pilot signal to the relay valve to modulate air brake pressure on the other end. MICO offers three different hydraulicover-air relay valve designs: single, dual and tandem. The single input design provides one hydraulic pilot port to control modulated air braking pressure. The dual input features two independent ports, either of which can accept pilot pressure. When pressure is applied to both ports simultaneously, the controlled air braking pressure ratio increases proportionally. The dual input ports can be set up for different pressure ratios, making the dual design a good fit for some steering-assist applications. Functionally similar to the single design, the tandem input provides redundancy by utilising two independent pilot pressure ports. This enables hydraulic pilot pressure to be applied to either port while allowing the pressure ratio to remain the same. The new relay valves can accommodate a maximum air pressure of 150psi and a maximum hydraulic pressure of 2,000psi. The valves can be adjusted to operate at anywhere from a 3:1 to 21:1 hydraulic-toair-pressure ratio. Maximum operating temperature for the valves is 250°F (121°C).
The truck’s service brake is supplied by Knott, whose particular forté is the rapid development and production of customtailored brake solutions of all sizes. The company is able to offer considerable experience in the development and construction of brakes for XXL-sized building machinery. A diesel-electric powered dump truck of this magnitude is braked initially by converting its electrical drive motors into electrical generators. Aircooled resistors dissipate this electrical
energy in the form of heat. When travelling on the level, the service brakes are only called upon at a relatively late stage of deceleration, while when travelling downhill or during emergency braking they are in continuous operation. When working on new designs, Knott is able to look back on decades of experience in the design, development and production of brake solutions capable of complying with even the toughest demands.
ABOVE: MICO hydraulicover-air relay valves BELOW: Big brakes from Knott
Liebherr’s largest and heaviest ever-mining truck, the T282, caused a stir when it was revealed at Bauma 2010 in April. The truck is now approved for a maximum gross vehicle weight of 600 tons. Its engine boasts an output of 3,650bhp, providing a maximum speed 64km/h. The question is, how do you stop a giant of these proportions in its tracks?
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Q u a l i t y i n F i n e D e t a i l.
New range of joystick grips - maximum versat ility and modular ity - lef t and r ight hand version - push buttons and thumbwheels can be combined, customised and fully illuminated according to your applicat ion - all controls are based on Reed or Hall ef fect for harsh env ironment - can be delivered w ith integrated CAN module & capacit ive presence detect ion - shell and control colours can be specif ied - opt ional redundancy for safety applicat ions - can be f itted on heavy and medium duty joyst ick bases
®
March 22-26, 2011 Las Vegas Convent ion Center Las Vegas, Nevada Booth #17630
GmbH & Co. KG Ze p p e l i n s t r. 4 4 88299 Leutkirch Germany
§ +49 7561 970-0 ¨ +49 7561 970-100 w w w.e l o b a u .co m info@elobau.de
CONEXPO PREVIEW
HYDRAULICS Hawe Hydraulics (S-13342) will reveal the V30E-270 variable-displacement axialpiston pump to meet a broader range of demanding applications. A new feature is the third mounting flange variant, and spline shaft variant, both conforming to SAE J744. If the pump is used as a tandem combination – two pumps of the type V30E-270 – the load increases. The end housing for the first pump was therefore newly designed to ensure safe transmission of higher drive performances from the first to the second pump. The user can flexibly select the second pump, irrespective of whether he wants to deploy the combination in mobile or stationary applications. The combination with Hawe’s variabledisplacement axial-piston pumps is very good. Like all other pumps from the V30E series, the V30E-270 type can also be combined, for example, with the manufacturer’s radial piston pumps to generate a second high-pressure level. The V30E variable-displacement axialpiston pump is designed as swashplate built. It is sturdy and generally suited for open circuits both in mobile as well as industrial hydraulics. The purpose-built followers, swashplate bearing and control plate provide the pump with longevity. The extensive controller program supports its many deployment options. The pump model also excels through its low noise level.
right: Marzocchi LS pump BELOW: Hawe V60N axial piston pump
The V30E-270 has been designed for an operating pressure of up to 5,075psi (350 bar), with a peak pressure of 6,000psi (420 bar). The output volume is up to a maximum of 124gal/min (470 litres) at 1,750rpm, with a geometric displacement of 270cc/rev. Combined with Hawe Hydraulics’ proportional directional spool valves and electronic controls, the new pump easily extends into a fully fledged and customised hydraulic system. The new nominal size 7 of the proportional directional spool valve is particularly suited for the tandem combination of two V30E-270 pumps. Marzocchi Pompe (S-16043) has taken the opportunity to complete the renewal of its product range, introducing new pumps with integrated valves, among which those with a priority valve aim to satisfy the requirements of the mobile market. The new LS range of pumps, with a priority valve, is only produced in the castiron version, in the families 2 and 3 and covers a range of displacements 4.5-87cc/ rev. The components of the priority valve, the controlled and the priority ports, and the load-sensing connection, are situated in the cast-iron cover of the pump. The working hydraulic pump operates in an open circuit, drawing up oil from the hydraulic tank and pumping it to the control block integrated on the cover. The job of the priority valve attached to the pump is to distribute the oil from the working hydraulics to the steering system. The oil supplied to the steering system always takes priority; the rest flows to the working hydraulics. The load-sensing system
guarantees that – in every operating condition – the steering system receives the oil according to the actual requirements. The pumps with a priority valve are available in various versions. It can be supplied with or without a load-sense signal (in both the static and dynamic versions). It is also possible to integrate a relief valve with internal drain in the cover. The LS pressure-relief valves prevent excessive pressure peaks in the steering system. The primary characteristic of a dynamic signal system is the improvement in the priority valve’s response time. Bucher Hydraulics (S-15929) will show the SVC25, a load-sensing proportional valve of a sandwich design suitable for high flow rates of up to Qmax = 600 l/min, with a correspondingly high operating pressure of pmax = 420 bar. Particular attention has been paid to power density, function, and versatility. Its good proportionality and stability characteristics are due to the special geometry along the control flanges of the individual valve pistons. This ensures that high flow rates are kept under control. A manually operated version is also available in addition to the models with hydraulic and EH controls. Manual versions work in a similar manner to hydraulically actuated pressure-reducing valves. The advantage of this kind of actuation is that the leverage forces are low and the leverage lengths involved can be kept short. Manual operation serves as a direct proportional control of the directional valve – a feature frequently required for winch controls, for example – or as an emergency hand lever. The advantage of this is that with electrical activation, the hand lever remains in its idle position. On the one hand this provides added security; on the other, hysteresis is kept to a minimum. Various input modules are available for different kinds of pumps. If required, optional features can be integrated, such as peak-pressure reducing valves or a pilotpressure supply unit, which can be switched off and which, when activated, also disengages the manual operation function (the safety circuit).
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Control Position Penny + Giles Industrial Joystick Controllers are designed and built for taking control on OEM vehicles in the Construction, Agriculture and Materials Handling industries. With a comprehensive range of single and multi-axis joysticks we’re able to meet today’s tough demands head on. Add to that our pedigree range of position sensors and solenoids, and we’ve got most applications under control: Contactless Single and Multi-Axis Joysticks for safe, long life operation Rugged Multi-Axis Joysticks for harsh mobile hydraulics Rugged Single-Axis Joysticks with ‘Person Present’ security Fingertip Joysticks for smooth, precise control Fingertip Rockers for panel and handle controls
Call or e-mail for a Product Range catalogue today! Penny+Giles Controls Ltd 36 Nine Mile Point Ind. Est, Cwmfelinfach Gwent NP11 7HZ, UK T:+44 (0)1495 202000 E:sales@pennyandgiles.com
Joysticks+Sensors+Solenoids www.pennyandgiles.com
CONEXPO PREVIEW
Consumer modules provide even more additional operations, such as ancillary antishock or anti-cavitation valves, or a combination of both, which can be adjusted independently of each other in work connections A and B. Upstream, twoway pressure compensators offer the advantage of a pressure cut-off (A and B sides separately). Wandfluh’s (Booth S-14916) MD2 digital amplifier and controller module has been especially developed for actuating hydraulic valves under extreme ambient conditions. Wherever moisture, vibrations, higher temperatures or fluctuating supply voltages occur, this module is appropriate. It fulfils the requirements of simple installation and commissioning, without the necessity of special programming knowledge. The digital amplifier and controller module is characterised by its robust and compact design. As a result, it is very suitable for applications in the mobile field. The module is available as a pure amplifier, for actuating proportional and switching valves or also in combination with controller functions. It is very easy and fast to set the most diverse controllers, such as pressure, volume flow or position controllers. For the communication in a modern Fieldbus system, a CANopen interface, conforming to the standards, is available.
ABOVE: Bucher SVC25 load-sensing proportional valve right: FD89 couplings from Eaton BELOW: MD2 digital amplifier from Wandfluh
The module has digital inputs and outputs, as well as powerful PWM outputs for operating the solenoid valves. In addition, the digital inputs are capable of processing frequency or PWM signals without any problems. For processing analogue process signals, up to four analogue inputs with a maximum resolution of 16bit are available. The assignment of the inputs and outputs relative to one another is variable. This enables an optimum utilisation of the hardware present and guarantees a flexible adaptation to the application without any programming knowledge. The device set-up and the process data analysis take place with a very easy to use software, PASO. The connection with the MD2 is made via a USB interface. Using PASO, all process and diagnostics data can be viewed or, if required, recorded in real time. In doing so, the complete signal flow from the control signal input to the solenoid output can be seen with all adjustable and set parameters. The parameters can be changed or stored in memory very easily, without losing the overview. Eaton’s new FD89-2000 Series of ISO 16028 stainless steel quick-disconnect/nonspill couplings featuring standard antiextrusion Teflon seals and Viton O-rings will be on show at S-13129. They provide customers with push-to-connect latching and flush-face valving, and incorporate a safety sleeve lock.
“FD89 couplings provide a globally interchangeable solution for a variety of applications that require both corrosion resistance and long product life,” explains Eaton product manager, connectors, Joseph E. Dzierwa. “They’re machined from 316 stainless steel and conform dimensionally to ISO 16028, which is found in applications including snow ploughs, marine systems, on- and offshore oil and gas rigs, chemical processing operations, clean rooms and pharmaceutical manufacturing systems.” Eaton FD89 couplings are available in sizes -04, -06, -08, -10, -12, -16, -24 and 32 (1/4in to 2.0in-ISO 6.3, 10.0, 12.5, 16.0, 19.0, 25.0, 27.0, 31.5 and 40.0) with operating pressure ratings ranging from 150-350 bar (2,175-5,075psi), depending on size. Fluid loss per connection ranges from 0.006cc to 0.100cc, again depending on size. Faster intends to focus attention on one of its crowning achievements at Booth S16643. 4BD is a block coupler designed for hydraulic quick change and is ideal for skidsteer loaders, tractor backhoe loaders and utility vehicles. It allows changes from one attachment to another within seconds and provides for connection under pressure. The 4BD has greater flow capability than standard 1/2in flat-face couplers and enables an overall reduced pressure drop. As a patented design, equipped with flat-face couplers conforming to ISO 16028, the Faster block coupler has been specified by industry leaders and has been in the market for 10 years – reliable, innovative and proven!
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Data Loggers
Intelligent Vehicle Controls from HED and Huegli Tech
User-friendly Development Software
Telematics
Displays Controllers
CAN Keypads
Visit us at ConExpo 2011 in South Hall Booth no. 13552
HED Inc. is excited to announce a new distribution partnership with Huegli Tech AG to provide mobile electronic vehicle controls in select regions around the globe. HED Inc. is a recognized leader in the development and manufacture of mobile electronic controls. HED has been supplying to fire and rescue, refuse, truck, bus, military, construction, agricultural, forestry, material handling, and stationary power equipment markets for over 20 years. For more information visit us at www.hedonline.com
HUEGLI TECH AG is leading Supplier and Whole-
HUEGLI saler with core competences in vehicle controls, TECH engine governing systems, generating set controls SWITZERLAND
and gas engine starting/management systems with locations throughout Europe, China, Russia, Japan, Korea, Asia-Pacific, India and the Middle East. For more information visit us at www.huegli-tech.com
TRIM 7.2047”
Visit us at CONEXPO-CON/AGG • March 22–26, 2011, Las Vegas • Booth S-18317
ENDURING COMMITMENTS.
We’ve delivered resilient and rugged products that stand the test of time and perform expertly under the harshest conditions and in the most demanding environments. We look forward to the results we can achieve together in the next half-century.
Visit www.ottoexcellence.com or call 847-428-7171. Precision Switches » Operator Controls » Custom Solutions ©C Co opyri p ght pyri ht 2011 2011 OTTO OTT OT TTO Engine Engine g n erin ering, g, Inc. Inc. ® OTTO OTTO TT TO and an nd the he e OTTO TO Exp Expect Ex ect c E ct Exce xcelle llen llence ce lo ogo o are re regi egi g ster gi ste ered ed trade tra rad rade ademark arkss of OTT TO Engine gineerin erii g,, Inc. ering, erin Inc. All All rights rig righ igh ghts g s rese re eser ser errve ved vved. e ed. 2 ed 201 20 2011-13 011 01 1-13 -13 3
TRIM 4.5276”
EVOLVING IDEAS.
CONEXPO PREVIEW
The Temposonics connector system from MTS Sensors (S-13728) is now available universally for the whole M-Series sensors product range. Developed for reliable position measurement, these sensors can be embedded completely into a hydraulic cylinder. Click-on mounting, without the need of any tools, saves valuable mounting time and increases the safety of the sensor installation. The sensor is installed in the cylinder and connected electrically within seconds. Time-consuming connection of the cable conductors, polarity errors or ‘dry’ solder joints are a matter of the past. It was developed primarily for the MH sensor model (the standard sensor for mobile hydraulics). After further development and optimisation, the unit can now be used to facilitate mounting and ensure safe connection to the machine electronics of both the compact Temposonics MS sensors and the redundant Temposonics MT sensors. The connector system is in compliance with the most exacting protection requirements according to DIN EN 60529. With protection type IP69K, the robust metal housing is not only absolutely dustproof, but penetration of water inside the cylinder is also prevented.
HED Inc is excited to announce a new distribution partnership with Huegli Tech to provide mobile electronic vehicle controls in select regions around the globe. Huegli Tech has been a leading global supplier in vehicle controls, including engine-governing systems, generating set controls and hydraulic systems since 1929. With locations throughout Europe, China, Japan, Korea, Asia-Pacific, India and the Middle East, it has a strong global footprint to provide excellent sales and application support for HED products. HED will be unveiling some pioneering innovations at Booth S-13552, including several new vehicle displays, telematics, data-loggers, control modules and CAN keypads. HED will be releasing its DataCom module, which can be configured as data-logger with up to 6GB of memory and optional WiFi communications, or as a telematics module with the ability to communicate vehicle data to a phone or website via cellular communications. In addition, HED has expanded its display offering by adding a 3in and 4.3in display to its existing lineup, which includes 5in and 7in high resolution displays. HED has also extended its operator interface products by releasing a new 12-button (2x6) CAN-based keypad equipped with the ability of controlling four inputs or outputs. Future plans include eight-button (2x4 and 4x2) and 12-button (4x3) variants. With a mission to provide substantial market differentiation to its OEM customers’ on- and off-highway mobile vehicles through superior electronic control solutions that enhance vehicle performance, HED is a recognised leader in the development and manufacture of mobile electronic controls utilising the highest technology and quality standards.
The connector system is prefabricated and delivered in conjunction with the MSeries position sensors, with its contact carrier already connected to the sensor conductors. When mounting, the contact carrier is taken out of the cylinder through a bore hole, and the flanged housing can be clicked in position easily from outside. During installation of the cylinder unit into the mobile machine, the M-Series sensors can be connected at different angles, using a universal M12x1 connector. The minimised installation height of the connector system ensures successful cylinder mounting even under limited space conditions.
Top left: 4BD block coupler from Faster below right: FW Murphy PowerView 450 display below left: MTS MSeries sensors
ELECTRONICS The PowerView 450 display is FW Murphy’s newest freely configurable display for the off-highway market (Booth S-16553). It was designed so that each of the primary components can be isolated and customengineered to customer specifications with minimal non-recurring engineering costs and shorter development time. Customise the display by modifying the button and enclosure shape and colour to create your own unique brand. Much like the larger PowerView 750, the PowerView 450 integrates electronic engine, transmission and machine information into one easy-to-read display, but its compact 4.3in bonded WQVGA LCD saves valuable space on the operator panel. It focuses on making customisation quick and simple, and provides intuitive tools, such as the PowerVision Configuration Studio, to reduce the complexities of programming. The PowerVision Configuration Studio provides direct access to all levels of software customisation on the PowerView displays – modify the graphics, create custom alerts, write custom code and more. Users can choose from a base library of templates and custom screen designs, or upload their own images to create uniquely customised screens. The PowerView 450 display comes equipped with a real-time operating system (QNX). Standard configuration includes three CAN inputs, which support several protocols including J1939, NMEA 2000 (for GPS data) and now CANopen. It allows users to easily integrate into Tier 4i/Stage IIIB emissions-compliant applications. For improved durability in even the harshest conditions, the display features a wide storage/operating temperature range
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CONEXPO PREVIEW
of -40 to +85ºC, high-impact protective casing in the front and back and an IP66 and IP67 environmental sealing. The display was designed to support optimum viewing angles, and features complete bonding of the LCD to the glass, which reduces glare while improving viewing angles and reliability. Ametek VIS will be displaying its full range of ruggedised instrumentation for demanding off-highway applications at Booth S-15142. Its new CAN-Communicator (C-COM) lightbar and gauges offer a 340x90 full-graphic display that allows easy vehicle interface, direct-read J1939 CAN, in a fully sealed package. The large, easy-toread graphics display provides real-time
data information, diagnostics, fault codes, user set-up features and maintenance requirements. C-COM offers flexibility to customise for any application in a timely manner. This means minimal development costs and quick time to market! The fully sealed message centre has a colour TFT display with a video input and J1939 CAN interface. The display has a wide viewing angle and temperature range, is daylight readable, and demonstrates the use of high-quality graphics for effective HMI in a rugged environment. The company will also feature more graphics concepts in its Universal Instrument Panel - Message Centre (UIP-MC). Multiplexed touchpads will also be exhibited. This environmentally protected touchpad, with backlit keys, utilises CAN J1939 interface to receive or send
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information from the vehicle and can be easily customised. The dead-fronted LED status indicators are controlled by command message via CAN J1939. Along with its customisable off-theshelf solutions, Ametek offers full custom solutions, and it will showcase a full line of custom clusters developed for a variety of applications. These clusters demonstrate what the company notes is its expertise in working with customers specifically to modify and customise its products to suit particular applications and environments. A breakthrough advanced control technology has been launched by the David Brown Hydraulics team (Booth S14457). T safeTgrip is a dead man’s switch without moving parts. This product has been developed following extensive customer consultation with construction equipment OEMs and operators whose primary focus is machine-control safety. In all moving equipment, the drive systems can only be activated following a positive confirmation that the operator has full control over it, typically by having to squeeze and hold closed a mechanical trigger. If the operator loses his grip of this trigger the machine stops moving. This has worked very well over the years and is widely recognised as a safe way to achieve this control – but is not without compromise. Customers have been looking for specific and sometimes vital improvements to this old and well-proven system of which three particular requests are: • Effort-free for user: this system has no switch to squeeze; • Redundancy inbuilt in system: it must always work, so safety has been doubled;
above: Wide range of products from Penny + Giles left: Rugged instrumentation from Ametek VIS below: safeTgrip from David Brown Hydraulics
• Cannot be overridden: safety first, without compromises. Penny + Giles, producer of high reliability position sensors, joystick controllers and solenoid actuators for industrial and offhighway speciality vehicle applications, will be showcasing a range of new products at Booth S-15307. The JC1500 non-contacting single-axis joystick controller will be shown, with the addition of a new ergonomic handle option. This handle can also be used on the Penny + Giles dual-axis rugged joysticks, or can be sold as a separate item for fitment on vehicle control levers. New multifunction controls, such as a Hall-effect thumb-operated miniature joystick and a Hall-effect thumbwheel roller are expected to make their debut too. New Hall-effect rotary position sensors on display will be the NRH285DR. This model has a co-moulded fully encapsulated sensor system that can withstand high shock and vibration, as well as operate up to 170°C, and endure high-pressure wash-downs (IP69K). The sensor is activated by a separate magnet, and features a choice of three magnet carrier designs. The sensor operates from 5V DC, with two independent power supply and outputs, enabling full redundancy from a very slim package. Penny + Giles offers a wide selection of standard configurable products and is an expert in the design of custom interface and controller solutions for operator controls, custom position sensor solutions and custom solenoid actuation solutions. iVT
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PRODUCTS & SERVICES alexander eisner
Evolution solutions Booth S-17315
RIGHT: ZF cPower – a fully powersplit CVT transmission below: ZF 2 HC 85 – compact and modular hydrostatic CVT for road speeds up to 50 km/h
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new power transmission developments are the answer to many challenges faced by the construction machinery market. check out this range of adaptations on display at conexpo
The trend towards lower engine speeds and the demand for engine stabilisation through a constant speed concept are the future challenges for the construction machinery market. The continuously variable cPower from ZF meets both requirements. In wheeled loader applications, hydrostatic-powersplit transmissions ensure considerable consumption benefits over hydrodynamic transmissions and purely hydrostatic concepts. CVTs clearly demonstrate their benefits during all ranges of the typical wheeled loader operating cycle: bucket filling, transporting and loading. In this process the percentage of hydrostatic power is kept low so that an optimal degree of efficiency can be achieved. Already part of the start-up process, the mechanics of the transmission give the biggest output and, even in very short loading cycles, the continuously variable technology will result in reduced fuel consumption. The application of an elaborate hydraulic transmission-control unit and transmission integrated onboard electronic optimally completes driving functions in reference to sensitivity and driving comfort and realises an aligned power management. The cPower transmission series deploys well-known and proven construction kit modules, and benefits from ZF competence in transmission and vehicle system engineering. The new ZF cPower benefits from continuously variable drive across the whole range, as well as hydrostatic-mechanical powersplitting, including the most frequently used range up to 10km/h. The reduction of diesel engine speed independent of driving speed leads to up to 30% lower consumption and up to 20% more efficiency, while the vehicle’s driving performance is identical in both forward and reverse travel.
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Continuously variable or powershift? The 2HC 85 transmission system with integrated actuators and sensors for construction machinery up to 10 tons enables continuously variable vehicle speeds up to 50km/h and does not require any additional shifting devices. Two crankshaft radial piston motors are an integral part of the drive unit. Highly precise manoeuvring during loading and unloading operations plays a vital role in any off-highway machinery application. The hydrostatic 2HC 85 transmission makes this possible at full traction throughout the entire speed range. The whole accelerator pedal play can be used to precisely position the vehicle by selecting the desired driving range. Further advantages include increased ride comfort, continuously variable operation without gearchanges and no
tractive effort interruption, resulting in higher work output. The electronically controlled driveline management provides a low start-up speed, and the load-sensing control ensures optimised diesel speed even under load. The ZF Ergopower L II is the automatic powershift transmission for dump trucks up to 50 tons payload and with a gross weight of up to 82,000kg. The transmission is characterised by its high loading capacity, it is powershiftable and offers up to eight forward and four reverse gears. The gears are shifted completely smoothly under electronic control. Due to the integrated primary retarder the Ergopower L II offers very good braking performance and considerably reduces wear on the service brake. The Ergopower L II is characterised by an optimum shift pattern, even under the highest loads.
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Best of both worlds On the basis of the well-proven Ergopower series, the ZF hybrid component is the logical evolutionary step towards an electric drive and is keeping pace with the trend towards more environmental protection and preservation of resources. ZF offers hybrid technology covering electric machines and complete hybrid systems from one source. Its hybrid system is suitable for all ZF transmission forms and can be implemented for direct and separate transmission mounting. The ZF Ergopower hybrid offers a number of advantages. Its stop/start function considerably reduces fuel consumption, and this, combined with simplified exhaust aftertreatment systems (meaning lower exhaust emissions), leads to lower operating costs, which can be further exploited by downsizing the engine. The recuperation of braking energy boosts performance, increasing work output, and the engine operation point has been shifted. This machine works as a parallel hybrid with an efficient electric machine – which can be integrated into the transmission – providing up to 85 or 120kW performance, depending on the size. The complete hybrid system comprises power electronics for the electric machine and a lithium-ion battery as well as a hybrid control unit. The optimised energy and hybrid drive management means the interaction between electric machine and IC engine is matched to avoid driving situations with poor efficiency and increased emissions. The Ergopower hybrid system is available for a wide range of vehicle applications and can also be combined with cPower, HL or HC 85 transmissions from ZF. Construction
machinery and diesel lift-trucks can all be equipped with this future-oriented and environmentally friendly technology.
Mix it with the best ZF’s new generation of the Ecomix range type CML (concrete mixer low speed) is designed for concrete mixers up to 10m³ drum capacity and an output torque up to 62,000Nm. The Ecomix II transmission CML 10 is up to 24% lighter and 50% shorter than previous models. With a tough bearing concept it was possible to considerably increase the output bearing strength, which leads to less sensitivity during off-road operation. The use of patented Elastomer units from ZF Boge Elastmetall enables an increase of the axial run-out at drum bottom and an increase in misalignment of the drum. With the new bearing concept, the installation angle is no longer dependent on drum size and drum filling – up to 20° is always possible. Acoustic and mechanic decoupling of drum and vehicle frame also leads to considerable noise reduction during operation and improved driving comfort. Serviceability has been improved due to an adapted, weight-optimised low-speedhydro motor, separate oil for transmission and hydrostatics, and the improved accessibility. The compact, light design offers the vehicle manufacturer more freedom in design and facilitates assembly.
for highly demanding applications, while nominal torque capacity could be increased by 33% over the previous model. As a result of more moderate axle weight and oil volume increases, the power to weight ratio has been improved. Despite this, the lifetime of axles with expected 15,000 operating hours for heavy-duty application could be considerably increased. In addition to the low-speed operating brake and the open differential, which can be locked by a powershiftable clutch, a great many individual measures are contributing to the fuel savings target. The MT-L 3135 has a 2,600mm flangeto-flange dimension for empty vehicle weights up to 40.5 tons, and offers a 33% increase in torque capacity at 263,000Nm axle output torque. iVT
left: 8 4 50 – hydrodynamic powershift transmission with eight forward speeds for up to 50 tons payload centre: The new Ecomix II – up to 24% lighter and 50% smaller, tougher, more flexible, more noise reduction and easier to service right: MT-L 3135 – the largest wheeled loader axle in the ZF portfolio; for empty vehicle weights up to 40.5 tons below: The ZF hybrid system can be implemented for direct or separate transmission mounting
Alexander Eisner has worked in marketing communications, construction machinery at ZF since 2007
Axles for the highest loads ZF has extended its well-proven axle series MT-L3000 by the three new axle types MTL3115, MT-L3125 and MT-L3135. These offer outstanding reliability and efficiency CONTACT www.zf.com gernot.hein@zf.com
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PRODUCTS & SERVICES neal shawaluk
Rapid response Booth S-16401
Right: Reliable and economical, VMaster Di and Stratis Di provide variablespeed fan control specifically tailored to your enginecooling requirements Below: The modular features of WindShift and Shogun fans allow for much greater flexibility in design, manufacturing and performance
Cooling requirements are constantly changing, so it is vital that these needs are met quickly. A variable-speed fan control that conforms to the European noise directive is the answer
VMaster Di or Stratis Di viscous fan drives and controllers provide economical, variable-speed fan control. These systems are engineered with a 70% fan-speed feature to help OEMs meet CE noise ratings. J1939 compatible, VMaster Di and Stratis Di are plug-and-play and save fuel while increasing productivity. Customised algorithms tailor cooling to the specific requirements of off-highway equipment, commercial vehicles and buses. Such variable-speed viscous cooling offers clear benefits over direct-drive and hydraulic-fan drive systems. Direct drives constantly run at full speed, unnecessarily consuming fuel, wasting horsepower and creating fan noise. Despite having variable speed, hydraulic systems are expensive to buy and maintain and cause safety hazards if they leak hydraulic fluid. VMaster and Stratis viscous fan drives, on the other hand, are not only economical, but also deliver excellent variable-speed performance, more available horsepower for auxiliary components and maintenance-free operation. Endurance-tested, VMaster Di and Stratis Di respond rapidly to changing cooling requirements, provide optimal fan idling speed and have greater torque transmission speed. Equipped with a double-row bearing for increased durability, the drives feature an improved fluid flow return path for better heat removal and tighter fan control. Completely sealed, they are durably constructed and require no maintenance. An integral fan-speed sensor provides closed-loop control, and an optimised magnetic design speeds up reaction time for better modulation and cooling. Stratis viscous fan drives also feature an innovative reservoir, actuator and valve system that delivers faster response and improved cooling with highertorque fans.
VMaster Di and Stratis Di systems are compatible with WindMaster, Shogun and WindShift Fans for complete Tier 4 cooling.
Fan club WindMaster Revolution high-efficiency, hybrid-flow fans are a revolutionary mix of the best features of axial-, mixed- and radialflow technology – minus all the disadvantages. This innovative high-efficiency, hybrid-flow technology means WindMaster Revolution provides the ultimate airflow solution. Designed specifically for today’s hotterrunning engines, WindMaster Plastic Fans combine maximum cooling performance and efficiency with a longer operating life. Horton’s ingenuity resulted in this lighter, innovative design, while extensive testing ensures maximum cooling and durability. WindMaster Metal Fans are competitively priced and custom designed to meet precise application requirements for airflow, size, tip clearance, fanpulley ratio, fan-speed
range and more. Horton’s technical experts work with customers to determine the right fan for their application. The fans are offered in clockwise or counter-clockwise rotations with single, double or quad spiders. The modular feature of WindShift fans makes possible greater flexibility in design, manufacturing and performance. WindShift is constructed with innovative clamshell knuckles that clamp each blade to a steel centre disc. This allows the blades to be set to a specific pitch angle for increased versatility and faster, easier testing and prototyping. The flexible design also allows for configurations from three to 13 blades and the ability to stagger the blades to alter the blade pass frequency. Shogun modular fans are designed to meet the cooling requirements of new reduced-emission engines. Blade segments are riveted to a centre disc allowing for maximum flexibility, efficient customisation and shorter lead times. Shogun delivers more stable airflow and higher efficiency. iVT Neal Shawaluk is director, sales off-highway, industrial and specialty markets for Horton Inc CONTACT www.hortonww.com/ivt2 info@hortonww.com
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South Hall Second Booth 14916
Pr Proportional valves with slip-on coil wi It is the high power density, the customer-friendly operation, the robustness as well as the ease of maintenance, which characterise the mobile hydraulics. These characteristics are also demanded of the hydraulic components, which are utilised in the applications in the mobile sector. Swiss made
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Building the world's most rugged instruments for the most demanding environments. Out here, failure is not an option. That’s why our C-COM lightbar and gauges feature direct J1939 CAN communication and are sealed to IP67 standards. The LMC’s full-graphic LCD provides quick, easy vehicle interface, while the rugged 2A and 3A gauges with their heavy stepper motor drives withstand high G forces. So no matter the shock, temperature, humidity, vibration, salt or dust conditions, vital vehicle information is communicated continuously. If these are your operating environments, they demand C-COM instruments. Learn more at (970) 244-1269 or visit: www.ametekvis.com
See us at ConExpo-Con/Agg Booth #11708
Hall 23 Booth B21
PRODUCTS & SERVICES JOHN EASTON
Waste not, want not Booth S-14728
Improvements in energy management and emissions reductions are welcome traits of new transmission products that will be introduced at conexpo
Fairfield’s new E07H electric drive for rough-terrain equipment
At ConExpo-Con/Agg 2011 in Las Vegas, Nevada, Oerlikon Fairfield will introduce several new products that provide mobile equipment manufacturers with a range of options for improved energy management. These new additions include the introduction of the E07H – part of a family of electrically driven Torque-Hub products for use in many off-highway applications – and the CT05M and CT07M, two new drives with integrated axial piston motors and a two-stage planetary gearbox. Focusing on the needs of access platform manufacturers, Fairfield has extended its range of successful electric drives to include the E07H, an integrated model for use in larger, rough-terrain equipment. The features of the E07H include a compact arrangement, highspeed AC induction motor (6,000rpm maximum), electromagnetic brake and a high-reduction gearbox to achieve a maximum output torque rating of 7,000Nm. The planetary gearbox also provides options for gear reduction ranges of 90:1 or 160:1. When powered with
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three-phase electrical power, this final drive solution can be used on boom lifts, large scissor lifts, telehandlers and large forklifts. Fairfield’s integrated electric drives can be easily incorporated into hybrid-electric systems that offer an alternative to standard hydraulically driven designs that frequently demand peak power from an IC engine. Boom machines, for example, usually only require peak power when climbing their rated grade. When less power would suffice, the hydraulic designs often waste power and are inherently inefficient. With increasingly stringent emissions standards, hybrid-electric systems are becoming more desirable. The same boom machine may benefit from a hybrid-electric configuration involving a gen-set and battery pack. This would enable the peaks and lows of the power requirements to be smoothed out by permitting the engine to be sized for the average power requirement rather than the peak power demand. In addition, energy can be recaptured from braking. This system leads to better efficiency, quieter operation and fewer harmful emissions.
One of the challenges associated with manufacturing for outdoor machinery is how to protect the equipment from external environmental factors. To achieve this, the E07H has motor options with IP67 ratings that prevent water intrusion at depths up to 1m. The E07H has a very short profile, because high-speed electric motors are more compact than low-speed motors for the same power rating. Fairfield was also able to design this product with nested input and secondary planetary stages to reduce the axial length of the unit. The reduction in axial length means this drive can be applied on steerable wheels without interference issues. This enables the E07H to be applied on four-wheel-drive machines where typically a traditional, hydraulically driven system has been used previously.
Final drives for harsh environments The other innovative product line expansion Fairfield has recently introduced is the CT05M and CT07M Torque-Hub final
PRODUCTS & SERVICES
drives. These drives are specifically designed for the harsh working environment they will encounter with demanding mobile applications, such as compact tracked loader (CTL) machines. These final drives use an integrated axial piston motor and a compact, two-stage planetary reduction. The latest technology was considered early in the design process for both the CT05M and the CT07M, with an emphasis on helping manufacturers meet the regulatory challenges of upcoming diesel engine emissions requirements. These new regulations may affect certain engine characteristics such as requiring a reduction in operating speeds to accommodate fuelinjection timing, which can lead to reduced pump flow. This is a challenge for OEMs who want to maintain or increase vehicle speed. To solve this problem, the two-speed final drives were designed specifically to have a high displacement ratio between maximum and minimum displacements. The lower minimum displacement values enable higher speeds even if pump flow is reduced due to engine speed reductions. In addition to the minimum displacement values noted in Table 1, Fairfield can also provide further choices for minimum displacement options to enable the OEM to fine-tune machine performance. A further advantage of the high displacement ratio is the opportunity for the OEM to incorporate the same drive system over a range of machine sizes. The high displacement ratio enables these drives to be adaptable to changes in pump size, rolling radius (sprocket) and vehicle speed design requirements. Other features of these integrated final drive designs include a large servo piston for a smoother shift and an optional speed sensor that has temperature-sensing capabilities. An integrated loop flushing valve is provided for added cooling and
Models Maximum displacement Lowest minimum displacement Displacement ratio Planetary ratio improved fluid quality. Both drives are fitted with an integrated spring-applied, hydraulically released brake capable of 100 panic stops with full hydraulic power and maximum vehicle inertia. The brake design also incorporates an active flushing feature to allow for deep case cooling. A mechanical face seal with a protective seal labyrinth is standard to protect the final drive from any foreign contamination. The CT05M and CT07M have each been through rigorous and inclusive testing in the laboratory as well as in the field. This validation process equates to thousands of hours of machine durability testing and a successful product launch from a major compact tracked loader OEM.
CT05M 43.5cc 17.3cc 2.5:1 21.67:1
CT07M 53.8cc 23.4cc 2.3:1 21.67:1
track drives. Featuring gear reduction ranges of 70:1 to 169:1, these new models will extend the application range of the company’s commercially successful final drives into larger mobile equipment applications including track-driven trenchers, drilling machines, tool carriers and cranes. Located in Lafayette, Indiana, USA, Oerlikon Fairfield – along with Oerlikon Graziano – form the Drive Systems Segment of Oerlikon AG. Oerlikon Fairfield specialises in custom gears, Fairfield Torque-Hub planetary drives and gearbox assemblies. iVT John Easton is manager of new product development at Fairfield Manufacturing
Larger applications
Table 1: Torque-Hub final drive specifications
Below left: CT90 and CT130 triple planetary designs are for larger mobile track-drive applications Below right: New CT05M and CT07M drives are designed for compact tracked loaders
In addition, Fairfield will also introduce the CT90 and CT130 triple planetary compact
CONTACT www.fairfieldmfg.com sales@fairfieldmfg.com
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Multi-Wing’s sickle fan quietly handles the pressures of Tier 4
Multi-Wing’s 7Z is a low-noise sickle fan with a shallow profile, making it the perfect answer in tight spaces. With Tier 4 emissions standards putting the squeeze on cooling, the 7Z takes the stress out of your fan selection, generating the static pressure you need using less space and producing less noise.
Multi-Wing International a·s Staktoften 16 DK-2950 Vedbæk Denmark +45 / 45 89 01 33 Phone +45 / 45 89 31 33 Telefax
The 7Z is tailor made for a variety of heat exchanger applications and is perfect for off-highway construction equipment. The heavy-duty 7Z: Delivering low-noise performance in tight spaces. Visit us at ConExpo-CON/AGG 2011 in Las Vegas – booth 4031 in the Central Hall – and see our innovative new impeller developed to help you meet Tier 4 emissions standards
info@multi-wing.com www.multi-wing.com
PRODUCTS & SERVICES colm gallagher
Coefficients of friction
Booth 11040
a series of acquisitions has added new products to carlisle’s portfolio – which, in conjunction with its ongoing R&D, means next-generation braking materials are now closer than ever
On 2 December 2010, the Carlisle Companies completed the acquisition of the Hawk Corporation, a move designed to accentuate its position at the forefront of high-performance braking solutions. The strength of Carlisle Brake & Friction’s brands, including Wellman Products, Carlisle, Hawk Performance, Japan Power Brake, VelveTouch and Field Pro, give off-highway-vehicle customers access to a diverse range of some of the most highly engineered braking and friction products available to the market. The addition of Wellman Products Group has added friction materials for clutch, brake (dry and wet), transmission, motion control systems, fuel cells and structural components to the Carlisle portfolio – one that it was already in the process of upgrading. The company invested considerable resources in 2010 renovating and upgrading its testing and laboratories for friction products. Friction materials used in dry calliper braking systems have not changed much over the past 20 years, although vehicles in mines, construction sites, or in fields have become heavier, larger, or been asked to perform in even harsher environments. The combination of organisational focus on friction through facility and machine upgrades at Carlisle, combined with Wellman’s friction competencies, therefore enable the delivery of an innovative blend of expertise to solve friction questions that have long plagued the off-highway industry. Carlisle has brought in technical expertise from the on-highway industry to bring innovative methods of development and production to the new lab and facilities. These now have the capacity for chemical and thermal analysis, physical analysis and testing of friction materials on a series of inertia and electric drag dynamometers. The goal of this increased focus on friction is to develop next-generation materials for off-highway vehicles. David Anderson, VP of Global R&D at Carlisle,
above: New pilot lab left: Renovated dyno lab
comments: “Formulations on the market today are, for the most part, 20 years old. With these recent investments, we believe we can develop friction materials with higher performance and improved life. The addition of Hawk only helps us to achieve our goals faster.” Charged with improving performance and lifetime while maintaining integrity, material chemists at Carlisle will be experimenting with new elements, compounds and processes. With a calliper brake on some vehicles weighing several hundred pounds, the goal is to improve the dynamic torque of the friction so that the size of the calliper does not have to increase; indeed, it might be reduced. Additionally, improved life of the pads leads to reduced vehicle downtime and enables the operator to change brakes and linings less often. With the setting up of new facilities and the renovation of materials and the pilot lab, 2010 was a busy year for Carlisle. Despite the construction, Carlisle was still able to launch new friction materials for the wind industry (noise free linings) and solve specific friction issues at major mining, ag and construction vehicle manufacturing customers.
With 11 manufacturing facilities globally, located in the USA, UK, Italy, China, Japan and India, and with over 1,800 employees, Carlisle Brake & Friction is a leading provider of high-performance braking solutions to the off-highway, highperformance racing, aerospace and alternative energy markets, serving over 100 leading OEMs in 55 countries. Carlisle Brake and Friction designs and manufactures a full solution suite of braking products. These include dry disc calliper brakes, drum brakes and mechanical brakes for both service and park applications. Additionally, it manufactures both wet and dry friction materials used for wet brakes, brake linings, clutches, fuel cells and transmissions. Carlisle also designs and delivers hydraulic actuation systems, including hydraulic valves, master cylinders, adjustors and boosted master cylinders. Carlisle’s experience and commitment to the global marketplace makes it the ideal choice for any new brake or friction design, no matter where you are in the world or what you want to be. iVT Colm Gallagher is director of global marketing at Carlisle CONTACT www.carlislebrake.com
customerservice@carlislebrake.com
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PRODUCTS & SERVICES warren joiner
Plus points Booth S-13428
right: Sauer-Danfoss electronic components are developed and manufactured in-house in North America and Europe below: The new DP250 colour display provides 240x320 pixel resolution with 15-bit colour support, dual CAN and USB connectivity bottom: PLUS+1 microcontrollers are designed to address all aspects of electronic vehicle control
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An ever-expanding portfolio of electronic hardware and software products helps design engineers do more with less to achieve complete vehicle control
In an increasingly challenging development environment, vehicle design engineers are regularly expected to accomplish more with fewer resources. Sauer-Danfoss continues to develop an ever-expanding portfolio of electronic hardware and software products to help address these demands. Customised vehicle control solutions entered a new phase in 2004 when the company launched the PLUS+1 control platform. Today, the many options bring endless opportunities to maximise the performance and efficiency of mobile machines. The PLUS+1 portfolio includes position controls and sensors, graphical displays, joysticks, foot pedals, and the PLUS+1 Guide development software – supported by a growing range of PLUS+1-compliant products. “We would like our customers to think of us as their strategic electronics partner,” says Joseph P. Maher, product marketing manager. “Our PLUS+1 hardware and Guide software are designed to integrate seamlessly with our PLUS+1-compliant electrohydraulic, human machine interface (HMI) and sensor products. This enables us to offer complete solutions, which combine our electronics, hydraulics, and vehicle control expertise. It’s this comprehensive approach that makes us a strong partner for our customers.” From basic software components, function blocks, and compliance blocks through complete preprogrammed vehicle and system control software, Sauer-Danfoss provides the tools to help OEMs develop control solutions and get to market faster. Software packages, such as the new subsystem application blocks (SSA), are thoroughly tested on operating vehicles. As a result, OEMs are able to considerably reduce
iVTInternational.com March 2011
the time and expense of vehicle control design and qualification. Another reason to consider Sauer-Danfoss as a strong electronics partner lies in its exceptional in-house product development and manufacturing facilities. Located in North America and Europe, these state-ofthe-art facilities enable a complete range of
hardware tests, for example, vibration, temperature, water ingression, and electromagnetic compatibility (EMC). “Being able to design, qualify, and manufacture our electronic products ourselves provides a significant advantage,” states Maher. “With these competencies inhouse, we gain a greater understanding of
What’s new? High current microcontroller: With the highest output current capability in the PLUS+1 family, the 38-pin MC038-010 is suitable for night lighting, emergency vehicle flashers and lightbars, control of variable-speed DC electric motors and high-current solenoids. It is also the first PLUS+1 controller to feature a sleep mode; when outputs are disabled, it enters a low power consumption state. When one or more inputs change state, it wakes up. This enables the designer to power certain functions
without the vehicle running, opening the possibility for more automotive-style features (Table 1). DP250 colour display: This innovative 3.5in display product family offers 240x320 pixel resolution with 15-bit colour support, dual CAN and USB connectivity. A new colour version of the Engine Information Centre software, allows OEMs to monitor and control engine functions straight out of the box. Further electronic component news will be announced at IFPE 2011.
PRODUCTS & SERVICES
our electronic components and their capabilities. This knowledge is then used to ensure continuous improvement, not only in the products themselves, but also in the already rigorous product-development process. These in-house capabilities help speed up the process of developing new product variants.”
More functions The latest PLUS+1 MC012-016, MC038010 and MC050-055 microcontrollers are designed for all aspects of electronic vehicle control. This enables OEMs to control other electrical functions on their vehicles, without having to source a separate electronics supplier. “In addition to the essentials of hydraulic control, we’re now able to offer options for control of small DC motors, lighting and other electrical functions, plus expanded input functionalities,” says Dan Ricklefs,
director global marketing. “The bottom line is that the new microcontrollers help address productivity and the effect of emission requirements on vehicle design – so that vehicles will work faster, longer and with lower fuel consumption.” Supporting Tier 4 fuel savings solutions, the new MC012-016 is designed for engine compartment operating temperatures up to 105°C. Available for all controllers are PLUS+1 Guide and C-code application development tools. PLUS+1 Guide users enjoy a graphical drag and drop approach to developing machine control software from an extensive library of application software blocks. Sauer-Danfoss further supports PLUS+1 users with basic and advanced classroom training, e-learning, and comprehensive help-desk support. iVT Warren Joiner works in the Sauer-Danfoss market communications department
Table 1: PLUS+1 Microcontroller range.
PLUS+1 Microcontrollers & I/Os 12-pin
24-pin
38-pin
50-pin
88-pin
Controllers MC012-010/12
IX012-010
MC012-016
OX012-010
–
IOX012-010
MC024-010/12
IX024-010
MC024-11/14
OX024-010
MC024-020/22
IOX024-020
MC024-21/24
–
MC038-010
–
MC050-010/12
–
MC050-020/22
–
MC050-055/05B
–
MC088-015
–
CONTACT
0741_Di_halfDP_ivt.qxd
12/21/10
1:52 PM
Page 1
www.sauer-danfoss.com/PLUS1 EUadvertising@sauer-danfoss.com
70% Fan Speed to Meet European Noise Directive Lower noise and raise performance with Horton’s VMaster® Di or Stratis® Di Viscous Fan Drive and Controller systems. • Reliable, variable-speed fan control tailored to your engine cooling requirements • 70% fan speed feature lowers CE noise ratings • Prevents overcooling and reduces radiator clogging • Saves fuel, increases productivity • J1939 compatible, plug-and-play system • Customized algorithms for specific cooling requirements • More economical, safer and easier to install than hydraulic fan drives • No maintenance • Combine with WindMaster®, WindShift™ or Shogun™ fans for a complete Tier 4 cooling solution © 2010 Horton Holding, Inc. All rights reserved.
I/O Modules
www.hortonww.com/ivt +1 651-361-6400
PRODUCTS & SERVICES peter söderberg
Less is more Booth S-13415
RIGHT: Hybrid technology on the road in Florida BELOW RIGHT: RunWise features an innovative hydrostatic drive system
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hybrid technology has an important role TO PLAY in lowering pollution and eliminating risks of financial penalties for failing to comply with schemes to reduce carbon footprints
Following years of R&D and extensive testing, hybrid-drive technology is now proving its worth on the streets, delivering notable fuel consumption savings along with the corresponding environmental benefits in terms of reduced CO2 emissions. Indeed, the fuel savings of a single refuse truck powered by a Parker Advanced Series hybrid-drive system translate to enough energy to power 21 households each year. Equipping 5,000 refuse trucks with the Parker Advanced Series hybrid drive would cut CO2 emissions by 174,421 tonnes – the equivalent to planting 7,930,000 trees. Never has there been a more critical time for such substantial reductions in carbon emissions, particularly as municipal authorities in many countries are now prepared to take strong action in order to dramatically cut local vehicle emissions. Legislation, such as the Low Emission Zone (LEZ) regulations in London, UK, is now in place that will see organisations facing heavy penalties should they fail to comply with specific environmental responsibilities. The carbon emission taxes that are being considered under cap-and-trade schemes also present a very real threat for vehicle operators across the globe. Under the LEZ scheme, for example, large diesel vehicles that do not meet EURO 3 emissions standards are faced with a hefty £200/day fine, taking a chunk out of even the healthiest of bottom lines. Although in 2008 it was initially applied to all vehicles over 12 tonnes, the LEZ rules have now been extended to include most dieselengined trucks and vans over 3.5 tonnes. From January 2012, the LEZ will also affect larger vans, minibuses, motor caravans and other specialist vehicles to ensure that EU air-quality targets can be achieved. Furthermore, such schemes are also happening in other parts of Europe, with more than 70 cities and towns in 10 countries already running or preparing to
iVTInternational.com March 2011
launch LEZs. Currently, most of these zones affect only vans and lorries, as in London, but some, including those in Germany and Italy, also affect passenger cars. Although LEZ regulations and the like have caused consternation among owners of older vehicles, the rules as they stand cause few problems for organisations running conventional modern trucks. However, such schemes are likely to become more widespread, and emissions limits will become tighter over the next few years. As a result, truck makers and fleet operators will be under extreme pressure to adopt new technologies that reduce fuel
consumption and minimise CO2 emissions and exhaust particles.
The hybrid approach Accordingly, it is easy to see that hybrid drive technologies in particular have the potential to minimise fleet owners’ exposure to carbon emission taxes and other penalties, as they have done in the passenger car market. Unlike that market, however, many of those hybrids are likely to use hydraulic rather than electrical energy storage. In particular, the new advanced series hydraulic hybrid technologies can deliver
PRODUCTS & SERVICES
considerable benefits in the drive cycles of urban delivery, city buses and collection vehicles, where continual braking creates many opportunities for energy recovery, and frequent acceleration benefits from that energy boost. For example, among Parker’s latest innovations is the RunWise Advanced Series Hydraulic Hybrid Drive, which makes possible the achieving of unprecedented reductions in emissions with the added benefit – given the rising cost of fuel – of considerable fuel savings in commercial vehicles by decoupling the engine from the rear axles during low-speed stop-and-start operation and recovering energy normally lost during braking. As well as the dramatic fuel savings, using this system rather than a conventional drivetrain considerably reduces noise levels and brake wear while optimising overall vehicle performance. RunWise features an innovative hydrostatic drive, which integrates both mechanical and hydraulic drive elements into a three-speed transmission that optimises efficiency at all speed ranges. All shifting occurs smoothly and automatically, and all speed modes accommodate brake energy recovery, enabling stored brake energy to be used to power the vehicle in all modes of transportation. Upon braking, the system works seamlessly with the vehicle’s standard friction braking system using pressurised hydraulic fluid to decelerate the truck, while transforming and storing the vehicle’s kinetic energy in lightweight composite accumulators for use once the truck starts moving again. Accordingly, the more stops a vehicle makes during the day, the more efficient the system becomes relative to a conventional drivetrain.
Half cut Most recently, Parker’s RunWise system has played a pivotal role in the introduction of a revolutionary hybrid refuse truck that cuts fuel consumption by up to 48% (with a corresponding reduction in CO2 emissions), minimises brake and engine wear, and increases driver productivity. Introduced through Autocar, a leading manufacturer of LCF Class 8 trucks, the E3 Hybrid is believed to be greener, more efficient, more economical and more reliable than any other truck on the road today.
The technology for the E3 has been under development for several years, using a disciplined stage-gate product design process, with technical experts recruited from across the globe. Accelerated track testing of a fleet of the refuse trucks has been ongoing for more than three years to verify the performance and efficiency of the groundbreaking technology. Prototype trucks have been subjected to severe operating conditions, including high loads and heavy repetitive start/stop cycles, to compress one week of customer field operations into one day of round-the-clock testing. Product robustness has also been validated in extreme hot and cold weather conditions, up and down steep inclines, over rough roads and through a variety of severe-duty tests. Extensive field testing has also been performed to obtain real-world results in a variety of severe environments, climate conditions and geographic locations, such as Michigan, Texas, southern Florida and Nevada, USA, which delivered impressive results. For example, trucks tested in Texas by a private fleet operator on an existing route with about 1,200 homes consumed 27% less fuel than the operator’s usual vehicles, while collecting 3% more recyclable materials and 3% greater tonnage of refuse. The E3 Hybrid used to collect refuse from 700-1,100 homes per day in Miami consumed an average of 42% less fuel than conventional trucks, while fuel savings in Michigan were up by 49%. The refuse trucks were also tested in Nevada, which is largely desert and semiarid, during peak hot weather conditions. Even in these challenging circumstances, the E3 Hybrid achieved 100% uptime, with no negative operational or functional impact from the extreme heat. During all of the trials, the drivers evaluated specific performance categories, including acceleration, braking, incline performance and truck responsiveness as well as vibration, harshness and noise levels, all of which received positive feedback. In particular, drivers were extremely satisfied with the smooth, automatic shifting of the hydrostatic drive during urban driving and collection on the routes, with one driver saying that the ease of shifting contributed to less fatigue and enhanced ability to monitor surrounding situations.
An economic slowdown Just as importantly, brake wear was studied in detail and verified by an independent party during the field tests. The replacement cycle for brakes was identified at 102 weeks, nearly two years, versus the standard 12week replacement cycle. Fewer brake replacement jobs drastically cuts vehicle maintenance costs and downtime. Using the RunWise system also reduces the brake dust generated by shoes and drums by hundreds of pounds per year, translating to yet more environmental advantages. As a result of the field testing – and following an analysis of the savings potential – three south Florida communities purchased a total of 11 Autocar E3 trucks: Miami-Dade County purchased six trucks, the City of Hialeah purchased four trucks, and the City of Miami purchased one. In this increasingly tough business environment, the need to reduce energy consumption and protect the environment is vital to success. The beauty of the latest hybrid-drive technologies, such as Parker’s RunWise system, is that they make use of well-proven technology to deliver concrete and measurable results rather than relying on something novel and not yet tested over time. As a result, companies can eliminate the risk of facing financial penalties by not complying with carbon footprint reduction schemes, while also making an immediate return on investment to quickly realise huge improvements in profitability. iVT
above: Parker’s RunWise technology cuts fuel consumption and emissions
Peter Söderberg is group promotion manager at Parker Hannifin, Hydraulics Group Europe CONTACT www.parker.com parker.uk@parker.com
iVTInternational.com March 2011
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Advanced Technology, Engineered Solutions
DESIGN AND MANUFACTURE OF HEAT EXCHANGERS ®
EMMEGI S.p.A. Via Newton 52 - 20062 Cassano D’Adda (MI) - Italy Ph. +39 0363 360236 - Fax +39 0363 360230 info@emmegi-heat-exchangers.com www.emmegi-heat-exchangers.com
VER_PRODUCT-03/2010
Ready for any challenge
PRODUCTS & SERVICES thilo nagel
Big brother is watched
Booth S-14123
BIGGER DISPLAY? CHECK. MORE FUNCTIONALITY? CHECK. BETTER PERFORMANCE? CHECK. An upgraded DISPLAY AND CONTROL CONSOLE THAT TICKS ALL the BOXES IS JUST A PLUG-AND-PLAY AWAY
The Opus A3 operator display and control console has found great market acceptance due to its remarkable, innovative design, power and its multitude of functions and features. Now it has been joined by the Opus A6, which is based on a common, powerful 32-bit electronics platform with a 7in display in 15:9 format, 800x480 pixel resolution and 262,144 colours. A brilliant, optional TFT display provides excellent sunlight readability. The Opus A6 a strong stablemate offers even better functionality and performance. At its heart is the i.MX35, a 533MHz processor capable of handling complex applications such as connecting up to three cameras to the display. The video picture can be scaled, positioned or cut to any size. Like the Opus A3, it can be standalone or panel-mounted, landscape or portrait format, and the live video images can be turned or mirrored. Two CANbus interfaces handle main communication and enable a flexible network topology. A USB connection can be used for software updates and retrieving data logged on the Opus A3 and A6’s 512MB to 4GB solid-state internal flash memory. Even inexperienced developers now have a comfortable and intuitive way to program the Opus A3 and A6 using the Wachendorff Projektor-Tool GUI development software suite. This new Java-based programming tool for Windows NT/2000/XP offers a truly ‘what you see is what you get’ environment and provides graphical access to all necessary features. Creating a screen can be easily done with no knowledge of programming languages. Adding a background image, picture graphic, bar graph, numeric display, meter object, list object, text or camera picture is just a mouse click away. Button actions can be easily programmed and the Projektor-Tool also handles the configuration of all CANbus messages. Graphical settings and properties can be changed easily and objects can be placed on a screen by simply dragging and dropping.
left: Opus A6 – the bigger brother below: Opus A3 – a small but powerful unit
Existing or custom-created picture libraries can be used, producing truly spectacular application-specific visual effects. The Projektor-Tool supports CANopen and J1939 CAN protocols plus exclusive CANfreestyle. This provides great flexibility, which is why even some larger customers have started using the Projektor-Tool to design their proprietary systems. CANfreestyle gives users the flexibility to implement their proprietary designs and communications, and Wachendorff Elektronik supports these protocols. In addition, the Projektor-Tool can be used to program the A3, A5, A6, RVC and upcoming displays. So one GUI development tool can now be used for all these displays, and projects can be easily adapted to suit the other displays. Installing a new project is simply plug-and-play: create a project, transfer it to a USB stick, plug it in to automatically download, and start playing. Although most standard applications can be programmed using the Projektor-Tool, customers can use C/C++ or CoDeSys 3.X for GUI programming to benefit from even more flexibility. Animation is no problem due to the flexibility of C/C++ and CoDeSys, combined with the powerful electronics of the Opus A3 and A6. The two CANbus port interfaces offer high flexibility in network design. The Opus A3 and A6 can talk CANopen on CANbus 1 and J1939 on CANbus 2, and therefore
process data from two environments. It is even possible to have two protocols running on the same CANbus port at the same time. CANfreestyle, a completely flexible protocol, can also be used on both CANbus interfaces, enabling new, more cost-effective system designs. And in all cases, none of these messages interfere with each other. Wachendorff’s experts conduct hands-on Projektor-Tool training to enable customers to master the power and flexibility of the tool and get some help in creating their first application. Application-specific issues can be discussed at the training, making the training session more like a workshop. The concepts and approach of the Opus A3 and A6 are right on target. The success of the Opus A3 in its applications makes the Opus A6 the logical next step for applications that need a larger display, more functionality and even greater performance. iVT Thilo Nagel is president of Wachendorff Electronics USA, Inc CONTACT www.wachendorff-elektronik.de Opus@wachendorff.de
iVTInternational.com March 2011
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Kn_10_A_Liebherr_en
10.02.2010
17:51 Uhr
Seite 1
Impressive performance: operating weight 7.7 t, speed: 20 mph. Loaders by Liebherr â&#x20AC;Ś
... brakes by KNOTT. To ensure that braking systems maintain consistently high precision and reliability with a minimum of wear even under extreme loads, they must be custom-built for the construction machine. Liebherr relies on brakes made by KNOTT. The Liebherr L 514 wheel mounted loader is equipped with two KNOTT hydraulic fixed calipers operating as dual circuit service brakes and a KNOTT spring-applied sliding caliper brake. Designed for low maintenance, long life and easy servicing, these units meet KNOTT's strict quality standards in every respect. When it comes to flexibility, service and delivery reliability, we are in our element. Well-known manufacturers from home and abroad value us as a dependable partner. We would be pleased and honored to have you too as a partner in the near future. Kindly feel free to contact us
Phone: +49 80 56/906-0
We make your brake
www.knott.de
www.skpwerbung.de
at any time!
PRODUCTS & SERVICES PASQUALE SOLDATI
Join forces
Booth S-16643
evolution of the most innovative product lines goes hand-in-hand with developing new products to satisfy the accelerating demands of the offhighway market All over the world, Faster stands for quick-release couplings for tough applications in the hydraulics field. Continuous research, technological innovation, ongoing investment and simultaneous engineering activity with the main players of the mobile hydraulic and industrial markets have led the company to be the chosen partner for hydraulics OEMs. Today, innovative solutions are required to contend with environments where there is dirt, sand and other hydraulic system contaminants surrounding the machine. In addition to the constant evolution of the most innovative product lines, Faster’s Research & Design Division continually develops new products to meet and exceed the accelerating demands of the hydraulics market.
Flat-face evolutions The first is the new flat-face series, FFH. Having worked hard to offer its customers a new and highly performing flat-face series, the company’s FFH (high-performance flatface) series has notably higher performance characteristics than its standard flat-face series FFI couplings. This series also exceeds the performance characteristics established by ISO 16028 regulations. Working pressure has been raised to 35MPa and the flow rates have been much improved. FFH couplings have undergone intense internal validation tests, such as one million cycles impulse tests (at 133% of working pressure) and burst tests at 140MPa. The coupling is available in 1 ⁄8in, 3⁄8in, ½in and ¾in sizes. An added feature is the zinc-nickel surface treatment that provides excellent resistance to corrosion, resistance to high temperatures and excellent ductility. FHV Series is a flat-face screw-on coupling to be used in heavy-duty applications. It can bear high working pressures and has exceptional flow capacity. The male coupler is assembled
with a double patented valve and can be connected under residual pressure. Connection is easier due to an innovative ball bearing system, while it is supplied with a safety sleeve against accidental disconnection. FHV couplings are also coated with zinc-nickel surface treatment. 4BD4FH is a block coupler designed for hydraulic quick changes and is ideal for skid-steer loaders, mini skid-steer loaders, tractor backhoe loaders and utility vehicles. It has greater flow capability than standard flat-face couplers and leads to an overall reduced pressure drop. The new 4BD4FH Series uses highpressure flat-face couplings FFH, all conforming with the ISO 16028 standard. The user can choose between a cartridge of ½in and ¾in. 3HF is a flat-face coupling designed for applications where it is necessary to connect under full working pressure, without using tools. 3HF couplings are particularly suitable for high impulse pressures and high flow inversions. They can be widely used in excavator booms, demolition machines and all heavy-duty applications in general.
Industrial couplings WF couplings are Faster’s most important recent development for the industrial sector. The range guarantees direct and safe connections to internal port threads for industrial testing, which enables the correct and simple connection of tools and attachments to hydraulic machines with minimal fluid loss. The coupling’s innovative design makes maintenance, repair and replacement operations for complex industrial circuits quicker and more efficient. It is also very compact, ergonomic and easy to use. Disconnection is performed in two steps to prevent accidental disconnection, with automatic shut-off of the internal valve. The WF connection thread is automatically protected against potential damage when the coupling is disconnected. It is available in 3⁄8in, ½in and ¾in sizes. Its main applications are in hydraulic valves, manifolds, pumps and cylinders. iVT
CLOCKWISE from ABOVE: FFH, FHV, 4BD, WF series couplings
Pasquale Soldati is sales marketing director at Faster SpA CONTACT www.faster.it faster@faster.it
iVTInternational.com March 2011
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PRODUCTS & SERVICES peter feucht
Safely mobile Booth S-13728
right: M-Series sensors for cylinder integration meet the requirements of SIL2 and PLd
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Safe smart sensors approved for safety-critical applications are now a vital requirement to ensure risk reduction and hazard prevention on intelligent industrial vehicles
To meet new safety regulations, smart sensors are required for many mobile applications. As approved devices for safety-critical applications, Temposonics M-Series position sensors enable hazard prevention and risk reduction. To achieve the utmost legal certainty, MTS has prepared documentation of their safety and provided evidence of their performance by extrapolations. As a result, vehicle and component manufacturers will find it easier to apply the new standards. The integration of smart position sensors into existing designs will be simple and cost-effective, even for applications in need of high safety requirements. According to ISO 13849 standards, the safety management procedure has to be implemented within the machine safety guide, including a description of software codes and an approval of the failsafe function. The results are based on reviews of the failure mode effects diagnostics analyses (FMEDA) report. The IEC 61508 standards will cover all architectures that have to be applied for electrical and electronic programmable systems. Design engineers need to access the whole system to classify the related safety level: safety integrity level (SIL) according to IEC 61508 or performance level (PL) according to ISO 13849. Both levels are linked based on the average probability of dangerous failures per hour (PFHd avg). The final rating for SIL classification is based on different failure status (safe and dangerous, detected and undetected) and defined in relation to the safe failure fraction (SFF) status. The PL rating requires figures for the mean time to (dangerous) failure (MTTFd) and the diagnostic coverage (DC) of the system, which are extracted out of the FMEDA report. The MTTFd value is expressed in years. The DC describes the capability of self-diagnostic function in percent, increases the MTTF and reduces the risk of a dangerous failure.
iVTInternational.com March 2011
Temposonics M-Series position sensors support performance and functional safety in accordance with the safety needs of the entire machine. They meet the requirements of SIL2 (safety integrity level two) to IEC 61508 standards and the requirements of PL d to ISO 138491. The absolute, non-contact sensors provide an SFF of 95% at a hardware fault tolerance (HFT) of 0. Based on the SIL2 approval, this corresponds to an average probability of failure (PFH) within â&#x2030;Ľ 10-7 and < 10-6 p.a.
Designing the system Essentially, all safety-related systems consist of three major components: the sensor, controller and actuator. Intelligent electronic systems and their components (integrated circuits and processors) operate with an internal diagnostic function. As soon as a dangerous failure appears, they run into a safe state, based on a predicted time of failure. The system can be shut down or run in safety mode to ensure the secure continuation of the operation. Redundant layouts of safety-related functions or circuits are a common design. Using sensors with two independent outputs (reverse channel operation) fulfils the requirement for redundancy, which
enables a cross-comparison, whereby the correct output of two signals is CH(A) + CH(-B) = 0. If this required result is not transferred, the controller runs the system into the emergency stop. The system can not detect which channel is defective if it misses the diagnostic performance of the channels. As a result, the controller will be busy with the comparison algorithm and its processing capacity will be reduced. Using a transducer with an internal selfdiagnostic function, like the Temposonics MH position sensors, the controller receives a failure message independent from the controller processing loop. The sensor itself will run into the failsafe state and the controller just needs to consider the alert once to enable this operation. This safety architecture can also be applied for redundant loops and will work with the same principle. The obvious advantage is that the controller is able to separate the channels and the system can then run in a safe mode, allowing the machine to perform the function with one channel of operation.
Environmental requirements To ensure the sensorâ&#x20AC;&#x2122;s safe operation, it is essential that the complete system meets the requirements of mobile hydraulics
PRODUCTS & SERVICES
applications, especially when compact design and easy handling are required. Therefore, Temposonics M-Series sensors are embedded into the cylinder housing. Fully embedded sensors need to be resistant to the highest oil temperatures, which can exceed 85°C in construction equipment where compact cylinder design and cyclic loads are applied. To cover these temperature peaks, the operating temperature range for the M-Series sensors is specified from -40 to +105°C. The effect of temperature and vibration is essential to specify the operating limits of the sensors. According to IEC 68-2-8, the tested frequency range is 20-2,000Hz with 20g(rms) and a maximum acceleration of 25g. By applying the high accelerate lifetime (HALT) test, the sensor destruction limits can be explored. The Temposonics MSeries sensors worked reliably at maximum acceleration of 45g when undergoing this test. When a dynamic pressure impulse test (up to 500 bar) with two million pressure cycles was performed, the sensor mechanics and the electrical output signal were stable and no symptoms of fatigue were detected. To measure these parameters while the vehicles are in operation, another test was implemented with loaded and unloaded buckets on different terrain. When dropping the bucket onto the ground, no extreme high frequency was measured for the cylinder or its embedded sensor. Frequency calculations showed that the device will not run into resonance. Separate tests for resonance determination were performed, revealing no damage to the sensor rod or housings. These tests were carried out with extreme acceleration applied to the sensor probe, yet, the sensor still survived.
left: Temposonics sensors monitor the outriggers’ position in truck-mounted loader cranes below: Comparison of redundant designs
Finally, the EMC performance requirements had to be fulfilled according to the OEM’s specifications and to existing industrial standards. Based on the magnetostrictive principle and MTS’s own design of the signal converter, the outstanding signal-tonoise ratio enabled the sensor to perform in electromagnetic fields up to 200V/m.
Where safety matters The increasing use of smart sensors enhances performance and machine safety in mobile hydraulics. Many applications can benefit from reliable, continuous position feedback. For example, to stabilise a truck-mounted loader crane while handling heavy loads within a restricted space, the outrigger’s cylinder position needs to be detected. The sensor signals are used for closed loop control in the load-management system. Cargotec Hiab uses Temposonics MSeries position sensors to monitor the
position of each stabiliser’s leg. The sensors feature CANbus output and are embedded inside the cylinders to keep them protected, ensuring long life. By using the sensor signal, the machine’s control system can calculate the stability of the crane. If all stabiliser legs are fully extended, stability is at its maximum. Based on this value, the lifting capacity (which weight, which working area and which extension of the boom is allowed) can be specified. As Temposonics sensors give continuous position feedback, the calculation is stepless. By calculating the stability limit of the crane, the maximum capacity can be achieved in critical working areas while operating with small outrigger spans. The position of each stabiliser leg is monitored and, if necessary, the capacity is reduced in sectors where stabilisers are not fully deployed. This safety feature protects crane operators, as well as the vehicle. Specifications and environmental conditions are essential to achieve the requested performance of mobile hydraulic applications. Both theory and real conditions need to be considered for reliable designs. The safety aspect will be covered by new standards, product design, and system architecture. Linear displacement sensors, based on Temposonics magnetostrictive technology, fulfil all requirements and provide machine designers with a product that they can truly rely on. iVT Peter Feucht is technical marketing manager mobile hydraulics at MTS CONTACT www.mtssensor.com info@mtssensor.de
iVTInternational.com March 2011
99
PRODUCTS & SERVICES STEFAN SANDLER
Lighten up Booth S-10924
ABOVE: In an HID/xenon bulb, the light is produced by two electrodes positioned close to each other in a small quartz tube ďŹ lled with gas and metal salt RIGHT: The Nordic Lights HID lamps are produced to withstand the most demanding environments around the globe BELOW: The Nordic N45 HID worklamp is extremely small and compact and is suitable for most applications
DESPITE COMPETITION FROM HIGH-POWER LEDS, XENON LIGHTS STILL SHOW CONSIDERABLE ADVANTAGES AND CAN BE BUILT TO WITHSTAND THE MOST DEMANDING WORK ENVIRONMENTS
Xenon, or high-intensity discharge (HID) lights, commonly known as gas discharge lights, are being seriously challenged by the upcoming high-power LED lights. But at the moment the HID/ xenon lights are still more efficient in terms of the lumen/watt output. HID lights offer many technological advantages over conventional halogen lights. Their illumination is considerably brighter and greater than that of a halogen light. In other words, an HID light gives twice the illumination of a 70W halogen for only half the power consumption. A greater proportion of the energy is converted to visible light and less is radiated away from the bulb as IR radiation than with halogen bulbs. The HID light will therefore also produce less heat. The lifetime of an HID bulb is on average 10 times longer than that of a standard halogen bulb, and they require less service. Combined with Nordic Lightsâ&#x20AC;&#x2122; patented dampening solutions and light engineering capabilities, they provide a very durable light. In an HID/xenon bulb, the light is produced by two electrodes positioned close to each other in a small quartz tube filled with gas and metal salt. When switching on an HID light, the gas eases the forming of an electric bridge between the electrodes. Once the bridge is formed it heats up and evaporates the metal salts to a plasma, greatly increasing the intensity of the light produced. As with fluorescent lights, HID lights require a ballast to start and maintain their operation. The light source differs totally from halogen lights; therefore HID-specific optics are used to collect and distribute the light. The HID lamp produces a white light and its colour temperature is very similar to daylight, making it pleasant for the eye to work in and suitable for most environments. Halogen lights tend to have a more yellow light and, to obtain the
highest lumen output, most LEDs deliver the cool blue-white light temperature. HID work lights are suitable when you need to spread light over large areas and/ or high light intensity is required. The areas of use vary a lot, from lighting up public areas, warehouses, roadways, indoor gardening and aircraft to projection TV sets. Drivers using HID/xenon auxiliary driving lights are able to see the road ahead further than with a halogen system.
Work lights Nordic Lights specialises in designing and manufacturing LED, HID and halogen work lights for the heavy-duty on-road and offhighway industries. Using its work lights ensures that darkness, vibration, shock, dust and humidity will not decrease visibility. Nordic Lights offers four different light pattern options (High Beam, Low Beam, Wide Flood and Flood) on its HID work lights to ensure the right illumination for
the particular application. The Nordic N200 HID worklamp has become a legend within the rugged mining industry for its reliability. It features extreme heavy-duty dampening, anti-vibration up to 20grms and shock resistance up to 60g. Its heir, the Nordic N400 HID work light, incorporates encapsulated ballast and a glass-fibrereinforced polymer body with Gore membrane vent to live up to its predecessor. The Nordic N45 HID worklamp is very small and compact. The tight and durable design makes it suitable for harsh working environments within the construction, mining, forestry, agricultural, materials handling and truck, trailer and emergency industries. Nordic Lights also produces high-intensity xenon auxiliary driving lights that meet European standards. iVT Stefan R. Sandler is R&D manager responsible for the development of new lights at Nordic Lights, where he has worked for 18 years CONTACT www.nordiclights.com nordiclights@nordiclights.com
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iVTInternational.com March 2011
Instrument Clusters CAN/CANopen SAE J1939 Standard fitting for your application
Robust Sensors for Mobile Working Machines
POSIROT® Magnetic Angular Sensors POSITILT ® Inclination Sensors PRAS5V
Our clever dashboards replace single indication instruments and not only improve the control and super-vision, but even provide a longer life duration and a more attractive look for the cockpit.
PTAM2
PTAM27
• Protection class IP67 / IP69K • With shaft or non-contact with external magnet (POSIROT®) • 1 axis or 2 axes (POSITILT®) • Analog, digital, CAN-Bus
POSICHRON ® Magnetostrictive Position Sensors PCST25
n CAN/CANopen, SAE J1939 Analogue + digitale I/Os TN-, STN- and TFT-Display, 4.3“, 5.0“ and 7.0“, 800 x 480 pixel access control and remote alert standard or individual solutions n high shock and vibration resistance
CeMAT , ing at Exhibit nd - 6th May 2 r, e v . o 6 2 n ll Han H29, Ha Stand
Phone: Fax: Web: E-Mail:
n specific components/ production treatments: n ultrasonic soldering for high protection class n anti-scratch treating for clear readability of the data n IP 67 provides protection to high pressure cleaning (front) n salt spray resistant (front) n IP65 provides optionally protection on the rear n perfectly readable data and warning indications (LEDs), even in direct sunlight
BAUSER GmbH & Co. KG Julius Bauser-Strasse 40 D-72186 Empfingen – Germany +49 (0) 74 85 - 18 1 - 0 +49 (0) 74 85 - 18 1 - 16 www.bauser-control.de mail@bauser-control.de
• Protection class up to IP67 / IP69K • Measurement range up to 226 in. • Analog, digital, CAN-Bus
POSITAPE ® Tape Extension Position Sensors WB85
• Protection class IP67 / IP69K • Measurement range up to 236 in. • Analog, digital, CAN-Bus
Las Vegas / Nevada, USA 22nd- 26th March 2011, Booth S - 15144
ASM Sensors, Inc. www.asmsensors.com / info@asmsensors.com Tel. 1-888-ASM-USA-1
PRODUCTS & SERVICES stefan maierhofer
LED reckoning Booth S-18100
right: Ultra-high-efficiency worklamp was specifically developed to reduce power consumption (just 11W with a measured light output of more than 1,000 lumens)
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who’d have thought The power and longevity of LED lighting would increase so dramatically in recent years? the latest advances in WorkLamp design suggest this is set to continue
When Hella introduced white light LED worklamps to the market in 2005, standard LEDs had an efficiency of approximately 40 lumens per watt (lm/W). Today’s technology allows for about 160 lm/W, which makes LEDs the most efficient light source currently used in the automotive industry. Within the next few years, leading LED manufacturers expect to achieve up to 250 lm/W. Even today, LED technology makes possible a conversion efficiency of electrical energy for worklamp systems that far exceeds halogen bulbs and approaches that of gas discharge light sources currently used in xenon worklamps. LEDs also offer a number of advantages in worklamp systems. As they have no filament that could break, LED products can offer high life expectancy, even under the harshest requirements. In the past, the light source was the weakest link with regard to failure of the worklamp. Today, mechanical defects such as the breaking of brackets, housing or lenses overshadow the light source with regard to lamp failure. This is why Hella uses the latest simulation software to further improve brackets and housing systems for LED worklamps and come up with heavy-duty mechanical solutions. Furthermore, to ensure the long service life of the worklamp system, the company’s latest LED products are equipped with a special nylon lens that is totally resistant to mechanical impacts and scratches. For this reason, Hella’s LED worklamps are an excellent solution for the toughest of application requirements. Hella’s high-quality LED worklamps are equipped with highly sophisticated digital temperature regulation and encapsulated electronics. State-of-the-art electronic features including multivoltage operation (such as Module 70 LED 10-100V), fast voltage transient protection, LED failure bridges (if one LED fails, all others continue to function) and electromagnetic compatibility (EMC) set the company apart
iVTInternational.com March 2011
from the competition. Poorly regulated electronics systems can cause disturbances to other essential electronic devices, such as causing interference on radio transmission, WLAN, GSM or Bluetooth. All Hella LED worklamps are therefore protected against electronic radiation so that these disturbances can be avoided. Hella has also developed an integrated electronics solution in the worklamp that can work as an interface with the vehicle board system (e.g. LINbus) with the advantage of a dimming function. It is not surprising that LED technology continues to advance on applications in the automotive industry and specialpurpose vehicles such as agricultural and construction vehicles, buses, RVs, traction vehicles and trailers. Hella, with more than 100 years’ experience in lighting, is one of the driving forces of this process and continues to expand its product range of LED worklamps.
Latest innovations The Flat Beam is an ultra-high-efficiency worklamp that was specifically developed to reduce power consumption (just 11W with a measured light output of more than 1,000 lumens) and is representative of the design flexibility that is achievable with the
very latest in LED technology (a flat design in a worklamp with a housing depth of just 31mm). The ‘Power Beam 3000’ on the other hand is the most powerful worklamp in Hella’s product range. It combines the light output of gas discharge systems (3,000 measured lumens) with all the benefits of the latest LED technology and a power consumption of just 43W. LED technology is extremely suitable for use in professional operation. With up to 60,000 hours’ operating time, LEDs have an exceptionally long service life – and therefore clearly beat halogen bulbs (about 500 hours) and xenon (about 3,000 hours). The other main outstanding feature of LED products is that they are specifically designed to resist vibration, dirt and water, making them much cheaper to run. Essentially, there are no additional costs incurred in the long term for required spare parts, service, maintenance and vehicle downtime. As well as the outstanding illumination of the working area, worklamps with LED technology also have a beneficial effect on operating profitability as well as the environmental footprint through reduced fuel consumption and lower CO2 emissions.
PRODUCTS & SERVICES
approximately 4,200 K. Further, the advantages of the Power Beam 3000 worklamp can be produced in a much more compact size than the xenon worklamps currently on the market.
LED innovations
Lifespan advantage One of the main advantages of LED technology is the exceptional lifespan that can be achieved. Most data sheets for highpower LEDs project a lifetime of up to 100,000 hours, although this can suffer dramatically based on the thermal characteristics of the lamp. The LEDs that reside on the PCB need to be kept at about 120°C or below to achieve the highest lifetime measurement. Often, lifetime and light output values seen in data sheets do not accurately reflect lifespan with respect to temperature, leading to consumer misunderstanding. As with any other light source, the LED lamp system’s temperature rises during operation. Hella’s thermal management solutions, compared with other worklamp systems, assure the best possible LED cooling. The higher the LED temperature, the greater the chance of a substantial reduction in light output and, throughout its lifetime, considerable heat can actually destroy the LED. Hella’s innovations and its use of high-tech simulation software have facilitated the development of optimised heat-removal solutions in worklamps. Simulation results are used to combine style and design elements of cooling bodies,
materials and surface treatments with the exceptional electronics that will provide an optimal thermal conductive solution to give the longest lifespan possible. Next to the mechanical thermal system, a sophisticated thermal protection system ensures constant light output of Hella’s LED worklamps up to a surrounding temperature of 50°C and also ensures that the light unit of the worklamp itself can outlive the machine to which it is mounted.
Replacing xenon With the introduction this year of the Power Beam 3000 LED worklamp, Hella will proudly present a lamp capable of exceeding the light output values that are typically associated with xenon worklamps currently on the market. While a xenon worklamp achieves about 2,700 lumenmeasured light output, the Power Beam 3000 offers 3,000 lumens, measured with a power consumption of just 43W. In addition, the light colour temperature of the high-power LEDs used in the product – approximately 5,700 K – will give a visual impression to the human eye of an approximately 20% increase in improved light output. For comparison, the light colour temperature for xenon is
As soon as new LED generations are introduced to the market, Hella is ready to develop upgrades of existing products as well as developing new products in its expanding range of worklamps. Its team of experienced light engineers is in close and constant contact with leading LED producers around the world to take advantage of any developments. Once it was unthinkable to have a truly flush-mounted LED worklamp solution, but Hella has already introduced a Module 70 flush-mount solution in LED. These latest developments will enable manufacturers to easily integrate LED worklamps into their vehicle design. Inspired by its innovative automotive roots for which it is so well known internationally, Hella is introducing full LED headlamps for the Audi A8 and A6. The company is poised to continue to provide the latest technologies into a variety of markets by offering the greatest flexibility for customised solutions with standard products, such as the lowbeam LED module and the modular LED flex-light systems. Both LED and reflector technology are skilfully integrated in the new Rota LED beacon (ECE and SAE): the electronics generate a rotating effect – similar to that of a rotary mirror beacon – by switching LEDs in succession. This rotation effect guarantees a highly effective warning, ensuring good and quick visibility for the vehicle. Due to its high vibration resistance, this beacon is particularly suitable for the agricultural and construction sectors, as well as roadsweeping vehicles and HGVs. OLEDs (organic light-emitting diodes) could become of interest for vehicle interior lighting but in the worklamps area there is unlikely to be a field of application within the next few years. Indeed, the quantum leaps in LED technology are quite likely to further increase the existing gap between LED and OLED. iVT
LEFT: The 3,000 lumen/43W light output enables replacement of xenon worklamps BELOW: Hella uses the latest simulation software to develop improved heavyduty brackets and housing systems for LED worklamps
Stefan Maierhofer is product manager for worklamps at Hella CONTACT www.hella.com info-ag-ce@hella.at
iVTInternational.com March 2011
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PRODUCTS & SERVICES Ric Marzolf
Entry-level technology?
Booth H-30812
that may be a typical view of door and access solutions, but As vehicles increase in sophistication, the need to combine security with convenience calls for the hardware to follow suit
With a global reputation for providing innovative access solutions, TriMark is able to save OEMs time and money by using its in-house manufacturing and engineering teams’ hardware knowledge, expertise, ideas and resources to rapidly respond to customers’ needs for product development projects. Global application experts design systems and products so that the end customer’s first and lasting impression is excellence. Engineering capabilities include ProE CAD, finite element analysis, mechanism/motion studies, prototyping, and product validation and testing. Noworry logistics services keep supply lines consistent in the ever-changing business of equipment manufacturing. World-class manufacturing produces the highestquality product at competitive costs, and test facilities provide the next best thing to real-world validation, ensuring that designs will thrive in the toughest environments. Programme/project management reduces the strain on client engineering capacity. More than emissions, Tier 4 translates into machine redesign, resulting in managing airflow and noise, forcing revisions to hood and access panels. The timeline and budget for Tier 4 integration is pushing the limits, leaving engineers searching for viable opportunities for packaging solutions while trying to hold or reduce costs. As a long-time partner with the offhighway OEMs who are working to address these challenges, TriMark is able to ease the burden on their engineers charged with searching for access solutions. Often those solutions are already at hand.
One key, one vehicle Gone are the days when convenience and security were mutually exclusive terms when describing keycode requirements and single key access control. TriMark offers a single-key locking solution for the operation of multiple locking products. The ‘One Key
left: ‘One Key – One Vehicle’ programme affords security and convenience to offhighway vehicle applications and includes ignition locks, cab and compartment doors and fuel caps below: TriMark KeyOne Plus Modular Locking System
– One Vehicle’ programme is made possible through the company’s patented KeyOne Plus modular lock design that can be easily installed as the last step. The design enables an OEM to linesequence the key codes without ordering locks or hardware kits in advance of builds. The complete locking program facilitates key code coordination and can include ignition locks and fuel caps in addition to cab and compartment doors. The automotive-style lock features a high-quality shutter and the perimeter waterproof seal reduces the infiltration of dirt and water into the lock. The product is available in a variety of codes, allowing flexibility in keying a unit alike. To protect overall security, KeyOne Plus can be keyed differently for each vehicle. It is possible to service or upgrade the lock, offering OEMs and dealers the option to adjust the level of convenience and security or to replace it in the event of lost keys or lock failure. It is convenient as no disassembly of the product or door is required. A customer looking to purchase a passenger car would be unlikely to buy one without remote power locking, and
the same increasingly applies to the offhighway industry. Vehicles are becoming more sophisticated, with OEMs incorporating many automotive-like aspects. TriMark’s successful e-ASK (electronic Access and Security Keyless entry) products include keyless entry, power-latch release, keyless ignition/start and control of lighting, horns and sensors, and motorised actuators. The company offers the right combination of products and services providing maximum flexibility to meet tight lead times for prototypes and production orders, without the need for expensive tooling and long lead times. The TriMark team can provide a solution to safely, simply and reliably secure a personnel or compartment door, improving the user interface and making it easier for the operator to use. The TriMark team can also put its expert engineering, prototyping and quick turnaround manufacturing resources and capabilities to work to produce rugged latches, handles, hinges and other hardware. iVT Ric Marzolf is VP of R&D at TriMark Corporation in the USA CONTACT www.trimarkcorp.com sales@trimarkeu.com
iVTInternational.com March 2011
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PRODUCTS & SERVICES KIERAN WRIGHT
Screen saviours as Ethernet migrates from the office into vehicles, this network for high-speed multimedia applications is performing wonders in terms of control, data transfer and high-quality displays
Nowadays we all recognise Ethernet as a reliable office-based network designed to connect our work PCs with various office devices. However, during the past decade, Ethernet itself has gradually crossed over into the industrial world in application areas such as factory automation and process automation. Modified Ethernet implementations and specifications have been developed to accommodate the more hostile industrial environment. As a result, those established non-automotive transportation (NAT) related application areas with Ethernet content, such as some mining-related applications, marine (LAN for ships) and high-speed networking for train carriages, have benefited from industrial Ethernet development and from the general availability of industrial Ethernet switches and interconnects (rugged M12 and RJ-45, connectors and cordsets). As often happens in the NAT industry, well-established technologies and products from the industrial and automotive sectors can cross over to provide innovative solutions in construction, agriculture, mining, truck, bus, marine and railway applications. Many Ethernet applications are now emerging alongside CAN-based network protocols (such as CANopen), and crossing into NAT space.
Interface solutions For control-type Ethernet applications, the industrial M12 interface format is well accepted. Both M12 and RJ-45 formats are used in NAT applications and are available in sealed IP67 and unsealed versions. M12 connectors and cordsets are particularly suited to the rugged, high-vibration requirements of most off-highway vehicles, and are applicable in both internal (cab) and external (outdoor) applications. For industrial Ethernet and NAT applications, M12 (D-coded) connectors and cables (four-pole, two-data pairs) are
LEFT: Leveraging its expertise at producing high-speed cable technology and adapting to the needs of the emerging ‘connected vehicle’ segment (vehicleto-vehicle communications, infotainment and telematics), Molex has introduced the HSAutoLink Interconnect System
normally applied. When used in combination with a pass-through M12-toRJ-45 panel adapter for instance, a flexible 10Mbps or 100Mbps industrial Ethernet application can be facilitated in the vehicle. More recently, M12 cables and connectors that integrate Cat 5e data speed with two separate power circuits have been introduced into the NAT market, enabling devices to be powered up and controlled using the same cable. To allow vehicle designers to go beyond fast Ethernet speeds into Gigabit Ethernet rates, M12 Cat 6 connectors are also now available that provide enormous bandwidth (1Gb/s) in a rugged and industrial waterproof M12 format. Some innovative M12 ‘push to lock’ or ‘push pull’ systems can be found in the market, which, in addition to reducing network installation time, can improve the reliability of the connection and, in some cases, provide waterproof sealing to IP69k level. Improving the reliability of the connection (versus screw thread options) increases the protection from vibrational
and mechanical shock, reducing the potential for loosening which could lead to intermittent signals, improper sequencing and, ultimately, failure. Achieving IP69k can be attractive particularly for externally placed devices, which can be easily cleaned down using a power hose. For those heavy-duty applications requiring extreme rugged M12 harsh Ethernet interconnects (for telematic or control applications in off-highway vehicles, for example), the Society of Automotive Engineering (SAE) committee defined the J2839 standard. The standard defines the performance requirements, size and mating interfaces for M12-style fourand five-pole heavy-duty, high-speed datalink connection systems. As an integral participant on the SAE committee, Molex has developed J2839-compliant products rated to 100 lb (445N) and 300 lb (1,335N) cable pull forces. Industrial Ethernet switches (both managed and unmanaged) are widely available for IP67, as well as IP20 or IP30 unsealed cab applications. Typically, M12
iVTInternational.com March 2011
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PRODUCTS & SERVICES
far RIGHT: Molex Brad M23 connectors and receptacles for signal and power applications for the harshest industrial environments RIGHT: The Brad Circular Hybrid Technology (CHT) Connector enables the use of Cat 5e data traffic combined with power lines. The connector is based on the circular M12 with four Cat 5e data lines and two power lines carrying 4A BELOW RIGHT: Brad harshduty industrial Ethernet switches provide IP67 sealed protection for outdoor and mobile applications
(D-coded) or RJ-45 cable assemblies are used. High availability is another feature available on industrial Ethernet switches, where an additional, redundant power supply connection is provided. Besides Ethernet switches, manufacturers offer digital network I/O modules (typically IP67 rated) which provide Ethernet connectivity for sensors and actuators in measurement and control systems.
At home in the cab Away from the traditional industrial markets, Ethernet has recently attracted the attention of the high-end automobile industry in the form of Ethernet audio video bridging (AVB), where it is seen as one of a number of promising network technologies for supporting real-time digital multimedia applications in the vehicle. These same applications are also of interest to nonautomotive OEMs in the commercial vehicle (truck), bus, agricultural and construction equipment sectors. The key driving applications for vehicle Ethernet AVB are multimedia infotainment
and driver assistance. Vehicle manufacturers want to integrate consumer electronic devices, such as MP3 players, mobile phones and DVD players into the cab, providing high-quality video displays and monitors, with externally accessible ports and even the possibility of internet access. On the other hand, driver assistance and safety – particularly in commercial vehicles – are escalating the interest in vision systems for applications such as lane departure warning (LDW), collision avoidance and externally mounted cameras for parking and blind spot assistance. With connectivity and bandwidth capacity being such a challenge, a high-speed multimedia network becomes a desirable necessity in the vehicle. While today’s vehicle-based network systems typically handle data speeds in the upper range of 480-600Mb/s, some notable systems are in development, including Ethernet AVB (1,000BaseT), LVDS (above 1GHz) and 1394Auto S1600+. Applicable to the automotive industry, these systems will increase data rates to
1Gb/s and beyond, providing a network for high-speed multimedia applications and allowing high-resolution monitors in the vehicle to become a reality. Molex is among those connector manufacturers working to provide NAT segments with industrial databus solutions and advanced automotive high-speed connectivity. One thing is certain when it comes to vehicle databus solutions – there is a lot of exciting interconnect innovation still to come. iVT Kieran Wright is industry marketing manager at Molex, overseeing the non-automotive transportation (NAT) interconnect markets in Europe. He joined Molex in 1997
CONTACT www.molex.com mxgermany@molex.com
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iVTInternational.com March 2011
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PRODUCTS & SERVICES juho partanen
Hot property heat exchangers that optimise product reliability, decrease lifecycle costs and improve profitability are just the ticket for increasing the lifespan and performance of off-highway machinery Very demanding sectors such as offhighway equipment, military systems, generators and locomotives can especially benefit from brazed copper-brass heat radiators, charge-air coolers and oil coolers. As a result, there is a new wave of interest in CuproBraze heat-exchanger technology replacing at least three core technologies: soldered copper/brass plate fin, soldered copper/brass serpentine fin and brazed aluminium serpentine fin. The main reason for the popularity of CuproBraze technology is that it enables the use of brazed serpentine-fins in brazed copper-brass heat exchanger designs. These are less expensive to manufacture than soldered serpentine-fin designs and are more durable because they have much stronger joints. As well as greater cooling efficiency, they are more rugged than brazed aluminium serpentine-fin designs, due to the thinner materials enabling more air to pass through. In addition, square-wave-type fins are not easily clogged and can be cleaned with pressurised water so that thermal performance can be maintained during operation. Aluminium has durability problems at the higher temperatures and pressures that are necessary to meet more stringent emissions requirements, such as Tier 4i. In selecting heat exchangers for tough applications, consideration has to be given to cooling efficiency and durability, including corrosion, fatigue and elevated temperatures. Compared with other materials, brazed copper-brass provides stronger, tougher joints, resulting in more durable products. Strong brazed joints and the reduction of galvanic corrosion at these areas make CuproBraze heat exchangers extremely rugged. In deciding which base materials to use for heat exchangers, the potential increase in productivity and the huge savings in downtime and the maintenance cost of the vehicle must also be taken into account. The heavy-duty vehicle industry – producing machines such as wheeled
loaders, terminal tractors, multipurpose machinery, piling rigs and other types of off-highway vehicles – is characterised by its high capital intensity compared with many other fields of business. This is because investment in machinery and equipment is economically significant, resulting in a situation where unplanned downtime, such as machine breakdowns, is unacceptable because it slashes productivity and decreases profits. Equipment out of commission constitutes a considerable add-on cost for any operation and often cannot be passed on to the customer. Heavy-duty machinery has to operate in extremely challenging environments, often with high and low temperatures, humidity and vibration loads, for example in marine, tropical and arctic conditions. For example, the information from the field regarding heat exchangers is that there have been difficulties with existing technologies, such as brazed aluminium products. Aluminium is an economical solution for light-duty applications, such as passenger cars and light trucks, because of its market price and lower density than copper alloys. In heavy-duty applications, particularly
such as machinery for the mining industry, the operational and environmental requirements favour the use of more precious metals, such as copper and brass. These also have a much higher tensile strength than copper. At room temperature, copper has a tensile strength of 330MPa (aluminium’s is 40MPa) and a thermal conductivity of 377W/m°C (aluminium is 222W/m°C). Copper’s metallurgical excellence further optimises product reliability, decreasing lifecycle costs and improving profitability. External corrosion resistance is required in coastal areas, humid areas, polluted areas and mines. External and internal corrosion resistance is better in CuproBraze heat exchangers than with the aluminium type, as has been proved in accelerated corrosion tests, such as SWAAT for salt spray and marine conditions. Even when corrosion eventually forms, in CuproBraze alloys the corrosion behaviour is even and predictable – vital information for every design engineers’ toolbox. iVT
above: When designing heat exchangers for off-highway trucks, there’s no room for compromises when aiming for maximum longevity and performance
Juho Partanen is export director at Finnradiator Ltd CONTACT www.finnradiator.com info@finnradiator.com
iVTInternational.com March 2011
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PRODUCTS & SERVICES LIINA HAUTANEN
Essential nervous system HIGH-END WORKING MACHINES IN DEMANDING ENVIRONMENTS CAN’T GET BY WITHOUT A BULLETPROOF, RUGGED CABIN PC DELIVERING THE PERFORMANCE CAPABILITY OF THE MOST POWERFUL LAPTOP
Fundamental to the operation of any working machine is its control system. Conditions for industrial vehicles, such as forest machines or underground mining machines are very demanding, requiring more than normal office PC technology. The more complex the system, the more it demands of the HMI. The demands to integrate high-end PC level competence with freely programmable graphical user interfaces are increasing. The most high-end working machines require HMIs that are more than just an embedded display, integrated to the machine control system. Therefore Epec is now providing a new intelligent EPC-i10 to be used as an HMI of a machine control system, and at the same time, it is also the most powerful rugged cabin PC on the market.
Same product, versatile usage EPC-i10 is a heavy-duty HMI/display computer specifically designed for the challenging operating conditions of mobile machines. Slim, compact, multifunctional and rugged, EPC-i10 adopts the Intel Celeron M up to Intel Core2 Duo processor. The unit also supports versatile I/O ports, Ethernet 10/100 RJ-45, RJ11 for telephone handset, four USB2.0 and a rich set of other communication interfaces such as 2x CAN, 2x Video Input, modem and the standard interfaces known from PCs to offer flexible capabilities to connect with devices. WLAN, Bluetooth, GPS, 3G modem and ZigBee are also available as options. A special feature of the modem used in the device is its two SIM card slots; one for telecommunication usage and another for GPRS connection. EPC-i10 offers an excellent platform for creating a reliable, efficient and user-friendly HMI for the control system. A standard operating system (Windows or Linux) allows the usage of commercial software. Machine-specific software can be written for instance with CoDeSys, SoftPLC or Epec’s own .NET-based software platform.
EPC-i10 is designed for use in extreme conditions where vibration, moisture and wide temperature changes are encountered every day. These were the criteria that inspired the design and determined the selection of the components used. The integrated EPC-i10 is also ideal for spacelimited applications. It has a re-heater for low temperatures, a robust aluminium housing and toughened-glass TFT screen, readable in the sunlight, with an LED backlight and dust and splash protection ensuring reliable operation – features that elevate it over competing products. EPC-i10 complies with normal automotive standards for EMC and environmental conditions, and is certified for automotive use according to e17.
Rugged and break-resistant Epec’s product portfolio also consists of robust controllers ready for extreme duties. Control units can tolerate dust, vibration, humidity and extreme temperatures and are tested to take shocks of 100g. “They do not break,” says Jouni Matikainen, Epec MD, adding that they could probably withstand more, but it was difficult to hit them any harder! This might seem a little extreme, but the harvester head is one of
the most demanding environments in which to fit such components. Shocks here can be up to 60g. Epec’s rugged machine control products, advanced display computers, scalable software platforms and personally customised solutions will not let the operator down even in the most extreme conditions. Founded in 1978, Epec Oy is one of the world’s leading producers of heavy-duty control system products and vehicle computers. It carries out its development and manufacturing in a modern environment in Finland, using the latest technology. The aim is to offer embedded control system products, as well as customised applications, to help customers to design and manufacture safe, efficient and environmentally friendly vehicles, enabling machine users to maximise productivity. Epec’s key customers include OEMs who build industrial vehicles for extremely demanding conditions. The embedded system technology solutions are based on distributed intelligence, where the various parts of the system communicate over a CANbus. iVT
ABOVE: New integrated EPCi10 functions seamlessly as an HMI of a machine control system. At the same time, it is also a very powerful PC MAIN AND BELOW: Rugged Epec computers are used in Ponsse harvesters, where the Opti5-PC is equipped with the Opti4G information system. This is the user interface to the OptiControl management system, and handles all the operations required for cutting from data transfer to marking for bucking and reporting
Liina Hautanen is marketing comms manager at Epec Oy, where she has worked since 2008 CONTACT www.epec.fi sales@epec.fi
iVTInternational.com March 2011
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PRODUCTS & SERVICES DAVID A. VARLEY
Thrills without spills as farmers increase spraying to control weeds and IMPROVE crop yield, they’re bound to be delighted by pump technologies that maximise chemical use and seal life yet prevent spillages
Ace Pump uses this same double mechanical seal in an air-pressurised buffer chamber on its Max Series Oasis Wet Seal Technology pumps such as the FMCWS-650F-HYD (go to www.OasisWetSeal.com for more details). With this pump and the larger FMC-750F-
Figure 2 (BELOW): Typical trailed field sprayer Figure 3 (BOTTOM): Performance comparison for typical centrifugal and Barske-style pumps
HYD pump, the pressurised buffer fluid is used as a source for the lubrication and cooling of the mechanical seals, keeping the seal faces from heating in excess of 250°F (121°C) should the supply tank run dry. The increase in the volatility of farming chemicals, the worldwide environmental awareness and the new stricter regulations against chemical spills, particularly in the EU, make the double seal and buffer chamber almost a necessity on modern crop-spraying equipment. Pressurising the buffer chamber maintains the fluid film on the seal faces, isolating them from abrasive material often found in modern fertilisers. This Ace centrifugal pump uses a straight blade, open-faced Barske-style impeller driven by a high-efficiency, pressurebalanced gear motor supplied by Marzocchi. This combination provides higher spraying pressures at a lower rpm and a very flat pressure-to-flow curve for easier spray-rate regulation through modern electronic spray controllers. Figure 3 shows the performance difference between the Barske and a typical centrifugal pump. This high-flow capability at high-pressure delivery improves crop canopy penetration and spray efficiency, in conjunction with a nozzle system designed to produce low drift of the sprayed fluid from the desired
coverage area. Additionally, the open face straight blade-style impeller enables a free and unrestricted flow of materials; even those with a high percentage of suspended solids.
Meeting farmers’ needs As the worlds’ farms increase in size, more farms share spraying machinery or employ contractors, so the equipment needs to offer improved reliability and longer service life. A system that improves seal life, combined with a pump that uses moreefficient electronic spray controls to deliver higher flows over a wider high-pressure range, should meet the needs of farmers everywhere. iVT David A. Varley is product development engineering manager at Ace Pump Corp PERFORMANCE COMPARISON Pump Flow (lpm) 0
80
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Figure 1 (LEFT): FMCWS650F-HYD pump with Oasis WetSeal
Pump Pressure (psi)
Throughout the agricultural community, the use of chemicals to restrict unwanted weeds and insects and to promote the growth of plentiful, wholesome crops is rising, as is the size and capacity of the spray equipment used to dispense them. With this size increase, the chance that the onboard chemical supply tank will run dry at the farthest distance from the main supply tank increases considerably. Although all operators know that centrifugal pumps should never be operated without a fluid present inside, they are keen to use every last drop of the expensive chemicals on their crops. Yet the operator’s attention is split between monitoring the boom system, the flow-rate controller and the GPS guidance to optimise coverage. When a typical centrifugal pump runs dry, the rotating and stationary faces of the mechanical shaft seal lose the fluid film that normally separates the faces. The increased friction causes an increase in heat up to the melting point of the surrounding elastomer seal components, causing seal failure and the pumped fluid leaks onto the ground. For many years, chemical and petroleum processing plant pumps have used systems with an intermediate chamber between the pressurised portion of the pump and atmosphere, and a double mechanical seal. One seal is situated on each side of the chamber, providing a buffer zone and trapping leaking chemicals and preventing their escape. The chamber is filled with a neutralising fluid that does not react with the pumped fluid and provides a continuous cooling and lubricating film between the rotating and stationary seal faces.
40 2
Typical Centrifugal 20
Barske Style Impeller 0
0 0
25
50
75 Pump Flow (gpm)
100
125
150
CONTACT www.AcePumps.com sales@AcePumps.com
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PRODUCTS & SERVICES RICHARD BECKERS
The hot topic REDUCING FUEL CONSUMPTION HAS NEVER BEEN MORE IMPORTANT – SO A HYDRAULIC FAN SYSTEM CONTROLLER THAT CAN SLASH IT BY UP TO 20% AND PROVIDE PAYBACK IN MONTHS IS WORTH TALKING ABOUT
In just a matter of months, it is possible to achieve a return on investment for a complete electrohydraulic system with a High Country Tek (HCT) fan drive controller. The HCT hydraulic fan system (HFS) controller suits virtually any style or type of cooling application and enables increased productivity by utilising available engine horsepower for work rather than cooling. This results in a fuel consumption saving of 10-20% for a mobile application. Suitable applications for the HCT HFS controller include bus cooling, emergency vehicles, surface-mining equipment and agricultural machines. The HFS controller works by optimising fan speed control relative to temperature requirements and includes a controller to expand existing system functionality. The product operates with all OEM electrohydraulic equipment and is suitable for new OEM build or repower, retrofit, or upgrade applications and is available as an on-or off-highway mechanical package. Its transient suppression design and specification makes it suitable for use on all kinds of mobile equipment and it is suitable for engines or systems with or without J1939 capability. The HFS controller features a pre-written graphical user interface for all modules and includes SAE-J1939 and RS232 serial communication, as well as a pre-written Windows software application, ready for user values. The product has a system ‘error’ indicator LED with blink code and uses an Opto 3000 system for set-up and PC communications. The HFS controller is sealed and protected to >IP68 ( NEMA 6P) and has a special ‘solid’ potting with flame-retardant materials. It also features open and short circuit cable protection with monitoring and a heavy-duty industry standard Deutsch connector. The HCT HFS controller is an optimal choice for fuel efficiency in mobile systems.
There are three discrete temperature zone sensor inputs, an additional two discrete switch inputs for fan speed override, and one PWM output for any make of proportional valve of pump control. The company provides the industry’s most ruggedised modular electronic control solutions for a broad variety of fluid power and other electrohydraulic applications. It is globally recognised as a market leader in the hydraulic fan drive arena – and now, the electric motor fan controller arena – with a proven product range to suit virtually any style or type of cooling application. Custom Fluidpower is the Australian distributor of the HCT product range and, along with product supply, is able to provide a full design service to either
integrate the HCT product into an existing system, or design a complete new system. Custom Fluidpower is a wholly Australian-owned company, offering hydraulic, pneumatic, filtration and lubrication product sales, along with complete system design, installation and commissioning and service and repairs. Custom Fluidpower services the mobile, agricultural, mining, materials handling, exploration, industrial, aerospace and marine industries Australia-wide. iVT
ABOVE: Mining haulers are an ideal application for HCT fan system controllers LEFT: The HCT hydraulic fan system controller BELOW: An HCT controller at work on surface-mining equipment
Richard Beckers is an engineering co-ordinator & product expert on the HCT range at Custom Fluidpower, where he has worked for 10 years
CONTACT www.custom.com.au www.hctcontrols.com
iVTInternational.com March 2011
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Why are so many leading vehicle manufacturers turers investing in Hella LED Work Lamps? High Power
Optimal Light Distribution
Ultra High Efficiency LED light is a fantastic invention. LEDs will last for almost the vehicleâ&#x20AC;&#x2DC;s entire life, they save energy and therefore reduce CO2 emissions. However: An LED work light is more than just a modern light. LED work lights only meet all expectations when three quality factors are perfectly tuned to each other.
Therefore before buying, always check the quality: 1. of the LEDs, 2. of the integrated electronics and 3. of the thermal management system. Or just ask for Hella. We always have the ideal LED product for your requirements, because we invest over 100 years of know-how into our headlights - so that your investments are safe.
Hella, Inc. 201 Kelly Drive P.O. Box 2665 Peachtree City, GA 30269 Toll Free: 1-877-224-3552 Fax: 1-800-631-7575 www.hellausa.com
Aurora-Where_the_Action_Is:Aurora 11/16/10 12:04 PM Page 1
Index to advertisers
Rod Ends and Spherical Bearings designed and manufactured to Aurora's exacting standards for quality and durability. Registered and Certified to ISO-9001 and AS9100. From economy commercial to aerospace approved, we've got it all !
Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538 Complete library of CAD drawings and 3D models available at:
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Ace Pump Corporation.........................56 Ametek................................................85 ASM GmbH........................................101 Association of Equipment Manufacturers (AEM)....................109 Aurora Bearing Company...................118 Battery Show.....................................116 Bauser GmbH & Co KG.......................101 Bondioli & Pavesi SpA..........................52 Bosal-Sekura Industries AS................112 Bucher Hydraulics AG Frutigen.............61 Carlisle Industrial Brake & Friction.......88 Carraro Drivetech SpA.........................72 Caterpillar Inc Industrial Power Systems...............................35 Cummins Ltd Business Services............3 Custom Fluidpower..............................58 Dana Corporation................................ IFC David Brown Hydraulics/Textron Fluid Power.....................................54 Delta Hydraulics Pty Ltd.......................58 Donaldson Company Inc....................114 Eaton Hydraulics..................................22 E-Controls (FW Murphy).......................81 elobau GmbH & Co KG.........................74 Emmegi Heat Exchangers SpA.............94 Epec Oy.............................................110 Faster SpA...........................................40 Federal-Mogul SP..............................104 Finnradiator Ltd...................................96 Flexxaire Manufacturing Inc.................94 FW Murphy..........................................70 Hawe Hydraulik GmbH & Co KG.............8 Hella Fahrzeugteile Austria GmbH......118 Horton Inc............................................91
Hydraforce Inc.....................................38 Hydro Electronic Devices Inc................78 Industrial Vehicle Technology Online Reader Enquiry Service.................106 John Deere Power Systems.................64 Knott GmbH.........................................96 Linde Hydraulics..................................43 MAN Nutzfahrzeuge AG..................... OBC Marzocchi Pompe SpA.........................30 MICO Incorporated...............................25 Molex..................................................28 MTS Sensor Products..........................32 MTU Friedrichshafen GmbH.................13 Multi-Wing International.......................88 Nimco Controls AB...............................61 Nordic Lights.......................................76 Oerlikon Fairfield Drive Systems..........10 Otto Controls........................................78 Parker Hannifin BG Ermeto...................54 Parker Hannifin, Hydraulics Group Europe...................................... 20 Penny & Giles......................................76 Perkins Engines Company Ltd.............4,5 Sai SpA................................................56 Sauer-Danfoss (Nordborg) Aps.............17 Scania CV AB.......................................66 SPAL Automotive Srl............................68 Stucchi..............................................112 Tri-Mark............................................110 Tuthill Drive Systems.........................104 Wachendorff Elektronik GmbH & Co KG..............................114 Wandfluh AG........................................85 Yanmar Europe BV..............................IBC ZF Passau GmbH.................................15
BULLETIN BOARD NO-TOUCH MEASUREMENT FOR TANK LIQUID LEVELS The new Motometer sensor is able to make a contactless measurement of the liquid level in the tank by using ultrasonic technology. Motosonic is a new ultrasonic-level sensor that generates a high-frequency sound wave to measure the time the wave needs to run to the fluid level and back, after reflection by the liquid surface. Based on the time measured and the speed of sound, the distance between the sensor and the liquid surface can be calculated so determining the tank content too.
The ultrasonic-level sensor works, even at extreme temperatures in a range between -40 to +85°C. Compared with classical level sensors, measurement is very precise. The distance is detected to an accuracy of ± 3.2mm and a resolution of 1.8mm. The contactless measurement avoids abrasion of mechanical parts and increases the sensor lifetime. It is important for the calculation to take the tank shape into account. By programming a table of interpolation values into the sensor, the tank contents of various tank shapes can be displayed exactly on standard gauges. The flexible Motosonic sensor can also be used for very many different liquids, such as water, diesel fuel, coolant liquids, vegetable and hydraulic oil. Further accessories, such as the focus tube make possible precise measurements even in extreme conditions when the vehicle is on a steep gradient. Motosonic is suitable for electrical systems using 12V or 24V power supplies. ENQUIRY No. 501 Iveka www.motometer.net info@motometer.net +49 7041 96950
TOP CLASS CLUSTERS
Bauser instrument clusters are impressive, whether used in utility vehicles or other offhighway sectors, such as construction machinery, forklift trucks, scissor lifts, industrial lawn mowers and specialised vehicles. The clusters are constructed to a very high standard and very robustly. Their parameters meet every relevant industrial and vehicle technical requirement.
Type 814 is destined for the cockpits of the most special class of utility vehicles. It caters for a particularly high-class vehicle, employing ASTN Technology for digital/analogue inputs, as well as CAN, CANopen and/or SAE J1939 interfaces. ENQUIRY No. 502 Bauser www.bauser-control.de mail@bauser-control.de +49 175 3611 590
FLEXIBLE CONTROL FOR INDUSTRIAL VEHICLE FUNCTIONS Müller Industrie-Elektronik GmbH has developed a very flexible vehicle control system for industrial vehicles. The VCS vehicle control system consists of a VCS-TU control unit which is designed to be small and mountable in an ordinary DIN radio slot in the vehicle cockpit. Alternatively, an operating unit in a robust heavy-duty-case is available with the wired capability of connecting the additional handheld remote unit VSC-RU, supplied in a case. This handheld remote unit can also be used as an independent controlling unit to control seven different functions. All Müller Industrie-Elektronik’s operating units have German Federal Motor Transport Authority E1-approval. The two mounted operating units
VCS-TU-DIN and VCSTU-HD are customised to be programmable with up to 19 control commands. They have push button slide-in labels for userspecific identification of the command functions. Programming can be performed without any specialist knowledge. It is done via an external programmable logic control or via the software included with the Müller power unit. The display enables vehicle data to be retrieved and input. The VCS-PU power unit is an additional and essential module of the vehicle control system. It is mounted directly on the vehicle between the functions that have to be controlled and is connected with the particular operating unit via a two-wire CANbus connection, reducing wiring.
ENQUIRY No. 503 Müller Industrie-Elektronik www.mueller-ie.com pr@mueller-ie.com +49 5032 9672153
iVT International March 2011
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THE INSIDER
“Colin shrugged, said, “Read the small print, sucker,” and sidled off to China with the product line that Trevor so badly needed
120
Call me old-fashioned, but I have never been too impressed with the idea of ‘leaks’. By which I’m obviously not talking about the slowly spreading pool of hydraulic oil under that Chinese backhoe loader you bought last year, but the recent furore over the WikiLeaks scandals. Unless you have been secreted in a Buddhist mission somewhere in the Himalayan foothills over recent months, you will have been either very bored or very excited about the revelations pouring into this website purporting to be text from actual documents referring to secret reports or conversations about prominent international figures and events. Question is, do I actually care? If the subject had been intimate details of Jennifer Aniston’s underwear drawer, I might have logged on to the website out of idle curiosity, but I have no interest whatsoever in questionable opinions expressed by questionable people about other questionable people, prominent or otherwise. To me, the whole subject has become a complete bore. What does concern me, though, is that the protagonists in this drama feel that they have the right to obtain and ‘out’ this possibly damaging information supposedly in the name of modern journalism. Even more worrying is the reaction to this unwelcome pressure by some of the world’s governments, which have resorted to bringing their judicial procedures to bear on the owner of the website, citing some hitherto unreported crime as their justification. Although cynics might say that the world has always been a nasty place, I prefer to think that in our industry at least, we are shielded from a lot of the sharp practices that other sectors feel. Certainly from my own experience, when I first got involved in the components business, this was very much the case. I can still remember calling competing OEM customers when we had shortages, asking if they would mind sharing the capacity we had so they could both keep building, and how rival designers would meet at
iVTInternational.com March 2011
Illustration: Julie Welby
inspired – or perhaps irritated – by the wikileaks saga, our own deep throat turns whistleblower on corporate sharp practice
shows to swap ideas on design. Sure, there was competition, but there was also a certain camaraderie. A year or so ago, I heard a story that confirmed this was no longer the case. It involves a few large companies and as I have no wish to find myself extradited by some obscure far-off European regime for owning a dog without a licence, I will keep the names secret. Let’s call the first company Colin and the second Trevor. Trevor was an Asian OEM that had a tie-up with another Asian company to produce and market roadbuilding machinery. Colin also made roadbuilding machinery, and Trevor sold a few of these in addition to its own brand. One day, Colin suggested that Trevor should consider manufacturing Colin’s own brand of machinery exclusively, dropping the product he was currently making, even though these were selling quite well. After a bit of toing and froing, they agreed that Trevor would make a massive investment and build a brand new factory specifically to carry out this task. All went swimmingly for a year or so – until, one day, Colin rang Trevor and told him that as he was moving his business over to China, Trevor’s factory was, in effect, surplus to requirements. Trevor was of course
somewhat mortified, citing the fact that they had signed an agreement which effectively meant that Colin would provide the required throughput for the factory. Colin shrugged his shoulders, said, “Read the small print, sucker,” and sidled off to China with the product line that Trevor so badly needed. Some of you may think this is all a bit vague to draw conclusions about, but others may think they know Colin. In that case, they might think that I am being too kind by masking the identities in this drama. If so, then here is your chance to strike a blow against corporate sharp practice and be a whistleblower too! Answers on a postcard to ‘I Know Colin,’ with your name, address, bank details, passport number and a passport-size photo (it all helps the extradition process). There’s no prize, but correct answers may be published in very big letters by our own Julian Assange lookalike on his rumoured WikiOEMleaks site! Alternatively, if in the interests of your own security you would prefer a feature on the contents of a certain American actress’s underwear drawer with salacious details of colours, styles and fabrics, I’m sure the editor would be only too pleased to oblige! iVT Comments: theinsider@ukipme.com
PUBLICIS
www.man-engines.com
Power up for grabs.
MAN engines. Power to build with. 19. - 25. April in Munich
MAN engines are the perfect building workers – extremely reliable, but with the emphasis on economy. With ratings of
110 kW (150 hp) to 882 kW (1200 hp) they really come on strong. But they‘re quiet and environmentally compatible too – just right for the construction sector. MAN Truck & Bus AG, Sales Engines & Components, Vogelweiherstr. 33, 90441 Nürnberg, Germany man-engines@man.eu
Engineering the Future – since 1758.
MAN Truck & Bus
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