Fluid Power World August 2017

Next-gen mobile electrohydraulic controls p. 26

Efficient design in industrial hydraulics p. 42

A look at hydraulic pressure intensifiers p. 48

www.fluidpowerworld.com

August 2017

Set it then forget it Elopak equips fully aseptic filling machine with robust pneumatics.

PAGE 34

COVER_FPW 8-17_FINAL MG.indd 1

8/18/17 12:50 PM

TOMPKINS QUICK DISCONNECTS Tompkins Quick Disconnect series allows for the connection of multiple hoses in multiple circuits easily.

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* Panel Mount Kit sold separately † Flow (SCFM) measured at 87psi with ∆P of 14.5psi All prices are U.S. published prices. Many other part numbers are available from all vendors. AutomationDirect prices as of 6/12/2017.

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The value of associations is in participation I’ve been a big proponent of associations over the course of my career covering the world of fluid power. They’ve helped me meet and interact with important industry leaders, network with readers, and understand the critical issues facing manufacturers today.

I recently had the chance to catch up with Joe Thompson, the Executive Vice President of NAHAD (the Association for Hose and Accessories Distribution) to see how the association is faring. NAHAD’s membership, which has hovered around 500 for the past several years, is a split of about 150 manufacturers and 350 distributors. And this year’s attendance at the annual conference was a very strong 950 people.

Thompson explained that NAHAD focuses heavily on education and networking, as well as building relationships between distributors and manufacturers.

“It’s all about relationships, even in this day and age of social media and networking,” Thompson said. “It’s still about face to face, handshake to handshake, business being done. The association provides, obviously, the venue for that at their events and conventions throughout the year. Our role is to really provide some of the services and support that the company needs to thrive and survive.

We’re dealing with a whole range of issues, such as workforce development issues, finding and keeping good people.”

Another key role is establishing industry standards, which NAHAD has been heavily involved in creating—especially in the area of safety protocols for quality and reliability. Thompson notes that they have spent a lot of time and effort creating the standards for hose and assembly fabrication.

But there’s also a real need for associations to have strong, capable leadership. While support staff is certainly very important, committed volunteers serving on boards, committees and task groups are critical.

“When you get right down to it, associations are groups of competitors that agree to play together nicely,” Thompson said. “By sharing with each other their experiences, problems, needs and issues—and then finding solutions—everybody benefits.”

FPW

Available In BSPP

Paul J. Heney Editorial Director pheney@wtwhmedia.com

Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423 Email: sales@superswivels.com

1-763-784-5531 www.SuperSwivels.com Editorial 8-17 FPW_Vs3 MG.indd 2

On Twitter @DW_Editor

2

FLUID POWER WORLD

8 • 2017

www.fluidpowerworld.com

8/11/17 3:37 PM

Robust Design for Rough Environments

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8/11/17 3:24 PM

AUGUST 2017 • vol 4 no 5 • www.fluidpowerworld.com

EDITORIAL Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Managing Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

NEW MEDIA/WEB/BUSINESS DEVELOPMENT Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave Senior Web Developer Patrick Amigo 860.603.2984 pamigo@wtwhmedia.com @amigo_patrick

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

Web Production Associate Skylar Aubuchon saubuchon@wtwhmedia.com @skylar_aubuchon

Nothing ruins a workday like a repair that could have been prevented. That’s why Tompkins Pro Wrap is the quick, convenient, and affordable way to protect your hose from unnecessary damage and costly mistakes. Wrap your hoses for increased longevity and even color-code them to reduce the chance of user error.

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Web Production Associate Janae Garrett jgarrett@wtwhmedia.com @janae_wtwh

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Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane Contributing Editor Carl Dyke @carlindustry

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FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2017 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

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8 • 2017

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vol 4 no 5

August 2017

C ontents |

|

fluidpowerworld.com

•

08

|

2017

F E AT U R E S MOBILE HYDRAULICS

Next-generation electrohydraulic controls for off-road machines

26

Integrated hardware and software replace traditional mobile-hydraulic control systems.

PNEUMATICS Set it then forget it

Elopak equips fully aseptic filling machine with robust pneumatics.

INDUSTRIAL HYDRAULICS

Efficient design in industrial hydraulics

34 42

26 D E PA R T M E N T S

02 Editorial

Understanding the properies of nature is critical in selecting efficient hydraulic technologies.

INTENSIFIERS

How can hydraulic pressure intensifiers improve your system design?

08 Korane’s Outlook

48

11 Association Watch 14 Design Notes 22 Maintenance

Reciprocating intensifiers generate higher pressure from a low-pressure hydraulic power source, helping to conserve energy, cost and space.

24 Energy Efficiency

SHOW PREVIEWS

25 Safety

PACK EXPO RETURNS TO VEGAS............52 ICUEE SHOW PREVIEW..............................56

65 Products

70 Component Focus

ICUEE PRODUCT SHOWCASE...................60

72 Ad Index

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A | S | B | P|E

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34 6

FLUID POWER WORLD

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8 • 2017

2017 Regional

Fostering B2B editorial excellence

2017 Regional

PR INT

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Just six clicks to precision.

Yates has long had a reputation for excellence in the manufacturing of tie rod cylinders.

They uphold that reputation when it comes to their state-of-the-art cylinder configurator.

Cylinder configuration isn’t just for engineers any more. That’s why Yates refers to it as the “people’s configurator.” And it’s more than just templates and plugging in dimensions. There’s even a new feature that allows for attaching accessories to the drawing. In the end, you get the specific tie rod cylinder you need. And it all starts with submitting your specifications with just six simple clicks. Just what you’d expect from Yates Industries; a third generation manufacturer of high performance cylinders with quick turn around times, quality support and the convenience of three locations.

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Ko ra n e ’s O u t L o o k Ken Korane • Contributing Editor

Will global warming kill fluid power?

Two new studies released this month paint a grim picture of the consequences of global warming. The papers published by scientists at the Universities of Colorado and Washington say that due to CO2 emissions, global temperature will likely increase more than 3.6°F by the end of the century, triggering a catastrophic rise in sea levels, super droughts, mass extinctions, and declining human health.

Like countless previous reports, the authors conclude that the international community must make major and ambitious changes in climate and energy policies that limit carbon emissions. One central theme that is emerging is the move to eliminate IC engines from vehicles.

Consider that the U.K. and France have announced they will ban diesel and gas cars and vans in 2040, to tackle air pollution and global warming. More aggressively, Norway will push to limit sales of all fossil-fuel based cars by 2025, by instituting penalties on conventional cars and offering incentives to embrace alternatives. Other nations like Belgium, Japan, the Netherlands and Switzerland are contemplating phaseouts or watching developments closely. In addition, Volvo announced in July it will only sell battery-powered or hybrid cars from 2019 onwards, in what the company called an “historic end” to building models that only have internalcombustion engines.

It’s not just cars in the crosshairs. Volvo Construction Equipment has been working on electromobility and hybrid technology since 1998 and says electrification of off-road equipment is the long-term trend. That could definitely impact fluid-power markets. Hydraulics has always been regarded as outperforming electrics in terms of power density and ruggedness. But anyone who thinks mobile hydraulics is immune to inroads by competing technologies is kidding himself.

Last year Volvo CE introduced its experimental LX1 electrichybrid wheel loader with an electric drive, battery energy storage system and a relatively small diesel engine. At Conexpo 8

FLUID POWER WORLD

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8 • 2017

Volvo CE prototype hybrid wheel loader and electric hauler.

| Image courtesy of Volvo CE

in March it presented the HX2 autonomous, battery-electric hauler with no diesel engine whatsoever. Two electric wheel motors eliminate less-efficient hydrostatics and a third electric motor powers a hydraulic pump to handle steering and actuate the dump cylinders. These machines are part of an electric-site research project in Sweden that predicts up to a 95% reduction in carbon emissions and 25% lower total costs in a quarrying operation.

And this May, the company unveiled a fully electric compact EX2 excavator that delivers zero emissions. The prototype replaces a combustion engine with two lithium ion-batteries, which store enough electric energy to run the machine for eight hours in intense digging applications. Electromechanical linear actuators that supplant the hydraulics are said to offer significantly higher efficiency, while removing the hydraulics and engine reduces cooling needs and makes for quieter operation.

“Volvo CE is committed to pushing boundaries and exploring the technology of the future,” said Jenny Elfsberg, director of emerging technologies at Volvo CE. Using electricity instead of diesel to power construction equipment has the potential to significantly reduce fuel consumption, CO2 emissions, environmental impact and cost-per-ton, she said. “The electrification of construction equipment will produce cleaner, quieter and more efficient machines—this represents the future of our industry.”

FPW

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8/11/17 3:39 PM

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Edited by: Mike Santora • Associate Editor

Column level indicators

ASSOCIATION WATCH

for glycol-based solutions

IFPS annual meeting

• For Glycol-based Solutions – Pyrex®* glass transparent tube available • Maximum Visibility Even from the sides

The IFPS 2017 annual meeting will be held September 25-28 at The Alexander in Indianapolis. In addition to committee and board meetings, optional events are planned throughout the week.

A Technical Workshop, “International Standard IEC 61131 for Programmable Logic Controllers” will be presented on Monday. This workshop will present complete coverage of the syntax, operands, and operators of the six available programming languages of the IEC61131-3 programming standard – Ladder Logic, Instruction List, Structured Text, Function Block Diagram, Sequential Function Chart, and Continuous Function Chart. The IFPS Electronic Controls Specialist Certification Test requires knowledge of this standard as one of the primary outcomes. Applications will be covered along with visualizations using each of the languages. Participation in this workshop contributes towards recertification and AI reaccreditation requirements. A Job Performance test is also scheduled for Monday.

• Safe – Transparent polycarbonate front protection, removable for cleaning • High-Temp Use Stainless hardware available for service to 130°C

Elesa. Always more...

Registration Fees - Registration must be received by September 8th (after September 8th, a $25 late fee will be applied.)

• Delegate: $225.00 (includes reception, business meetings, lunches and annual dinner.)

• Spouse: $150.00 (includes reception and annual dinner)

• Technical Workshop: $150.00 (includes lunch)

• Job Performance Test for Mechanic, Technician and Connector and Conductor Certification Monday, September 25.

• Optional Events include a tour of Horner Industrial, an escape room, The Indianapolis Motor Speedway and a show at the Indiana Repertory Theatre.

Operating elements

Indexing and positioning elements

Clamping knobs

Lift & Pull handles

Leveling elements and supports

Hotel Reservations - Hotel reservations can be made online or by calling The Alexander at (317) 624-8200. A discount hotel rate of $189.00 + tax /night has been secured. Mention the International Fluid Power Society to secure the group rate.

Reservations must be made by August 28 to receive discounted rate. After August 28, contact Jeana Hoffman at jhoffman@ifps.org.

Control elements

Hinges and connections

Rotary controls

Accessories for hydraulic systems

Request our Hydraulic Accessories Catalog

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Edited by: Mike Santora • Associate Editor

ASSOCIATION WATCH

NFPA Education Roundup

On Manufacturing Day 2016, Paragon Technologies invited 35 students from Centerline High School to participate in hands-on, interactive tours of their Warren, Michigan facility.

High school students engage at Manufacturing Day Event On Manufacturing Day 2016, Paragon Technologies invited 35 students from Centerline High School to participate in hands-on, interactive tours of its Warren, Michigan facility. Paragon partnered with Macomb County Economic Development Committee, the Macomb County School Superintendents, and educators with a goal to engage 2,000 local students by opening the doors to manufacturing facilities in Macomb County.

According to a press release provided by Paragon, “This is Paragon’s opportunity to share who we are, what we do, what skills are required to perform our jobs and what careers exist in the industrial market. This initiative is very important to the future of these students, Macomb County, and the long-term sustainability of Paragon Technologies.”

Paragon Technologies had such a positive experience with the students that they’ve signed up to sponsor another MFG Day event this year on October 6th.

12

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8/11/17 3:58 PM

STFF-3

ASSOCIATION WATCH

High school STEM initiative When the NFPA workforce team traveled to Houston for the FIRST Robotics Competition, they encountered many teams with creative branding and marketing ideas. One highlight was a spin on “Flat Stanley,” the children’s book character turned children’s pen pal activity.

The new spin came from the team from Walton High School in Georgia in the form of a mascot named Flat Walt.

The mascot was created to encourage people to learn about science, technology, engineering, and math (STEM). Flat Walt has already traveled the world and even into space.

After spending some time at the NFPA offices in Milwaukee, Flat Walt also accompanied the NFPA’s very own

Denise Rockhill, International Standards Development Manager, and Katrina Schwarz, Association Marketing Manager, to San Antonio, Texas for the ISO/ TC131 standards development meetings.

leadership in STEM programs, and the degree of employee involvement and volunteering are considered for the award.

FPW

NFPA | nfpa.com

The 2017 Spirit of STEM award This year at the STEM Forward’s 64th Annual Engineers Week Banquet & Awards Ceremony, Caterpillar was recognized for its involvement in science, technology, engineering and math (STEM) education.

According to the press release, the Spirit of STEM award was created in 2012 and recognizes organizations that have demonstrated a commitment to advancing STEM education and talent development in southeastern Wisconsin.

Financial support of STEM education,

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Now STAUFF Line covers all services that we can offer to customers, in addition to components. From analysis and optimization of existing tubing and hose layout and fixation to the design of new tubing runs to the supply of all plumbing components packaged as kits or pre-made assemblies ready for installation.

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DESIGN NOTES

A creative approach to mobile-hydraulic controls In industrial applications, a superordinate PLC often takes on the coordination of processes and the control of individual components.

With hydraulic functions, for example, position control of a hydraulic axis or pressure control of clamping or pressing actions are controlled by the PLC and corresponding electronics. In this case, the electronic controls only regulate a single function.

The requirements of mobile machines are much more complex.

Here, the controls should both coordinate processes and directly control hydraulic valves, as well as take on other electric, non-hydraulic functions.

This also requires a change in thinking in the design of mobile equipment and the cooperation between systems specialists in the 14

FLUID POWER WORLD

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8 • 2017

Adrian Feuz • Wandfluh AG fields of hydraulics and electronics. For instance, operations are no longer limited to individual pressure controls. Instead, several machine functions should be coordinated and controlled, and additional sensors need to be read and actuators directly controlled.

With a new generation of control devices, Wandfluh AG, Frutigen, Switzerland, is able to close this gap and connect its extensive know-how in the field of hydraulics with the technical control requirements of mobile machines.

The new family of devices, called Programmable Mobile Electronics (PME), consists of various electronic modules for

www.fluidpowerworld.com

8/14/17 9:59 AM

Wandfluh Programmable

DESIGN NOTES

Mobile Electronics system controls the drive and braking of a heavy logging trailer.

operation and control as well as for graphically displaying machine data. As a result of the modular design of these PME devices and simple networking via a CAN bus, the control structure can be decentralized and the system simplified, which can greatly reduce assembly costs.

Extensions of a base system and additional functions can be easily integrated, and the free programmability of the modules leads to greater design flexibility and more-creative engineering solutions. With various displays, flexible I/O devices and keypads, the system can cover many diverse applications. In addition, telemetry

Close-up of forestry trailer with PME electrohydraulic controls.

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DESIGN NOTES

modules permit remote access via GSM or Wi-Fi, and enable remote diagnostics, vehicle tracking, and control revisions and updates.

As a real-world application, Wandfluh has implemented the hydraulic-electric controls in a logging trailer for forestry applications. Fully loaded, these trailers carry a significant weight which, using conventional technology, requires a large and powerful towing vehicle that is not suitable for narrow roads or rough terrain. In addition, the mechanical brakes of the trailer are not generally designed for high and long-term braking forces. They can overheat, and the engine brake of the tractor cannot sufficiently decelerate the weight of the trailer.

WDMFA 10 valves produce the required back-pressure to brake the trailer.

Using Wandfluh hydraulic valves and a PME intelligent control system, the company has now developed a hydraulic drive support and a hydraulic brake. System engineers have been able to fully exploit the inherent flexibility of the different devices

Custom Features: • Integrated linear position sensors

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NEW Instant Online

DESIGN NOTES

Configurator.

Now you can configure Fabco-Air products anywhere.

On the shop floor. At the airport. At a remote job site. And you can do it with almost any device.

Even your smart phone!

The Fabco-Air configurator is the most comprehensive, user-friendly, and dynamic program in the industry.

It generates everything you need from one location.

PME graphic display shows system status and diagnostic data, and permits operator adjustments.

in the PME family. For example, the free programmability of the modules lets the software be adapted to match the required functions, and a graphic display reads the status of the operating elements and permits the adjustment and diagnostics of important data. It was straightforward to wire the decentralized input/output modules for sensors and hydraulic valves via the CAN bus, and to easily integrate standard Wandfluh electronics.

The drive shaft powers two hydraulic pumps, which provide the necessary oil pressure uphill for the drive support. Via an in-cab display in the towing vehicle, the operator can easily adjust electronicallyregulated proportional pressure relief valves and provide additional power when needed.

Downhill, the trailer’s axles are hydraulically braked, where the same valves indirectly limit the rotational speed of the axles. The hydraulic motor now pumps the oil, the valves produce the desired backpressure and, in doing so, they brake the trailer. The braking power heats the hydraulic oil which is simply cooled by builtin fans.

The transmission of the two axles can be individually engaged or released to drive at higher speeds on flat terrain. Additional sensors, for example in the drive shaft or the transmission, allow functional analysis and error monitoring in the software. Operation www.fluidpowerworld.com

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by means of switches and display in the towing vehicle lets the driver constantly keep track of all the important data such as speed, hydraulic pressures and the system status of individual functions. Through creative collaboration between hydraulics and electronics, particularly the PME devices, Wandfluh has been able to carry out the project successfully.

A few clicks instantly give you: • Product Part Numbers • List Prices • Lead Times • CAD Files • Seal Part No's & Prices • Repair Kit Part No's & Prices • Mounting Hardware • Accessories & Attachments • Switches/Sensors

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Wandfluh | wandfluh.com

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Additionally, the program includes an unprecedented DECONSTRUCTION feature.

Simply input a valid Fabco-Air part number to display all relevant information.

DECONSTRUCTION can also be used to re-configure a basic part number for different mounting, stroke, added options, etc.

online.

Try it out now at

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Phone (352) 373-3578 • Fax (352) 375-8024 E-Mail service@fabco-air.com

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DESIGN NOTES

Edited by: Paul Heney • Editorial Director

A special construction design and

Lightweight piston accumulators used in hydraulic systems for hybrid powertrains

new joining technology have allow ed Freudenberg Sealing Technologies to reduce the weight of its high- and low-

pressure piston accumulators.

Hydraulic energy recuperation with hydraulic accumulators responds to demands for increasingly energy efficient and fuel-conserving solutions.

Developers at Freudenberg Sealing Technologies have succeeded at significantly reducing the weight of high-pressure and low-pressure piston accumulators thanks to a special construction design and a new joining technology.

Hydraulic accumulators are used to store braking energy in hybrid vehicles, among other tasks. During braking, the accumulator is initially filled, exerting a force against the gas pressure. This stored energy is then available when needed to accelerate the vehicle. It makes a significant contribution to low fuel consumption, reduces CO2 emissions, and makes it possible to downsize individual components. Hydraulic accumulators are primarily used in mobile work machines, along with fairly small delivery vehicles and trucks with many start-stop cycles.

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Developers at Freudenberg Sealing Technologies have succeeded in significantly reducing the weight of the accumulator system—which consists of high-pressure and low-pressure piston accumulators. This has made them more appealing for mobile use. Hydraulic accumulator systems in smaller vehicles are also an alternative to electric hybrid solutions. Unlike batteries, the accumulators do not wear and operate without difficulty at low temperatures.

The low weight of the new steel highpressure accumulators has been achieved with special design features. They include an end cap design optimized for the force curve, and an aluminum piston as a media separator, and a partial reduction in material thickness in the pressure vessel area. In a high-pressure steel accumulator with about 20-l in gas volume, this leads to roughly a 60% reduction in weight. The cover’s firmly bonded connection with the housing is reliably handled using an electron beaming welding process.

In the newly developed low-pressure accumulators, housings, covers and pistons are made from aluminum. The firmly bonded connection between the cover and the housing is carried out with electromagnetic

pulse forming technology. The approach, which guarantees high stability, is being used for firmly bonded joining in aluminum accumulators for the first time. To increase wear resistance in the interior, a gas-tight anti-friction coating is also applied.

For condition monitoring of the two hydraulic accumulators, combined pressure and temperature sensors are provided. Security is safeguarded in each of the two hydraulic accumulators. In the event of overpressure, the system opens with the help of a rupture disk—and with a fuse in the event of a vehicle fire and the accompanying high temperatures.

On the liquid side, a valve is available for filling the entire system. It can also be used to prevent possible air pockets by bleeding.

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Freudenberg Sealing Technologies | fst.com

You have a new source for NFPA Hydraulic Cylinders

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Operation to 3,000 PSI Bores: 1-1/2" to 24" Strokes to 10 feet All NFPA Mounting Styles Oversized Piston Rods Proximity Switches and more

online.

“Developers at Freudenberg Sealing Technologies have succeded in significantly reducing the weight of the accumulator system—which consists of high-pressure and low-pressure piston accumulators.”

Tel (352) 373-3578 • Fax (352) 375-8024 www.fabco-air.com E-Mail service@fabco-air.com www.fluidpowerworld.com

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DESIGN NOTES

Edited by: Mary C. Gannon • Managing Editor

First eco-friendly hydraulic oil earns approval on rigorous OEM test New piston slipper pad

PANOLIN HLP SYNTH 32 Test passed on piston slipper pad

Failed test on piston slipper pad

Test wear laboratory comparison s of new components to those used

PANOLIN HLP SYNTH 32 is the first and so far only eco-friendly hydraulic oil to obtain the Bosch Rexroth RDE 90245 Fluid Rating List, considered to be currently the most rigorous OEM test on the market.

HLP SYNTH was the first hydraulic oil to obtain the ‘Blue Angel’ environmental award around 20 years ago and has already been approved by numerous manufacturers.

“Yet again, we have proven that our biodegradable products such as PANOLIN HLP SYNTH 32 also meet the highest industry requirements,” says Patrick Lämmle, Chairman of the Board of Directors of PANOLIN International. “The Bosch Rexroth test results were excellent, the rigorous requirements of the RDE 90235 were met without a doubt.

PANOLIN HLP SYNTH is the first rapidly biodegradable hydraulic oil to obtain the Fluid Rating (ISO 15380 in combination with RFT-APU-CL test).”

Recent years have seen a sharp increase in the requirements to be met by hydraulic oils.

Growing power density—the result of higher working pressures, motor speeds, oil circulation cycles, and temperatures—has driven the development of hydraulic systems forward in past years, imposing more demanding requirements on the hydraulic liquids used in these systems. These liquids have a decisive impact on the friction characteristics of the hydraulic components, amongst other things.

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with PANOLIN HLP SYNTH hydraulic oil versus those that failed, above and right

The ongoing technical development of high-performance hydraulic systems and suitability of new hydraulic media and additives are only partially reflected in the tests used to date. Whereas in the 1970s, specific power density was approximately 4 to 5 KW/kg pump weight, that figure had almost doubled by 2010 to more than 8 KW/kg. Today’s hydraulic fluids must be carefully engineered to cope with these developments, i.e., smaller pump units with a higher output and a range of other efficiency-improving modifications to the hydraulic system.

“Mineral oils in the DIN 51524 T.3 category and eco-friendly lubricants in the ISO 15380 category naturally have to pass a pump test to meet the requirements of these standards, but those tests are a minimum requirement only,” explained Lämmle.

Indeed, more than one hydraulic fluid which meets DIN 51524 T.3 or ISO 15380 fails in new-generation hydraulic systems because it no longer meets the requirements

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of state-of-the-art hydraulic systems such as higher pressures, shorter circulation times, smaller reservoirs and shorter rest times, commented Lämmle. Which is why, in recent years, Bosch Rexroth has come up with a neutral evaluation procedure designed to realistically reflect current requirements.

Hydraulic fluids that successfully complete this procedure are featured in the Bosch Rexroth Fluid Rating List.

This new, scientifically standardized evaluation procedure is designed to test the fluid characteristics and interaction with key components, i.e. pump and motor, in realistic operating conditions.

Amongst other things, the test includes verification of the liquid technical ratings for accuracy and standard conformity. An application-oriented pump and motor test, plus a specific seal test, put the liquids through their paces in demanding conditions and varying cycles over several hundred operating hours, at both high temperatures and low viscosities. Conventional tests are conducted at 350 bar; the new test imposes up to 500 bar. Hence, the quality of the hydraulic oil has an ever more important impact on the service life and dependability of hydraulic systems.

“This proves that we continue to set the industry standard in the field of rapidly biodegradable hydraulic oils. Users of HLP SYNTH have the peace of mind of knowing that these oils reduce the maintenance and downtime costs of their machinery and plant whilst increasing operating reliability, thereby delivering a significant reduction in total operating costs,” concluded Lämmle.

more drop-in interchanges

New A6 pistons

PANOLIN HLP SYNTH 32 Test passed on A6 pistons

from the air cylinder source

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PANOLIN | panolin.com

Failed test on A6 pistons

FABCO-AIR

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Phone (352) 373-3578 • Fax (352) 375-8024

online.

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MAINTENANCE

Mary C. Gannon • Managing Editor

Proper hydraulic system maintenance: organize your documentation If you’re looking to improve your hydraulic maintenance program, you must begin by organizing your documentation. The experts at CD Industrial Group (CDIG) explained in a recent webinar that they feel there is a documentation crisis at play in so many of the sites they visit around North America. “It’s very hard, we believe, to get your maintenance program organized if the documentation for a hydraulic system isn’t accurate, up to date, and gathered in one place for easy reference,” said Carl Dyke, founder of CDIG.

Mark Pszczolkowski, consultant trainer with CDIG, added that it is impossible to work on something if you don’t know what you have. He stressed the importance of keeping original documents and schematics and updating them as the system is accurately updated over the years. “Those books that get put on the shelves or shoved to the back side of something, they 22

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are the key to the whole system when it was designed, but they very likely are not accurate to what you have today.”

Using this documentation allows system operators and maintenance personnel to know what normal is. Truly knowing your system and how it should operate is key to efficient operation. And this all begins with documentation.

First, keeping your schematics up to date is the most important tool in maintenance and troubleshooting. Not having updated schematics means time will be wasted. Review the schematic on a regular basis—say once a year at least—as changes will be fresh in the memory and can be duly noted. If you leave a schematic unchanged for years, chances are, the person that made that change may not remember or may no longer be with the company.

Next, you must organize your bill of materials and keep that updated as well. If the machine has been running 10 or 20 years, it is likely that the same filter housing and unit isn’t in place anymore.

Some other components, such as valves, may have been updated.

Having all the BOMs in one place with the schematic means you have the baseline for understanding what your system’s correct operating functions should be.

Not only does having updated BOMs give technicians a glimpse inside the machine, it also ensures that spare parts are on hand for replacement should there be a machine failure.

Keeping data sheets and even photos of the machine and any alterations is a good idea as well. Manufacturer data sheets may include recommendations for system maintenance.

Finally, proper documentation should include shop records with any system analysis and scheduled maintenance or test results as well. If there is no record of particle counts or oil changes, said Pszczolkowski, “then we can’t make a good, sound decision. We must discipline ourselves to make some key notes as to what’s been happening within the system.”

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Organizing your system documentation, including manuals, schematics, bills of material, etc. helps in proper hydraulic system maintenance.

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ENERGY EFFICIENCY

Ron Marshall • For the Compressed Air Challenge

Compressed Air Fail: The value of measuring

A food processing plant was running out of compressed air capacity and decided to bring in an auditor to assess the size of the new compressor. The auditor hooked up his instruments to measure compressor pressure, power consumption and flow. Very soon, the auditor began to notice that things didn’t quite add up.

When in the compressor room, the auditor observed that two compressors were running fully loaded—yet when looking at the compressed air flow meter that he’d installed, he noted the actual plant flow was much lower than the running capacity. This started an investigation of the plant air dryer, which was located between the compressor discharge and the flow meter.

Originally, the plant had installed a heated blower dryer to ensure very dry air for its unheated production area to prevent freezing. From the beginning, this dryer was trouble and had difficulty maintaining dew point. Control replacement and desiccant changes did not solve the problem; eventually the plant personnel decided to live with the problem.

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But the auditor didn’t give up so easily. Some special testing was done and it was determined that the dryer was consuming more than 100 cfm of compressed air during its heating cycle (should be zero), and 200 cfm during a cooling purge operation that cools down the desiccant (should be 65 cfm). Nobody noticed this dryer had a leaky valve inside that was passing wet undried air into the side being regenerated. Further to this, it was discovered after carful inspection that the dryer had been misassembled with a re-pressurization valve swapped out for a cooling valve. This was the cause of the missing air!

The service personnel confirmed the problem and the mistake was corrected. This greatly reduced the compressed air consumption and improved the dryer operation. It is looking like there may be no need to purchase another compressor. This is another example of why compressed air system efficiency should be monitored and analyzed.

Learn more about air dryers in our next Compressed Air Challenge seminar in your area.

Visit www.compressedairchallenge.org for more information.

FPW

www.fluidpowerworld.com

8/11/17 3:41 PM

Paul J. Heney • Editorial Director

SAFETY

Hose wraps means hose safety

I recently had the opportunity to speak with Jerry Pawluk, President of Safeplast NA, a manufacturer of hose guards and sleeves.

The oil and gas sector is a big one for the company, and Pawluk said the company has seen a big uptick in the sector over the past few months. In fact, the company has really been getting the word out on the need for these types of products—over 10 years in business, they have had growth every single year. We discussed why safety is so important when you’re working with high-pressure hydraulics.

“There are various reasons for focusing on hose safety.

Employee safety is number one, but then also for equipment safety.

Hydraulic fluid is quite volatile itself. So, if you spring a leak, there are many instances where that fluid has caught fire and machinery is lost as a result,” he said.

Some designers may incorrectly believe that their hose is tough enough and additional hose protection products aren’t necessary.

But Pawluk was quick to counter this line of thinking.

“In one instance, we put some spiral wrap on a hose that was on a drill ship—this was for a modified hose. That hose itself was worth $150,000 dollars. Hoses are expensive. And for the cost of about $3,500 worth of our spiral hose wrap, the customer figures they got twice the life out of the hose, Pawluk said. “So, there’s certain economic benefit aside from the safety issues.”

Safeplast uses a high-density polyethylene for their wraps and the company has a unique production method for creating the spiral wrap.

“Most of the spiral you see in the marketplace is actually extruded pipe where they then cut the spiral,” Pawluk explained.

“Doing that, using that sort of process, really weakens the plastic because you cut the strength of the material. Whereas when we produce ours, we actually produce it in the spiral shape. So, the

strength of that plastic follows the spiral and that gives it some unique attributes. We’re also able to produce the wrap in colors.”

One of the interesting parts of the color aspect is that the company can produce dual color wraps—one color on top of another. This is critical for some customers for picking out problems before they occur. If the operator starts to see, for example, yellow starting to bleed through the black wrap, he knows that’s his pressure point. Maybe he can fix it before it becomes a problem.

Colors in general are also helpful from a safety aspect, as it can make otherwise dark hoses that may be temporarily stretched across a floor much more visible.

“We’re now doing laser marking where you can actually mark the spiral—for advertising or promotion,” he said. “But it can also be used to identify the underlying hose. Some companies don’t want to use wraps because they can’t tell what the hose is underneath. So, if we can mark the spiral to indicate what the hose is underneath, it eliminates that problem.”

“Hydraulics move the world,” Pawluk said. “You have so many moving points in those systems. And those moving points are naturally going to cause abrasion on the hose just by the fact that they’re moving around. That’s where the danger to hoses is for sure.”

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Safeplast North America | safeplast.com

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Next-generation electrohydraulic controls for off-road machines Integrated hardware and software replace traditional mobile-hydraulic control systems.

Ken Korane • Contributing Editor

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Today’s mobile-equipment manufacturers, for the most part, face a number of common challenges. OEMs want to streamline engineering and production processes yet build machines that are highly efficient, reliable and productive. And, increasingly, their customers want to monitor and track how these products operate—to ensure they live up to expectations and generate a healthy ROI.

To support those goals, Parker Hannifin, with headquarters in Cleveland, recently upgraded its range of mobile-equipment controls with IQAN Connect, an electrohydraulic motion-control platform that bridges machines to the IoT world. According to the company, IQAN Connect dramatically reduces development time, optimizes equipment performance and gives OEMs and fleet managers a better handle on how machines are actually used.

IQAN Connect, explained Johan Liden, IQAN product manager at Parker’s Electronic Controls Division, is a seamless “digital ecosystem” that ties together the hydraulics and electronic-control hardware and software inside a machine but also, via the Internet, provides access to the cloud for remote monitoring and asset management.

“One way to look at IQAN is in terms of the whole initiative around IoT as it pertains to electrohydraulics in the control space,” said Robert Lorance, strategic business development manager. It focuses on three areas. First, the platform relies on “intelligent” components with on-board electronics and sensors that communicate with each other and with higher-level systems via a standard SAE J1939 CAN bus, he explained.

“Second, our IQANdesign tools offer the next generation of control software with lots of functionality and are easy to use,” Lorance continued. “And third is our connectivity initiative around how we take data, get it to the cloud and then begin the process of moving from information to insight.” Equipment builders and operators can use that information to benchmark machine performance and output—and ultimately leverage that knowledge to improve productivity, reliability, efficiency and overall economics, he said. Here’s a look at some IQAN Connect highlights.

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IQAN Connect is suited for a wide range of construction, ag, forestry, and mining equipment.

Smart components Parker engineers have developed an extensive suite of IQAN-compatible products over the past 20 years. It includes hydraulic components like mobile pumps, valves, motors, cylinders and accumulators, as well as electronic hardware like operator displays, joysticks, cameras, and IoT gateways. In addition, a family of high-performance controllers provides precise, real-time management of mobile electrohydraulic systems.

They support tasks that demand high levels

of computing capacity as well as functional safety applications.

The components all run on customizable IQAN software and standard J1939 communication networks for straightforward system integration, resulting in complete machine control and asset management. “IQAN Connect, in its most simple form, is all about plug-and-play,” said Lorance. “Our components are connected in the IQAN software and recognize each other and, for the engineer, it’s easy to set

parameters, get the system up and running, and then send that information to the cloud.”

“These intelligent components also hold significance around engine management,” added Anthony Vaughan, vice president of technology and innovation. For instance, the new P1M piston pump with built-in electronic controls permits advanced closed-loop control in demanding applications, while simplifying the surrounding systems with a local controller for the pump. “It takes information from the engine and other components via the J1939 CAN bus for operations like torque control and torque summing. Optimizing flow control and pressure control ensures you’re not stalling engines while you’re maximizing your torque curve and pump flow. That’s really the key for fuel efficiency.”

Simplified design IQAN Connect also simplifies the development process and gives engineers more design flexibility, which in the end leads to both faster turnaround and better-performing machines, they explain. Parker’s newly released IQANdesign 5 software tools include an intuitive graphic interface, a component library and drag-and-drop features that do away with previously tedious engineering tasks.

A building-block approach simplifies controls design and layout without requiring extensive programming skills to effect advanced machine functions. It also cuts the time required for prototyping, testing and validation. For more details, see the accompanying sidebar, “Building hydraulic-control systems with dragand-drop ease.”

Cloud access Another significant feature of IQAN Connect is that components and controllers, via an on-board gateway, provide two-way communication with the cloud. All data available on the J1939 CAN bus, including infor-

IQANdesign 5 software includes an extensive component library and an intuitive, drag-and-drop graphic interface. Its building-block approach simplifies controls design and layout without requiring extensive programming skills, yet ensures sophisticated machine operation.

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mation on the engine, transmission, sensors or specific hydraulic components can potentially be tracked and displayed as a web application or even on a mobile phone.

Engineers can tap into this operating data and use advanced statistical programs to fine-tune the system and improve performance and efficiency. Changes and updates can be quickly downloaded to the machine’s IQAN master via a laptop, or remotely via a communications link. And for security, multiple levels of access can be customized as needed, said Lorance.

Likewise, users or third-parties can access the data for troubleshooting or apply the information to maintenance software, analytics programs and tracking tools. For instance, customized dashboards can provide diagnostic information to operators and fleet managers, send alerts as needed, and enable predictive maintenance that reduces downtime, maximizes ROI and improves safety and productivity.

“Parker engineers have developed an extensive suite of IQAN-compatible products over the past 20 years.

It includes hydraulic components like mobile pumps, valves, motors, cylinders and accumulators, as well as electronic hardware like operator displays, joysticks, cameras and IoT gateways.”

Another key facet of the platform is IQAN Asset Monitoring.

This enterprise-software tool connects ground-based machines to the cloud to provide vital insight on the overall performance of an entire fleet, noted Nick White, senior systems engineer.

For example, a fleet-overview screen displays the location and status of every networked machine. Users can quickly browse the general status of all the equipment or drill down to a specific machine. “A fork truck, for instance, could send process data such as the total weight it moves over the course of day, and the total number of lifts—information valuable to a fleet owner,” he stated.

“And this data can be used in more-complex ways, such as determining the distribution of bin weight picked up from 0 to 100 pounds, 100 to 500 pounds, and so on. This gives insight into how each machine operates. We can also compare how one operator is performing against the others,” said White.

This gives users the power to scale a solution and make it (continued on page 33) 8 • 2017

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Building hydraulic-control systems with drag-and-drop ease The time it takes to engineer a machine and get it to market is one of the most important contributors to an OEM’s return on investment. It is primarily determined by design time, application programming, simulation, testing and creating all the necessary documentation. IQANdesign software, a key part of the IQAN Connect system, reportedly streamlines that process to significantly reduce engineering time and expense.

The latest version, IQANdesign 5, is a high-level graphical design tool that simplifies control-system application development for mobile machines, explained Johan Liden, IQAN product manager. Five different sections let engineers define a machine’s control system, specify application logic, and set up diagnostics, user interfaces and system security, he said.

Typically, they first select appropriate modules from a database in the IQAN Connect library. These represent hydraulic components, engines, gearboxes, electronic hardware and diagnostic interfaces like Bluetooth adapters and modems. Users drag-and-drop the modules to configure the system, and then connect them with a suitable CAN bus. Control modules serve as a standalone controller or CAN bus master, and a gateway module sends data to the cloud.

Once the layout is set, canned software routines available within IQAN let developers quickly program operating functions and optimize sophisticated applications. A wide range of predefined building blocks include options such as closedloop control, signal processing, math calculations and PID regulators.

Engineers have the freedom to choose the I/O and commands for each module and set parameters like the spool position and current levels in an electronic valve, explained Liden. Then IQANdesign internally handles initiation and programming to create the logic that ultimately controls machine behavior.

In a traditional system, by contrast, a significant amount of development time is wasted just figuring out how to make components work together, he explained. Engineers on a conventional controls project may spend half the development time just solving integration problems so all the parts communicate with each other. That leaves less time to actually make the machine move and behave as desired. IQANdesign 5 cuts integration time by perhaps 80%, giving engineers much more time to optimize machine operation and behavior while completing projects faster. It makes for easy implementation of distributed machine control, said Liden.

Designers use the diagnostic section to specify data logging capabilities, methods for communicating with the cloud, and parameters for service technicians and operators to measure or display, he continued. It also defines machine security levels that apply to different users. Finally, the operator-interface display is completely configurable.

To further speed time-to-market, IQANsimulate software simulates the performance and interaction of all the hardware modules in an IQAN application in parallel with machine-function programming. This is a safer, quicker and more-economical way to test new applications versus building a physical prototype.

This virtual tool lets engineers generate inputs and measure the resulting outputs, view logs, identify errors, adjust parameters and test the operator interface—just like real components on an actual machine. “Because it is so user friendly, you don’t have to be a core programmer to do this.

A skilled application engineer who understands hydraulics and the logic behind it can readily tune the system,” said Liden.

“IQAN lets engineers create not only efficient system layouts, but also the controls logic behind it,” noted Robert Lorance. “And that allows them to bring their products to market faster. You don’t need a massive IT organization to have a controls suite like this. It is very customer specific with a tremendous amount of flexibility to accommodate individual applications. We take care of all the tedious work, the diagnostics and all of the details so that our customers can focus on functionality—making the machine move and behave like the customer wants.”

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(continued from page 29) unique and operator specific, whether the focus is on cost, productivity or downtime, said Lorance. The ability to extract that data and gain a deeper understanding of machine operations is a real game changer, he emphasized.

“Customers no longer have to be a major OEM to have insight,” added Jacob Haas, vice president of marketing of Parker’s Hydraulics Group. “Literally anyone with this type of control system, even a small OEM, can have data insight, and that will truly be a differentiator. We can now put this in the hands of our operators and help them become more efficient and grow their business, too.”

Diverse applications The IQAN Connect system is suited for a wide range of construction, forestry, agricultural, material-handling and mining equipment. For example, it’s been used on telehandlers, refuse trucks, crop sprayers and rock drills, just to name a few.

Parker’s experts expect mid-size machine builders to have the most interest in the entire IQAN Connect offerings. And smaller manufacturers, often with the help of local distributors, will also take advantage of IQAN’s ease-of-use and plug-and-play features. Large OEMs tend to have proprietary control systems, although IQAN is compatible with Tier 1 systems using standard J1939 networks.

“There’s a tremendous amount of interest with the mid-tier segment in terms of solutions that they can scale and run with. It is truly intuitive how customers can quickly customize their designs, launch simulations, do calibration and troubleshooting. It is really made for the mid-tier and lower tier of the market,” said Haas.

“And the focus may be different for most every customer,” he added. In some cases, it is about fuel efficiency, for others downtime is just not acceptable. Or the focus might be on lowering engine speeds, reducing emission, or eliminating non-value-added tasks to raise productivity and save money.

“Our customers’ value propositions are often very unique and very tailored. But at the end of the day, it’s all about our ability to either help our customers save money or help our customers make money,” said Haas. And the ability to capture data and do the analytics will let engineers gain insight in areas like reliability, predictive maintenance, controllability and safety, he said. “That, in turn, will help us design better next-generation products that ultimately benefit the customer.”

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Set it then

forget it

Elopak equips fully aseptic filling machine with robust pneumatics.

Xavier van Aelst • Director Food & Beverage Christian Broich • Sales Engineer AVENTICS GmbH • Laatzen, Germany

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Machines for filling consumer-friendly containers with milk or juice have to work around the clock, and disruptions and downtime are not at all welcome. For this reason, availability plays a major role in selecting machine components for Elopak’s E-PS120A, the first fully aseptic filling machine for gable-top packaging. With an output of up to 12,000 cartons an hour, this high-precision, efficient and flexible system ensures high reliability—in part thanks to food-compliant pneumatics from Aventics.

The next-generation E-PS120A platform combines the latest aseptic technology with attractive, convenient Pure-Pak packaging, guaranteeing the integrity of high and low acid products stored at room temperatures for up to one year.

A look at concepts

In developing the E-PS120A, Elopak is pursuing its strategy of highly functional packaging and, in the process, making the company a trendsetter in the area of aseptics. The machine’s new Pure-Pak Advanced filling concept meets both increasing expectations of consumers regarding product design, functionality and quality, and industry and engineering requirements in terms of maximum efficiency and machine availability.

The E-PS120A is the first fully aseptic filling machine for gable-top packaging. | courtesy of Elopak

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Used in many Elopak machines, the proven HF03 series valve systems will be gradually replaced with the new AV valve series.

The E-PS120A aseptic filling machine relies on the latest automation technology and consists of six modular stations that seamlessly combine to produce a filled carton. First, packaging material gets inserted, recorded, set upright and pre-folded. The sealing cap is then attached and ultrasonically welded, and the bottom prefolded, heated and pressed to seal the carton.

The next chamber sterilizes the packaging with hydrogen peroxide, then the container is precisely filled in a single shot while avoiding splashes or residual liquid on the carton. Finally, the packaging top is induction-welded and transported out of the machine, while any improperly filled cartons are ejected.

With this system, users can choose from three packaging sizes of 500 ml, 750 ml, and 1 l. Because all machine processes are geared to the packaging height, the only adjustment required to switch between them is the height or position of the carton’s bottom. Controlled by a pneumatic cylinder, this movement takes just a few minutes and provides a major advantage compared to competitor machines.

Reliability is key

ED02 electropneumatic pressure regulators dynamically control pressure to precisely move the packaging.

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The design and construction of such a modern filling machine are complex tasks. A sterile environment and aseptic packaging are vital to maintain product quality for the long term at room temperature without cooling the products or using preservatives. This means the ultra-sensitive drinks, dairy products, and liquid foods have to be filled hygienically and securely while machine components are subjected to high strains by cold, humidity, and splashes.

Despite the rugged operating conditions the filling machines have to work around the clock. For this reason, availability plays a major role in selecting machine components. According to company engineers, Elopak’s motto is, “Set it then forget it.”

“The latest technical features are not our main concern when selecting components,” stated Wolfgang Buchkremer, Senior Manager for Research & Engineering at Elopak EQS GmbH in Mönchengladbach, Germany. His greatest requirement focuses much more on reliability.

“We need components that play their part without standing out—we want to be able to install and then forget them. And that isn’t possible with just any component,” he said.

Elopak owes its success to technical expertise and decades of experience, he continued. “Frequently, permanent reliability comes down to the details,” emphasized Buchkremer, referring to the close collaboration with

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Global supplier Elopak, based in Oslo, Norway, has a long

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and proven track record for breaking new ground at every level of packaging, from food science and processing standards to container concepts and engineering expertise. And its products and equipment are continually evolving to match the changing demands for packaged food. That includes a wide range of state-of-the-art machines for efficient filling of fresh, extended shelf life (ESL) and aseptic liquid food products in a variety of package sizes.

If your milk carton doesn’t spill or make a mess when you

open it, the container is likely from the Elopak Pure-Pak series.

As a supplier of paper-based packaging for liquid food products, Elopak develops, produces, sells, and maintains complete systems for packaging non-carbonated liquid products, such as milk and dairies, juices, wine, water, and soups. Widely recog-

To accommodate different carton sizes, all machine processes are geared to the top height of the packaging. The user simply has to adjust the bottom height using the Aventics CCI compact cylinder to switch products.

Aventics. “Even though the pneumatic components installed here at first appear insignificant, they are crucial to machine availability and aseptics. In addition to reliable components, we also need close contact and collaboration with suppliers based on partnerships to detect optimization potentials and drive improvements forward together.”

Tapping pneumatics expertise

Buchkremer cited several pneumatic components as key to reliable and efficient aseptic filling. For example, Aventics SSI Series compact cylinders isolate sealing caps by moving them from one side to another.

It sounds like a simple task, but it has to function precisely around one-million times a week in day-to-day operations.

Based on concrete application data supplied by Elopak, the Aventics cylinder experts reinforced the piston package— extending cylinder service life—which in turn has a positive effect on machine availability. Other cylinders move packaging forward up to the next processing step.

Pressure varies depending on the position and amount of packaging on a rail. Here, the ED02 electropneumatic pressure regu-

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nized for its gable-top Pure-Pak brand packaging, the company annually produces around 13 billion cartons.

lator ensures precise, dynamically controlled pressure, enabling a highly energy-efficient operation.

Another small but critical component is the throttle. Hydrogen peroxide (H2O2) is used to sterilize the packaging, but the substance can have a detrimental effect on all reactive components, including seals and lubricants inside the throttles. Over the long run, choosing the wrong material poses a risk to the entire sterilization process. “We worked with Aventics to find a suitable solution, and now use a throttle that

has been cleaned on the inside, with a special sealing ring on the sterilization system’s vaporizer. These design details allow us to achieve higher stability,” stated Johannes Platen, Manager for Engineering and Mechanical Design at Elopak EQS.

The same concerns hold for valve systems.

H2O2-impregnated air also resulted in an application-specific development. To extend the valves’ service lives, engineers at Aventics combined a standard valve system with an aluminum corner strip that included an all-around seal. Now, the

Depending on the application requirement, Elopak combines shut-off and ventilation valves to optimize a compressedair system’s energy efficiency. Compressed air treatment steps such as filtering, regulating, and dehydrating are integrated in the AS maintenance units to ensure high air quality.

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The Price Alternative

Cylinders in Elopak’s aseptic filling machines must precisely cycle around one-million times a week.

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valve pilots engage directly in the closed cable conduit within the machine, while the outlets exit the machine. This effectively prevents problematic contact between valves and hydrogen peroxide, contributing to optimized reliability.

Other pneumatic components combine durability with safety and include quick-exhaust and soft-start valves. A special unit on the E-PS120A aseptic filling machine consists of three Aventics components that mainly aim for machine safety to meet the required performance level. Combined with a soft-start and a blocking valve, an AS series maintenance unit offers an array of functions.

After a safety cut-out and the system is depressurized, for example by opening the doors, the valve systems are not subjected to the full 6 bars of pressure immediately upon restart. The application-specific design now ensures the valve systems slowly fill with compressed air, helping protect workers and equipment.

Aventics pays exacting attention to such details thanks to its many years of experience in designing hygienic components. This is reflected in numerous properties of the ‘best-in-class’ components customized specifically for utmost food safety.

In plain terms, this means no recesses or sharp edges, easy cleaning and disinfection, as well as the use of food-compliant materials and lubricants and resistance to chemicals.

“Aventics provided us at Elopak EQS with support right from the start and knows what it means to monitor a near-series machine in development. The pneumatic components made 40

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a major contribution in the reliability and low-maintenance requirements of our innovative aseptic filling machine, not least for these reasons. This all boosts machine availability,” emphasized Buchkremer. “Furthermore, Aventics and Elopak support the VDMA initiative to standardize consumption measurement so we are on the same level when it comes to determining energy efficiency, able to implement this together to the user’s advantage.”

Elopak will soon also incorporate the Advanced Valve (AV) series, which is optimized for future requirements for continuous data exchange from the control to the lowest field level. The AV pneumatic directional-control valves are smaller, lighter and more efficient than most similar valves. They include a polymer design and require up to 45% less space than comparable valves.

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Aventics hygienic components permit easy cleaning and disinfection for the utmost in food safety.

Two sizes are available with flow capacities of up to 300 and 700 lpm, respectively. They can be combined on the same valve manifold, with up to 128 valve coils per manifold. The plug-in design allows for quick valve change-out and, with a 12.5mm valve slice width, the compact units can be mounted closer to actuators.

Users can quickly configure custom valve manifolds using Aventics online tools. And the related Advanced Electronic

System (AES) lets engineers add bus modules, I/O, or electro-pneumatic pressure regulators to a manifold. The AES ensures smooth serial communication between a controller and the AV components.

“This meets our desire to continue driving fieldbus technology forward, also in pneumatics,” says Johannes Platen, adding: “This development, too, will be realized in close collaboration with Aventics.”

FPW

AVENTICS | www.aventics.com/us

8/14/17 10:51 AM 6/7/2017 2:25:31 PM

Efficient– (of a system or machine) achieving maximum productivity with minimum wasted effort or expense.

“Efficient.” en.oxfordictionaries.com. 2017.

Josh Cosford • Contributing Editor | Illustration istockphoto.com

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Efficient design in industrial hydraulics Understanding the properties of nature is critical in selecting efficient hydraulic technologies.

Sometimes a simple dictionary reference can explain better in a few words what may take me a paragraph or more. I think we can all agree on the definition of efficient, especially in this day and age, where cars, dishwashers and light bulbs are marketed for their careful use of natural resources. Nobody can argue the natural order of the world encourages intelligent use of energy, if not for ecological reasons, but at least for economic ones.

There is a lot of hypocrisy in the world of ecological activism, I

must admit. I’ve never understood how it makes sense to buy a 50-mpg hybrid car from Japan when it must travel on an ocean liner that uses enough fuel to supply a fleet of Hummer H1s over the next millennium. Then again, if one was a true environmentalist, one simply would not drive. But I digress; the point of this article is efficient design in industrial hydraulics, not as an outlet to criticize hypocrites, which I myself can sometimes be.

Efficient use of energy is just plain smart, whatever your motivation may be. Given the option, there is no reasonable logic in avoiding intelligent selection and use of efficient hydraulic components for industrial machinery. I do understand capital allocation for ma

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chinery can be limited, which sometimes prevents machine manufacturers from employing the best components and designs, especially since free market dictates (mostly) the quality of the machinery itself.

If you are an end user in the machinery food chain, it is your obligation to ensure you’re not shooting yourself in the foot by choosing a machine that ends up costing you more in the long run than what money you saved with a poorer design.

So what makes a hydraulic machine efficient? The first step is a deep understanding of the basic properties of nature

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a hydraulic power unit to run a hydraulic motor, which in turn is powering a generator … well, you are in the “others” group.

Every time you must convert energy from one form into another, you waste energy and lose efficiency. The above example converts mechanical energy into hydraulic energy, back into mechanical energy and then into electrical energy. Meanwhile, you could have just used your prime mover to power the generator directly.

Okay, so what if there is an absolutely essential reason for your hydraulically powered generator? Like say your generator is stuck inside the belly of a giant mechanical snake, a circus clown is riding a unicycle with a hydraulic pump attached to the hub, and there was no direct way to mechanically link the unicycle with the generator except with a trail of hydraulic hose. Hydraulics now kind of make sense, but there would be a right way and wrong way to do it.

The wrong way to transmit energy far from its source is to use inefficient components. If you absolutely must transmit hydraulic energy deep into the belly of a monster, you absolutely must choose efficient components. This is where my own definition of efficiency, as it relates to fluid power, comes into play: efficiency is the difference between the input horsepower and output horsepower.

If your (non-clown) power unit runs with a gear pump, which itself is being powered by a 10-hp low duty electric motor, you’re off to a bad start. If your prime mover starts out with 75% efficiency, you’ve already reduced the hydraulic input power available to the pump by a quarter. Now your gear pump only has 7.5-hp to work

“The choice of electric motor, pump and hydraulic motor must be of the highest quality and most efficient design. Some jurisdictions have already started to regulate electric motor efficiency, requiring certain ratings of power be only sold as premium efficiency or better.” … specifically the Second Law of Thermodynamics. This law states that total entropy in a closed system can only increase over time. In layman terms, it says energy can only get more disorganized over time, and the harder you try to get energy to behave itself, the more you’ll end up wasting it.

This means no perpetual motion machines, and no getting something from nothing.

Every single process in the universe results in some form of waste. No exceptions.

For any good engineer, physics comes as second nature. For others, it’s not so intuitive. If you think it’s a good idea to use

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with, and that’s before it’s done its own terrible job of converting energy. I should mention that an electric motor’s power rating describes how much energy it uses rather than how much it outputs. Creating a measly 7.5 mechanical hp still sucks back 10 hp worth of electrical energy, and that’s what your meter reads when it comes to your electricity bill.

Depending on pressure, gear pumps are lucky to be 80% efficient. As pressure rises, they become less efficient as pressure bypasses internally at an increased rate. Remembering that we’re now only working with 7.5 mechanical horsepower at the pump’s input shaft, we can reduce the hydraulic energy being delivered to the circuit down to 6 hp. The 1.5 hp missing from the equation is lost as pure heat (just as is the first 2.5 electric hp). If you’re looking for a space heater, give yourself more than 10,000 Btu/hour of heat being thrown off by our pump-motor combination … and we haven’t yet introduced our hydraulic motor to turn the generator.

With all the fanfare of a Renault Le Car at the Pebble Beach Concours d’Elegance, I introduce to you the gerotor motor. The gerotor motor is a type of internal gear hydraulic motor using a spool valve to distribute fluid to the rotor set, which itself rotates the shaft. These are also called “low-speed, high-torque” (LSHT) motors.

Although they can produce adequate power over limited ranges of speed and pressure, they’re less efficient than even a gear motor. The problem is due to many moving parts and large clearances between them; they leak like a screen door, wasting upwards of 40% of incoming fluid as heat.

With merely 6 incoming hp, your motor is applying only 60% of that to the generator. The generator is left with only 3.6 hp available to it. And you would be correct to guess the generator itself doesn’t entirely convert that 3.6 hp completely intact.

When all is said and done, the electrical power available to run a smoke machine

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in the mechanical monster snake is lucky to be one-third of the original power input! So what’s a circus clown to do?

Bozo needs to respect the laws of nature, and I’m not just talking about his capacity to squeeze two dozen of his colleagues into said Le Car. I’m talking about the respect he and everyone else must have for the Second Law of Thermodynamics. If you want an efficient machining running in your plant, you have to first ask for it.

Once you ask for it, here’s what can be done….

The choice of electric motor, pump and hydraulic motor must be of the highest quality and most efficient design. Some jurisdictions

have already started to regulate electric motor efficiency, requiring certain ratings of power be only sold as premium efficiency or better. Standard and high efficiency motors (IE1 and IE2) are quickly becoming obsolete, which themselves are limited to 75-85% efficiency, depending on horsepower rating.

Premium and above-premium efficiency motors (IE3 and IE4) can supply 95% or more efficiency, meaning our 10-hp example provides a whole 9.5 hp to the hydraulic pump.

Speaking of hydraulic pumps, there is just as much a range of efficiencies in pumps as there are in electric motors. Of the major common types of pumps, bring-

ing up the rear is the external gear pump.

They’re inexpensive and reliable, but they are typically in the 80% efficiency range.

Coming in second place is the vane pump. The vane pump is quiet, which is why it’s the staple in an industrial environment.

Anyone spending time working around a hydraulic power unit for an extended period of time can be brought to tears by the highpitched harmonics of a hydraulic pump, so it’s understandable that the vane pump is used frequently. However, they hover in the mid to high 80 percent range in efficiency, leaving much still to be desired when efficiency is concerned.

Hitting the highs of efficiency are the piston pumps. Although there are a few

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major designs of piston pump, I’ll skip over those details and just say a piston pump is good for 90-95% efficiency. Sure, they’re expensive, but within the cost of ownership for a pump, only a few percent of the money you’ll spend is on the purchase price, with the remainder being gobbled up by energy usage.

To run your snake’s generator, we are obviously going to skip the gerotor motor, which doesn’t even have a baseball glove, let alone belong in the ball game. Just as with pumps, hydraulic motors are available in the same gear, vane and piston varieties, all with similar efficiencies. There are some variations of each with improved performance, but it’s safe to say a piston motor is the most efficient, and should be chosen.

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So if we use an above-premium efficiency motor (95% efficient), a high quality piston pump (95% efficiency) and a piston motor (95% efficient), total system efficiency (comparing input energy to output energy) = 0.95 x 0.95 x 0.95 = 85.7%

Now with 10 hp worth of electrical power being used, the hydraulic motor turning the generator has nearly 8.6 hp available to it. That’s a lot more juice to supply robotic functions to our mechanized snake. Our gerotor motor was only able to supply 3.6 hp in the previous example, which means if that level of power is adequate enough, you could actually make due with a 5 hp motor, and save over 3,700 W on incoming electrical power!

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Understanding and respecting the physical laws of nature is the first step in ensuring your industrial hydraulic system is designed efficiently. Other tricks can be used, such as hybrid pump drives, closedloop pump control and load-sensing circuits, but those things are like splitting hairs compared to simply selecting well-made, efficient components. Better yet, start with your efficient components and add the tricks to those components to achieve total efficiencies well above 90%. After all, nobody wants to be the clown trying to power a giant snake with a unicycle.

FPW

www.fluidpowerworld.com

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How can

hydraulic pressure intensifiers

improve your system design?

Anders Levinsen • Sales & Marketing Manager • ScanWill

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Reciprocating intensifiers generate higher pressure from a low-pressure hydraulic power source, helping to conserve energy, cost and space.

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Hydraulic pressure intensifiers, sometimes referred to as hydraulic pressure boosters, generate a higher pressure from a lowpressure hydraulic power source. They always work powered by a pump, which is operating at a set pressure and from this the intensifier simply generates a higher output pressure. They are most commonly used in hydraulic power packs but originally had their beginnings in the workholding industry for use with CNC machines.

How reciprocating intensifiers work

These devices are based on a differential piston principle, where a larger diameter piston pushes a smaller diameter piston, increasing the pressure to a factor equal to the ratio: Larger diameter area divided by smaller diameter area. Outlet pressure will always be proportional to the supplied pressure. The movement of the intensifier pistons is controlled by internal valves, and the piston speed can be as high as 20 Hz when

• Hydraulic pressure intensifiers are available in many sizes, pressures and for a variety of mounting requirements. www.fluidpowerworld.com

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Why should you use an intensifier Characteristics • Low operating pressure in the system • Use existing installed power source • Use standard tubing, hoses and valves • Easy to accommodate where needed • No need for extra tubing or special parts • Full flow available at pump pressure • Use existing equipment for the new task Advantages • Higher pressure precisely where needed • Higher pressure by low pressure power source • Low pressure supply to intensifier • Intensifiers are compact solutions • Intensifier fitted directly to cylinder • Built-in bypass valve and POV Benefits • Energy savings for the total system • No need of expensive horsepower components • Less cost for the total system and higher safety • Cost savings by installation • Cost and space savings by installation • Fast operation until high pressure is reached

• Hydraulic pressure intensifier for high-pressure

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power packs up to 3,000 bar/43,500 psi

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increasing the pressure. At this point the intensifier continuously delivers flow to the high-pressure side. When end pressure is reached, the piston movement stops. In case of a pressure drop on the high-pressure side, the intensifier will automatically start working to maintain the pressure.

Design and pressures

The design of the intensifiers is very compact, and they are easy to install. They are offered as in-line models, which fit standard pipe clamps used throughout the industry, as flange-on models, as cetop models and as cartridge type intensifiers. Despite their compact design, the intensifiers have all the required high-pressure check valves integrated.

Depending on the intensifier model, they can be used for flows starting at 0.3 gpm and up to 21 gpm. If built into a bypass, they can be used in very high flow systems. Most commonly, they are used in systems to generate end pressures between 1,000 and 7,300 psi. Some models go up to end pressures between 20,000 and 60,000 psi.

Where intensifiers are used

The most commonly known solution to achieve high pressure is to create a power pack or HPU, where the pump will generate the required high-pressure. In this solution, the whole system must be designed for the high pressure. As an alternative, you can add an intensifier in a system—existing or new—designed for lower pressure, and get the higher pressure exactly where needed, and at the same time conserve energy and space.

An important point to remember is that when using intensifiers, you will initially have the full pump flow supplied to the high pressure side, e.g. to move a cylinder rod in position. After pump pressure has been reached, the intensifier automatically kicks in and increases the pressure in the cylinder to the higher pressure required.

In a typical application, for example, when operating a clamping cylinder, the intensifier is positioned between a directional valve and the cylinder. Connecting the P-port of the intensifier to the pump and the T-port to tank allows the full pump flow to go straight through the integrated check valves in the intensifier, and the cylinder rod will move into position at pump speed. When the cylinder has moved into position and pump pressure has been established inside the cylinder, the intensifier automatically increases pressure to the required end pressure.

As the cylinder now is filled with oil, the pressure increase is done swiftly, typically within a few seconds. Here, the intensifier will automatically maintain the pressure. To revert the cylinder rod, the directional valve on the pump side is activated, connecting pump pressure to the intensifier T-port and the P-port is connected to tank. This prompts a pilot signal to an integrated pilot-operated check valve (dump valve or POV), which opens, www.fluidpowerworld.com

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I NTE N S I F I E R S

and creates a direct passage from the cylinder through the intensifier and back to tank.

Intensifiers can work with any type of fluid used in standard hydraulic components, including aggressive fluids like Skydrol. They cannot operate with gases.

ScanWill Fluid Power ApS / IC-Fluid Power Inc. icfluid.com

Specifying hydraulic pressure intensifiers

Four parameters must be considered when specifying a hydraulic pressure intensifier: • What is the actual requested output pressure that is needed in psi?

• What is the inlet flow in gpm?

• What is the supply pressure?

• How will the intensifier solution be mounted (flange, brackets, pipe clamp, etc.)? How will it be built into your hydraulic system?

• ScanWill’s In-line hydraulic pressure intensifiers for medium size

FPW

hydraulic systems (top,) flange-on mountings (bottom left), and Cetop DO3 / NG6 with separate high pressure ports

Diagnostic test equipment & data logging

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Flow & directional control valves, pumps and motors.

Custom versions available

Fax: 414-769-6591

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Pack Expo returns to Vegas Edited by Mike Santora • Associate Editor

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Pack Expo will be held Monday, September 25th through Wednesday, the 27th at the Las Vegas Convention Center from 9 a.m. to 4 p.m. each day. The event brings together more than 2,000 suppliers of advanced packaging equipment, materials, containers, and automation technologies including several pneumatics and hydraulics manufacturers. Attendees run the gamut, from plant and project managers to production supervisors and engineers to logistics and supply chain management professionals from all vertical industries.

Fluid power technologies are critical in motion- and vacuum-centric systems that make up most packaging machinery. From industrial shock absorbers to pneumatic cylinders for actuation and control and vacuum systems to sensing technologies, fluid power is no stranger to packaging equipment. That’s why you will find here a list of nearly 40 exhibitors showcasing the latest in fluid power components and systems.

The show will feature several pavilions with specific focus areas.

The Containers and Materials Pavilion is a showcase of paperboard, glass, metal, plastic, flexible and resealable packaging, state-of-the-art labeling and decorating technologies, innovative containers and sustainable choices. It is a priority stop for brand managers and designers.

The Showcase of Packaging Innovations draws attendees from all across the convention center to The Containers and Materials Pavilion for a look at award-nominated packages. The Confectionery Pavilion is where candy and snack producers head for aeration, batch refining, shaping, cluster production, cooling conveyors, easy-open packaging, enrobers, resealables, portion control and other industry-specific solutions. The Reusable Packaging Pavilion provides a single destination for the best reusable products, services and supply chain solutions. Over 30 industry-leading companies showcase the latest reusable packaging innovations for sustainable business operations.

Educational opportunities abound at Pack Expo as well.

Engineering students can learn the ins and outs of packaging engineering by participating in the Amazing Packaging Race. Additionally, robotics teams from local high schools will bring the robots they’ve built to demonstrate how each works at the Future Innovators Robotics Showcase. And of course, The NextGen Networking Fair offers a unique opportunity for PackExpo 2017 exhibitors and attendees to meet with the emerging workforce. The event provides employers in the processing and packaging industry the opportunity to meet and connect with a targeted audience of students from packaging, processing, materials, package design, and mechatronics programs.

FPW

Pack Expo | packexpolasvegas.com

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Exhibitor List

Pack Expo

Las Vegas, Nevada | September 25-27, 2017

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Company Name

Booth #

ACE Controls Inc.

8225

Adsens Technology Inc.

6856

Allenair Corp.

7871

ASCO Numatics

5222C

Atlas Copco Compressors LLC

7186

Aventics Corp.

5903

Bimba Manufacturing Co.

6149

Bosch Rexroth Corp.

5206

Clippard Instrument Laboratory Inc.

5933

Compact Automation

7456

Coval Vacuum Technology Inc.

5924

Eisele Connectors Inc.

8324

Elesa U.S.A. Corp.

614

Elobau Sensor Technology Inc.

7125

Enfield Technologies

3738

Esco Technologies

442

Essentra

540

Festo Corp.

5408

Gardner Denver Industrials Group

6180

igus Inc.

6307

ITT Enidine Inc.

7456

Kaeser Compressors Inc.

8144

Lubriplate Lubricants

6185

Motion Industries

8066

New Age Industrial

6075

Nexmatix LLC

8265

Parker Hannifin Corp.

7965

Piab Inc.

3927

QA1

7647

Quincy Compressor

7367

Ross Controls

5807

Schmalz Inc.

7401

SIKO Products Inc.

5633

SMC Corp. of America

6169

Soft Robotics Inc.

5925

Staubli Corp.

5956

Tolomatic Inc.

5837

www.fluidpowerworld.com

8/14/17 11:19 AM

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8/17/17 2:21 PM

ICUEE expands with more education and demo space Edited by Mary Gannon • Managing Editor

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It only comes around every two years, but this year’s ICUEE 2017, the International Construction and Utility Equipment Exposition, is looking to be bigger and better, with more exhibit space, education opportunities and networking events.

ICUEE 2017 will be held October 3-5 at the Kentucky Exposition Center in Louisville as the largest event for utility professionals and construction contractors in the electric, telecommunications/ cable, natural gas, water, and wastewater sectors. Show organizers have said the event has reached record size with 28 acres of the latest utility and construction equipment, products and technologies from more than 900 exhibitors. More than 50 of these exhibitors will highlight fluid power technologies, including controls, pumps, motors, cylinders, filtration, and more.

ICUEE 2017 will feature exhibit pavilions for fleet management, safety and green utilities, China and Korean exhibit pavilions, and the Lift Safety Zone from the National Commission for the Certification of Crane Operators (NCCCO).

A 2-mile Test Drive Zone will allow attendees to operate equipment in job-like conditions, and the indoor Demo Stage features more than 20 fast-paced 20-minute exhibitor presentations.

Education is a mix of old and new The ICUEE education lineup will see the return of popular programs including the Utility Safety and Utility Fleet conferences and the indoor Demo Stage.

ICUEE 2017, the International Construction and Utility Equipment Exposition, opens its doors October 3-5 at the Kentucky Exposition Center in Louisville.

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More than 75 sessions will help utility and construction industry professionals enhance safety knowledge, increase efficiencies and reduce downtime on the job.

New this year will be the Field Classrooms. Ten 90-minute walk-around sessions will use the show floor instead of PowerPoint presentations to provide an overview of topics geared for those new to the industry.

Also new for 2017 is a “Discover ICUEE” walking tour prior to show opening.

The iP Utility Safety Conference begins October 2, for three days. The Utility Fleet Conference runs concurrently, with insights on maximizing fleet efficiencies.

In addition, industry certifications offered will include the Certified Utility Safety Professional (CUSP) certification program and National Commission for the Certification of Crane Operators (NCCCO) written and recertification exam administrations.

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Networking opportunities The ICUEE benefit auction returns, with all proceeds again going to the Call of Duty Endowment, which helps military veterans secure high-quality jobs and raises awareness of the value vets bring to the workplace.

An expanded Bourbon, Beer & Bites event on October 5 will feature complimentary tastings of the foods and beverages of Louisville.

Download the mobile app Attendees can use the online show planner and ICUEE mobile app to create a personalized agenda of exhibits, education sessions and networking meetings.

The online exhibitor directory, with floor plans, is searchable by company name, type of product or market area, booth number and location on the show floor, and includes a New Products and Technologies preview section.

FPW

ICUEE | www.icuee.com

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2017 Exhibiting As

ICUEE exhibitor list Louisville, Kentucky | October 3-5, 2017

Booth Number

Exhibiting As

Booth Number

Auburn Gear LLC

5326

Hydraulic Repair Specialists LLC

2464

Bailey International LLC

2725

Hydrolico US

4759

Bezares USA LTD

2563

International Fluid Power Society

2802

Bondioli & Pavesi Inc.

5106

J.R. Merritt Controls Inc.

3910

Bucher Hydraulics

2012

Kar-Tech Inc.

2919

Cat Pumps

2129

Magnetek

1817

CEJN North America

3008

MSP Seals Inc.

4565

Comer Industries Inc.

5405

MTE Hydraulics Inc.

3228

Coxreels

4017

Muncie Power Products

4552

CRC Industries Inc.

2958

NBB Controls Inc.

2808

Cross Fluid Power

4628

North American Hydraulics (NAHI, LLC)

2519

Dalton Bearing & Hydraulics

4353

Parker Hannifin Corp.

3260

Danfoss Power Solutions

1440

Permco Inc.

4834

Dixon Quick Coupling

5520

Piranha Hose Products

4656

Dynamic Fluid Components Inc./PVS Sensors Inc.

2907

Reelcraft Industries

2339

Salami SpA

1840

FORCE America Inc.

3251

Schroeder Industries

2935

GS Global Resources

2134

SMC

3364

Hannay Reels Inc.

2810

Stucchi Inc.

3255

HAWE Hydraulik

2506

Texas Hydraulics Inc.

HBC-radiomatic Inc.

2034

The Hose Co.

1744

HED

4407

Thomas Magnete USA LLC

1921

Hengli America Co. Inc.

1925

VIS HYDRAULICS

2758

Hercules Sealing Products

4835

Walvoil Fluid Power Corp.

4558

Holmbury Inc

2833

WIKA Instrument

4463

HUSCO International

4540

Young Powertech Inc.

1826

HYDAC Technology Corp.

2434

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JCB Hydradig

The International Construction and Utility Equipment Exposition (ICUEE), slated for October 3 to 5 in Louisville, Ky., will let industry professionals and engineers explore some of the latest technology innovations related to mobile equipment and fluid power. Of particular interest will be the opportunity to get a hands-on look at hundreds of new machines ranging from aerial lifts and skid steers to trenchers and forestry equipment—along with the latest hydraulic components, systems and controls that make them go. Here’s a quick overview of just a few of the newest products and machines that will be on display.

JCB will showcase its recently introduced Hydradig, what the company calls a “revolutionary, new tool-carrying machine that delivers unparalleled visibility, stability, maneuverability, mobility and serviceability” for urban construction, highway maintenance and municipal contractors.

The Hydradig is powered by a Tier 4f EcoMAX diesel engine and has a sturdy, all-wheel drive, four-wheel steer chassis based on JCB’s proven Loadall telescopic handler. Its hydrostatic drive combines a variable-piston pump, a variable-piston drive motor and a central transfer box to power both axles. This layout offers a stepless 0 to 25 mph range without multiple gears or a loss of traction when speeds change. The machine is equipped with two-wheel and fourwheel steering modes, and crab steering for maximum maneuverability on site.

According to company officials, a key requirement was to lower the machine’s center of gravity, to boost stability and mobility. As a result, the engine, driveline, hydraulic pump and tank, and diesel tank all mount on the lower chassis, making the Hydradig incredibly stable during lifting operations—even without stabilizers. That also gives the upper structure a reduced tailswing of just over 4 ft,

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Terex HyPower IM

about 30% less than competitive machines. This permits work in confined construction sites or within a single-lane roadway.

A high-flow auxiliary circuit is standard, and the machine can be equipped with two low-flow circuits, plus dedicated hydraulics for quick-hitch operation.

Fully guarded hose-burst check valves are available on the boom, dipper and bucket rams for optimum lifting safety. An optional hand-held tool circuit lets operators work with hydraulic tools like breakers and HAWE EV2S-BT proportional road saws. The JCB Hydradig is amplifier a versatile tool carrier and can be used with nearly 50 differ-

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ent attachments, making it suited for wide-ranging applications.

Terex HyPower IM for telescopic aerial devices lets users take full advantage of a machine’s hydraulics while reducing fuel consumption and exhaust emissions. HyPower IM is an efficient and lightweight idle-mitigation system. It includes a 48-V lithium-ion battery circuit that charges from either a standard 120-V plug-in or the engine alternator during road travel. It’s similar to but more economical than a hybrid system.

The system automatically switches from battery power when the truck is idling to engine-supplied power when hydraulic controls engage. According to Terex officials, the aerial hydraulic controls on a typical trouble truck are only engaged for about one hour in a normal eight-hour shift. By switching the hydraulic system to engine power during those brief intervals, HyPower IM provides emissions efficiencies plus optimum hydraulic control functions. The transition is seamless, and operators experience no lag time in hydraulic responsiveness.

In addition, HyPower IM keeps the truck cab heated or cooled without the engine running. The unit is currently available for Class 5 Chassis, such as Ford, Dodge, and GM trucks, used with Terex Hi-Ranger telescopic aerial devices.

HAWE North America’s EV2S-BT electronic proportional amplifier controls all standard proportional solenoids, including solenoids for directional and pressure valves, and pump controllers. The amplifier is designed as a plug which simplifies assembly. Preset parameters for most common types of mobile and industrial hydraulic valves significantly facilitate start-up operation. Standard input signals include 0 to 10 Vdc, 4 to 20 mA and CAN bus. Direct connection to a CAN network, and data within the device, can relieve the main machine control of many tasks.

The amplifier is also equipped with a Bluetooth interface, letting the EV2S-BT be installed in inaccessible places and controlled wirelessly using the HAWE eControl App via a smart-

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Load Independent Proportional Valve PVG 100 PVG 100 is a load independent proportional valve with flow up to 180 l/min [48 gpm] and pressures up to 350 bar [5076 psi]. It offers equitable flow sharing for precise control of multiple machine functions under varying load conditions and pressure requirements.

Building on the modular, flexible, and proven Danfoss load-sensing proportional valve concept, PVG 100 offers easy, fast configuration, thereby helping vehicle designers meet tight time-to-market deadlines. The new valve is positioned between the existing Danfoss PVG 32 and PVG 120 with flows up to 130 l/min [34.4 gal/min] and 240 l/min [63.4 gal/min] respectively.

I C U E E

P R O D U C T

S H O W C A S E

PVG 100 optimizes system design for engineers who must incorporate new emissions restrictions by providing a more efficient hydraulic system that maximizes power and conserves energy. Typical applications include backhoes, telehandlers, wheel loaders, forklifts, and forestry equipment.

PVG 100 proportional valve controllabilit y and s Solution sharing for maximum y Flow from Danfoss Power safety. All sections will continue to function

Features

regardless of load differences and pump flow.

y Load-independent flow control for smooth operation and improved productivity.

y Modular design providing a wide range of configuration possibilities. y Up to eight different sections per valve group.

Maximum flow per section: 180 l/min [48 gpm]. y Can be configured in combination with our modules and/or PVG 32

range of HIC hybrid technology for higher efficiency, y Load-sensing phone. Users can display or set important of modular valves is designed flexibility. for maximum safety, reduced energy consumption, and longer system lifetime. and electrical actuation hydraulic, y Mechanical, parameters—like input signal, minimum to handle complex control options. y Configurable as advanced electrically as well as valve proportional controlled and and maximum current, dither ramp challenges and demanding load-sensing directional control valve. times—in seconds; nominal value, output machine tasks. current and device temperature are dis The electrohydraulic played in real time. valves permit flexible and

Configuration work can also be stored, customized system design and loaded and replicated quickly.

This is espeprovide for a variety of configurations— 520L0940 • Rev BA • Oct 2013 cially valuable for applications with series from simple load-sensing solutions to CAN production. EV2S-BT users can download bus communication—ensuring smooth the HAWE free eControl App from the App machine control. And because PVG parts Store or the Google Play store. are interchangeable, valve specifications

The PVG load-independent proporcan be easily altered to accommodate new tional valves from Danfoss Power Solutions functions and meet rapidly changing marhelp users meet requirements for high conket needs. trol and productivity with optimum safety,

Users can devise a valve stack for most and at the same time minimize emissions any work and control task incorporating from mobile machines. The broad range both simple load-sensing and advanced

Hydra-Qube from Harrison Hydra-Gen

electrically controlled load-independent proportional flow valves. Load-sensing technology provides higher efficiency and safety, lower energy consumption and longer system life. It also reduces wear and tear on other components in the system. Load-independent flow control enables precise operation and improves productivity.

Stroke measurement in hydraulic cylinders - say goodbye to drilling pistons!

SGH10 - simply revolutionary!

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Absolute detection of the cylinder stroke No piston drilling necessary Can also be used in telescopic cylinders High shock and vibration resistance, IP69K

More information: www.siko-global.com/p/SGH10

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SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com www.fluidpowerworld.com

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Dur-A-Lift’s new DAT3 articulating telescopic aerial lift ICUEE PRODUCT SHOWCASE

The PVG 100 post-compensated flow sharing valve lowers the oil flow to all basic work functions in response to a limited supply from the pump. In addition to enabling a smaller pump, flow sharing helps prevent power losses—optimizing productivity when less power is available.

The Hydra-Qube from Harrison HydraGen is a compact, lightweight and efficient hydraulic fluid-conditioning module for mobile systems, permitting continuous hydraulic operations while controlling oil temperature and filtering return-line oil.

Hydra-Qube uses a 3 to 5 gal reservoir, compared with a traditional tank as large as 75 gal. The all-in-one module includes a heat exchanger, reservoir and oil filter, and it readily mounts and integrates into a work truck. Two sizes are rated for up to 25 and

50 gpm flow. It uses a 12 Vdc-powered cooling fan and has an optional pop-up filter dirt alarm.

Dur-A-Lift’s new DAT3 articulating telescopic aerial lift is a bucket truck that features a non-overcenter design for greater stability and side reach, as well as a novel upper telescopic boom. It provides a working height to 75 ft and maximum side reach of 48 ft. The unit features a closedcenter, pressure-compensated hydraulic system with joystick control at the platform,

an automatic on-demand throttle system, individual outrigger controls and an outrigger/boom interlock. It also has a hydraulic platformleveling system with platform tilt, and the hydraulics permits 360° continuous rotation. A 25-gal hydraulic reservoir includes a shut-off valve, and there’s a set of hydraulic tool outlets below the point of rotation.

The DAT3 is also available with the company’s new Outrigger Analyzer.

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PRODUCT WORLD

High pressure stainless steel filter

Compression fitting Beswick Engineering beswick.com

Argo Hytos argo-hytos.com

The MCB-3-303 is designed with a two-piece ferrule and a 10-32 UNF thread along with the

The HFL 180 high-pressure filters of the HFL series

captured O-ring face seal. The front ferrule seals

are suitable for applications with extreme ambient

on the outside diameter of the tubing. The rear

conditions thanks to their corrosion-resistant

ferrule provides an anti-rotation feature. As the

filter housings made of stainless steel. Typical

assembler tightens the compression nut, the front

applications are in the energy and disposal industry,

ferrule is pushed into the tapered angle of the

the mining industry and, among others, in the

fitting body and compresses the ferrule onto the

offshore sector. Three different housing lengths

outside diameter of the tubing. This interference

as well as various filter finenesses are available to

creates the seal and also secures the tubing so it

provide the best possible filtration concept according to

cannot slide out of the fitting.

the respective requirements.

High-pressure filter HFL 060 offers nominal flow

The MCB-3-303 is manufactured in corrosion

resistant 303 stainless steel. It is suitable for use

rates up to 180 lpm, filter fineness of 10 to 60 µm(c),

in analytical instruments, bomb and toxic gas

and operating pressure up to 400 bar. It can be used with

detection equipment, medical and pharmaceutical

mineral oil and biodegredable fluids.

devices, semiconductor manufacturing equipment, environmental sampling instruments and other high technology type products. These

Cushioning adjustment tool

applications require low dead-volume and leaktight connections void of contaminants. The MCB-

Aventics aventics.com

32-303 is rated to withstand working pressures of up to 3,000 psig (207 bar).

The CAT (Cushioning Adjustment Tool) diagnostic tool assists the installer with an LED display and visualization in a smartphone app.

Optimal adjustment of cushioning is important for trouble-free operation, quiet running, and high cycle frequencies in systems.

The diagnostic tool is simply fixed to the cylinder. CAT detects if and how the

cushioning setting must be changed by evaluating the position and speed of the piston using magnetic sensors. The device only measures 5.5 by 8.3 centimeters and can be removed once everything has been set correctly. An integrated battery that can be recharged via a micro USB connection supplies the power. The associated app is compatible with Android and iOS smartphones.

www.fluidpowerworld.com

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Miniature pneumatic pinch valves Clippard clippard.com The NPP series 2-way pneumatic pinch valves are air-piloted devices designed to open or close tubes for controlling flow of liquids and gases.

Other valve types have internal passages that may cause small amounts of fluid to

Features include: • Small, compact design

remain in the valve. Pinch valves have no areas of dead volume where fluid can become

• Normally-open or normally-closed styles

trapped. Only the inside of the tubing has contact with the fluid.

• Hygienic and easy to clean (replace tubes)

• Can handle whole blood and

Common industries that use pinch valves for the benefit of isolating fluid from a

mechanical valve including drug dispensing, laboratory equipment, wastewater, medical

particulate matter

devices, chemical, food and beverage equipment, ceramic/glass/plastic, and solids handling and more.

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For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com

Overhung load adapter for robust motor applications

EtherNet/IP connectivity to IO-Link devices

Zero-Max zero-max.com

Festo www.festo.us

The model 650 overhung load adaptor features heavy duty

The CTEU-EP universal interface

bearings, strong shafts and a long profile. Designed with a

module from Festo makes EtherNet/

solid, permanent mounting surface, it provides more radial

IP connectivity low cost and plug and

and axial load support for hydraulic motors and pumps and

play for IO-Link devices and Festo

reduces premature failure. It features an extra heavy-duty cast

valve terminals. The CTEU-EP is ODVA

iron housing, 130,000-psi stress-proof steel shaft and heavy-

conformant and is also a Rockwell

duty spherical roller bearings. Designed for either face or foot

Encompass referenced product.

mounting applications, it is rated for speeds up to 3,500 rpm.

For maximum flexibility, OEMs

can cost effectively integrate IO-Link devices such as pressure and flow sensors, RFID readers, and light stacks along with a valve terminal with up to 64 solenoid coils. With a splitter, twovalve terminals can be served.

High performance hose Eaton eaton.com Expanded hydraulic hose portfolio includes the GH681 hose series, a one-wire braided hose qualified to 1 million impulse cycles. This highperformance hose provides customers with industry-leading durability in harsh environments.

Standard EN857 Type 1SC hoses are qualified up to 200,000 impulse cycles. The GH681 exceeds this standard by 5 times and is designed to

withstand the toughest applications. This durability helps decrease maintenance costs, improves safety and minimizes downtime.

The GH861 hose is used as part of a hydraulic system, working under pressure to transfer oil to the cylinders in mobile machinery like

tractors, lifters, sweepers and agricultural equipment. It is also used for industrial applications such as presses to connect moving parts.

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PRODUCT WORLD

Rear mount power take-off Muncie www.munciepower.com A rear mount PTO, the RS6S-P89M power take-off has an integral hydraulic mount for structural support of hydraulic pumps up to 60 lb without additional transmission support but has a bending moment limit of 29.5 ft.lb maximum.

The RS6S-P89M takes advantage of the full torque capacity of the transmission

and is a solenoid-activated, mechanical shift PTO. This new PTO is capable of different ratios, several different outputs and the ability to mount larger displacement pumps. It is available with direct mount or companion flange output options.

The RS6S-P89M series PTO is designed to fit Detroit DT12 transmissions in

Freightliner or Western Star Class 8 Cascadia or 5700 trucks. The transmission requires the 362-822 Detroit power take-off prep kit option.

The American Champ is built with quality globally sourced parts and 100% tested in the U.S.A.

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ForFor further further information information about about products products onon these these pages pages visitvisit thethe Fluid Fluid Power Power World World website website @ www.fluidpowerworld.com @ www.fluidpowerworld.com

Variable displacement piston pumps Parker www.parker.com The C series piston pump has been designed for use in closed-circuit hydrostatic applications and features a rugged swash plate and bearing design.

It offers a full range of controls, such as a manual lever with feedback, hydraulic proportional and electric proportional. The pumps are available with a variety of accessories, including hydraulic pressure override, electric cut-off valve and cross-port relief valves to protect from pressure overloads.

The C series enhances reliability with durable

construction and design flexibility. Engineered for a variety of applications, the C series hydrostatic pump is rated to 420 bar (6,090 psi) continuous pressure and 3,800 input rpm. The C055 is the latest unit to be released in the C series product line. The C055 is a 55 cc/rev (3.35 CIR) unit that also features a compact and robust design.

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| courtesy of Accumulators Inc.

COMPONENT FOCUS

How does a hydraulic accumulator work?

Ken Korane • Contributing Editor

Hydraulic accumulators are energy storage devices. Analogous to rechargeable batteries in electrical systems, they store and discharge energy in the form of pressurized fluid and are often used to improve hydraulic-system efficiency.

An accumulator itself is a pressure vessel that holds hydraulic fluid and a compressible gas, typically nitrogen. The housing or shell is made of materials like steel, stainless steel, aluminum, titanium and fiberreinforced composites. Inside, a moveable or flexible barrier—usually a piston or rubber bladder—separates the oil from the gas.

In these hydropneumatic units, hydraulic fluids only compress slightly under pressure. In contrast, gases can be compressed into smaller volumes under high pressures, and engineers take advantage of this property in accumulator design and application. In essence, potential energy is stored in the compressed gas and released on demand to force oil from the accumulator and into a circuit.

To use the device, the gas volume is first precharged—generally to around 80 to 90% of the minimum system working pressure. This expands the gas volume to fill most of the accumulator with only a small amount of oil remaining inside. In operation, the hydraulic pump raises system pressure and forces fluid to enter the accumulator.

(Valves control oil flow in and out.) The piston or bladder moves and compresses the gas volume because fluid pressure exceeds the precharge pressure. This is the source of stored energy.

Movement stops when system and gas pressures are balanced.

When a downstream action such as actuator movement creates system demand, hydraulic system pressure falls and the accumulator 70

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releases the stored, pressurized fluid to the circuit. When movement stops, the charging cycle begins again.

Three common types are bladder, piston and diaphragm hydraulic accumulators. Bladder accumulators typically have large ports that permit rapid fluid discharge. This helps ensure that the device is relatively insensitive to dirt and contamination. A general rule is to mount bladder accumulators vertically, although they can also mount on their sides in low-cycle applications.

Bladder type accumulators are usually designed to have a 4:1 pressure ratio (maximum pressure to gascharged pressure) to protect the bladder from excessive distortion and material strain.

Experts tend to view bladder accumulators as the best general-purpose units. They come in a wide range of standard sizes, and good response characteristics make them well suited for shock applications. Depending on the design, a bladder can be easily replaced in the event of failure or damage.

A piston accumulator is much like a hydraulic cylinder without a rod. Similar to other accumulators, a typical piston accumulator consists of a fluid section

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COMPONENT FOCUS

“An accumulator itself is a pressure vessel that holds hydraulic fluid and a compressible gas, typically nitrogen.”

| courtesy of Accumulators Inc.

and gas section, with the moveable piston separating the two. Less common are piston accumulators that replace highpressure gas with a spring or heavy weight to apply force to the piston.

Piston accumulators are generally recommended for large stored volumes— to 100 gallons or more—and can have high flow rates. Pressure ratio is limited only by the design, but they’re usually not recommended for shock applications.

They are often built for rugged, heavyduty applications. However, they are more sensitive to contamination that can damage the seals—although most piston accumulators are readily repaired by replacing the piston seals.

Diaphragm accumulators operate much like bladder accumulators. The difference is that instead of a rubber bladder, this version uses an elastic

FPW

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diaphragm to separate the oil and gas volumes. Diaphragm accumulators are economical, compact and lightweight devices that offer relatively small flow and volume—typically to around one gallon.

A diaphragm accumulator can handle higher compression ratios of up to 8 to 10:1 because the rubber barrier does not distort to the same degree as a bladder. They also enjoy wider mounting flexibility, are insensitive to contamination and quickly respond to changes in pressures, making them suited for shock applications.

Accumulators store energy that can be used to supplement pump flow, improve system response or serve as a back-up during power failure. They can also compensate for leakage or thermal expansion, and reduce vibration, pulsations and shock.

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