How to use hydraulics in machine tools p. 40
IMTS features 7 co-located conferences p. 48
Time-honored process embraces pneumatics p. 56
www.fluidpowerworld.com
August 2018
Hall-effect transducers
ensure consistent crop rows PAGE 16
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FluidLines Mary Gannon • Editor
No Kinks No Hose Twisting
The reality of women in engineering leadership Last month, I wrote about the need for mentoring to get more young people — young women, in particular — studying engineering and entering the field. There’s a reason for this. Despite strong recruiting efforts, women just aren’t entering the engineering space. According to research by the Society of Women Engineers, while more women are entering STEM occupations, the bulk of them are heading into the life sciences, where the gender gap has continued to close. But, says SWE, “the percentage of women in engineering and computer science occupations has stagnated.” In 2017, a mere 13% of engineers were women, while computer and mathematical occupations came in at 26%. Female chemists and material scientists made up 38% of that workforce and more than half — 54% — of biological scientists were women. When you break it down further, only 7% of mechanical engineers are female compared to 25% of environmental engineers. What’s wrong with this picture? Why do women continue to shy away from engineering careers? I think much of this can be attributed to perception. Women continue to perceive engineering as a man’s profession, where strong women are far and few between and where they don’t belong. They need to see more strong role models, to see women who were excellent students, now creating and designing powerful machines, leading manufacturers to the top of their games with innovative ideas, and inspiring teams every day. That’s one of the reasons our sister publication, Design World, is launching a special Women in Engineering issue this November. As editors who work with engineers on a daily basis, we know that women have always made important contributions to the engineering field — but have not often been acknowledged. We would like to take this opportunity to recognize women in different points in their careers, across our industry. Our editorial staff is profiling women who are doing interesting work in the design engineering space at OEMs big and small. We are seeking out the best and the brightest, from patent-holding design engineers to team leaders and managers who inspire their teams every day. I’d love to be introduced to more of these amazing women, so if you work with someone you think should be on this list, please reach out through the email address below.
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From the Field
As workers, we’re more than the sum of a spreadsheet At the recent Fluid Power Technology Conference’s VIP dinner, the evening’s keynote speaker was Natalie Bell, the President of Aladdin Engineering & Manufacturing and Aladco. Bell spoke about some of the current challenges that manufacturers today are facing. She stressed that many companies are tending to focus on people as commodities. But we are each more than our technical expertise, we’re the sum of many different aspects that can’t easily — or fairly — be summarized on a spreadsheet.
“It’s important to me to know the whole person, not just the knowledge and skills,” she said. “It is my belief that accounting practices have devalued employees as unique people, especially in manufacturing. The alarm is now sounding because the needed head count is not available.” Bell said the devaluing of technical workers over the past 25 years has severely constricted the pipeline of younger workers going into the technical field—regardless of the gender. “Today, we see computers running 3D software, versus drawing boards, scales and different diameter and color pencils,” she said. “The basics of mechanical engineering are still the same—engineering mechanics, hydraulic machines, thermodynamics, internal combustion engines, engineering materials, industrial engineering and production management, and hydraulics and fluid mechanics. The basics of electrical engineering is just as comprehensive. But after schooling is complete, a new graduate still needs experience to be marketable. How do they get this experience?” Bell noted that the current starting salary for graduate engineers is too much for many small businesses to cover while they learn on the job. Many large businesses are not willing to invest in training, as they did from the 1950s through the 1960s, because it lowers profits. She said that it’s a Catch-22. Bell displayed an original job advertisement that her grandfather had created six decades ago. It listed: • Preferred education is high school plus four years technical training or engineering degree. • Duties are the ability to do original layout and design of complete projects, supervise others as a group leader, check complete projects, and do calculations as required. • A composite rate of $8.25 per hour for 50 hours was allowed then. The wage calculates to $21,450 per year. PEOPLE, PASSION & SOLUTIONS
(continued on page 6)
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From the Field (continued from page 4)
“Aladdin Engineering and Manufacturing is still looking for this design engineer today, and some of your companies may be also,” she said. “They are unicorns. The main reason, in my opinion, is the solid rate of growth. In the 1970s, when manufacturing began leaving the U.S., that discouraged young people from going into STEM careers. That trend has not changed until recently.” Using the 1950 salary compared to a STEM salary of $65,000 today, Bell said that there has only been a 2% rate of growth over 60 years. “I think one way to change this trend is for colleges like MSOE to recruit students, male and female with high scores in any STEM discipline, like colleges recruit athletes, personal meetings with the student and their parents,
more grants and scholarships,” she said. “Students and their parents need to see a viable future career, and not a future of losing your job like a commodity in a cost of sales formula. STEM employees are not commodities on the product costing spreadsheet.” FPW
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vol 5 no 5
August 2018
C ontents |
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fluidpowerworld.com
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8
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F E AT U R E S
INDUSTRIAL HYDRAULICS
How to use hydraulics in machine tools
The machine tool is a machine that uses a guided tool for the shaping of materials, typically by cutting, grinding, drilling, boring or forming, etc.
IMTS PREVIEW IMTS features 7 co-located conferences Annual manufacturing conference and exhibition returns to Chicago’s McCormick Place September 10-15.
40 48 56 D E PA R T M E N T S
02 FluidLines
PNEUMATICS Time-honored process embraces pneumatics Food-safe pneumatics automates traditional cheese production.
04 From The Field
56
12 Korane’s Outlook 14 Association Watch 16 Design Notes 26 Energy Efficiency 28 Distributor Update 30 Safety 32 Maintenance 36 Fundamentals 66 Products 71 Component Focus 72 Ad Index
A | S | B | P| E Fostering B2B editorial excellence
ON THE COVER
Rota Engineering’s LA transducers help to ensure even crop rows on RoGator selfpropelled row crop applicators. | courtesy of AGCO Corp.
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American Society of Business Publication Editors
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AUGUST 2018 • vol 5 no 5 • www.fluidpowerworld.com
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EDITORIAL
VIDEO SERVICES
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor
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Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon
Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek
Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora
DIGITAL MARKETING
Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane Contributing Editor Josh Cosford @FluidPowerTips
units on display
Contributing Editor Carl Dyke @carlindustry
• Copy function • Power-save mode
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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© 2018 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. SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. SUBSCRIBER SERVICES: To order a subscription please visit our web site at www.fluidpowerworld.com FLUID POWER WORLD (ISSN 2375-3641) is published eight times a year: in February, April, May, June, August, September, November, December by WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, Ohio 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Fluid Power World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103
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A PARTNERSHIP WITH PASSION TO PERFORM.
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Ko ra n e ’s O u t L o o k Ken Korane • Contributing Editor
| istockphoto.com
Fluid power a trade-war loser
It has been a solid year for sales and profits among equipment builders, industrial firms and fluid power manufacturers alike. The same can’t be said looking ahead. Many financial experts predict a hit to economic growth next year, in large part due to protectionist sentiments and the volatile future of U.S. trade policy. Earlier this year the Trump administration enacted tariffs on steel and aluminum imported from trading partners like Europe, Canada and Mexico. And it has threatened to impose more than $250 billion in tariffs on goods from China, including construction and agricultural equipment and components. In talks in late July the U.S and EU agreed to try avert a trade war, although tariffs and retaliatory measures remain in place. The reality is that with foreign steel restricted from domestic markets, U.S. steel manufacturers have little incentive to rein in prices, which are reportedly up 40 to 50% versus a year ago. That directly affects items that use a lot of steel, everything from ag tractors to hydraulic cylinders. John Deere, 12
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for example, announced price hikes on its product line. Eaton said it could see a $50 million increase in its raw materials costs. And tariffs are more than just a tax on farmers, manufacturers and consumers. In a roundtable with Wisconsin Sen. Ron Johnson last month, as reported in the Milwaukee Business Journal, business leaders explained how the administration’s trade policies and resulting retaliations are hurting their bottom line. “There certainly is an enormous amount of loss productivity and wasted time and effort from all of this,” said Mark Gliebe, the CEO of Regal Beloit. “The biggest issue we have is the uncertainty
A lot of steel goes into a now-moreexpensive cylinder.
of it all.” Fears are that tariffs could force businesses to move additional production overseas and, more insidiously, make companies outside the U.S. more efficient and economical. “This policy is designed, or at least has an effect of making our overseas competitors more cost competitive in the U.S.,” said Austin Ramirez, the CEO of Husco International. “It’s a terrible impact of this.” That certainly seems to be playing out. While free trade is out of fashion in the U.S., the EU and Japan—which together account for around 30% of global economic output—just inked a deal to eliminate most bilateral tariffs and create one of the world’s largest liberalized trade zones. The Europeans have also agreed to trade pacts with Canada and Mexico, and initiated trade discussions with China, Latin America trading bloc Mercosur, and Australia and New Zealand. America’s attractiveness as a manufacturing base declines and global supply chains shy away from U.S. suppliers when we raise duties on imported raw materials and components. In a remarkable turn, China is now touting itself a protector of international rules while castigating the U.S. for disrupting global commerce. “The last thing America’s manufacturing workers need is an escalating trade war,” said National Assn. of Manufacturers President Jay Timmons. “Instead of more tariffs, the U.S. and China should immediately begin working toward a fair, bilateral, enforceable, rules-based trade agreement to end China’s market-distorting activities. China cheats, and manufacturers want to see China held accountable.” But more tariffs will punish America’s manufacturing workers, he said, and could undermine hard-won reforms which have increased our global competitiveness and led to higher investment and more American jobs. \FPW
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ASSOCIATION WATCH
Edited by Mike Santora • Associate Editor
Here is a little bit about Jacob, in his own words: I was born and raised in Orcutt, California and attended Orcutt Academy High School. My hobbies include singing tenor in a barbershop quartet, participating in FIRST robotics, playing video games (of course), and I am a third-degree black belt in Shaolin Kenpo. I spent four informative years on my high school’s FIRST team, 3512 Spartatroniks, where I was on the electrical sub-team and the Electrical Lead my senior year. Team 3512 qualified for the FIRST World Championships 3 out of the 4 years I was on the team. FIRST provided me with a tremendous amount of real-world, job-like experience. I will be pursuing a Masters Degree in Electrical Engineering at my dream school, Cal Poly, San Luis Obispo, taking advantage of their 4 + 1 masters program and their “learn by doing” philosophy. This scholarship will help tremendously, allowing me to focus more on my studies instead of having to worry about finances. I am very thankful for the opportunity given to me by the NFPA, and I am looking forward to being a part of the bright future of the fluid power industry.
2018 NFPA Robotics scholarship winner The National Fluid Power Association has announced that Jacob Barnes of Orcutt, Calif. is the winner of the 2018 NFPA Robotics Challenge Scholarship. This scholarship program awards $40,000 ($10,000 per year for four years) to a high school senior who participates in a FIRST Robotics or National Robotics League Competition Team. It may be used to study engineering at any accredited technical college or university in the United States.
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The NFPA judges who interviewed Jacob were impressed by his knowledge of pneumatics, his initiative and plan to mentor FIRST Robotics teams. Judges included: Andrew Kleitsch of Caterpillar, Bill Haley of FORCE America, Jim Kaas of Iowa Fluid Power, Bob Hammond of Deltrol Fluid Products, Bradlee Dittmer and Charles Werdehoff of IMI Precision, Tom Peterson of HUSCO, Frank Langro of Festo, Jonathan Steigerwald of Gates Corp., Larry Davis of Daman, and Barb DeCesare of Hydraforce. NFPA received 105 applications for this scholarship, which helps to create awareness in high school students about the benefits of fluid power and its many associated exciting careers.
www.fluidpowerworld.com
8/13/18 3:19 PM
Slow down to speed up
ASSOCIATION WATCH
Fourth annual report on the U.S. Fluid Power Industry now available on the NFPA website
...with ACE industrial shock absorbers.
Fluid power is a workhorse of the American economy and is used in dozens of industries and hundreds of applications. As in previous reports, this new document for NFPA members outlines the size and economic impact of the fluid power industry, provides energy and efficiency information, and summarizes key research challenges and opportunities in fluid power technology. The information provided in the report is useful to fluid power professionals, customers, and prospects alike.
Decelerate moving loads
Key conclusions include: • U.S. manufacturing of fluid power components reached a record-high $21.7 billion in 2017. • Fluid power exports continue to increase since recession-era lows, reaching customers around the globe. • The supply, manufacturing, and distribution of fluid power products directly employs more than 67,000 people and indirectly supports jobs for 775,000 more.
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DESIGN NOTES
Mary C. Gannon • Editor
Hall-effect transducers ensure consistent crop rows When the planting season begins, farmers will plant different crops at different row widths, requiring the sprayers to match the row width by running wheels between the plants and not over them. In the past, this was a time-consuming task, as users would have to jack up one wheel of a tractor/sprayer, loosen its hub bolts, measure and move the wheel to its new row width, then retighten hub bolts. That was just on one tire. The farmer would then have to repeat this operation three more times. It was easily a one-hour job.
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To reduce this time, modern equipment manufacturers began to use hydraulic cylinders to move the wheel in and out. Here, mechanical markers would indicate wheel position. As these machines became more sophisticated (with more items attached to the machine) it in turn became more difficult to find a location for the mechanical markers so they could be viewed. Today top of the line sprayers allow the operator to set the wheel position at the push of a button and sensors determine that position. On its track adjust cylinders, AGCO RoGator uses four LA internal transducers from Rota Engineering for axle widening cylinders. AGCO turned to Rota because it needed a small size sensor to maintain the cylinder’s pin-to-pin dimension. Rota says its LA series is the smallest active transducer on the market. It uses a clip-in mounting design that does not change the pin-to-pin dimension on existing cylinder designs. The small and compact size of Rota’s LA transducers allow them to be mounted between clevis ears of a cylinder where they are physically well protected, said Mark Hoffman, VP Sales and Marketing.
8 • 2018
AGCO Corp.’s RoGator self-propelled row crop applicators use Rota Engineering’s LA transducers to ensure even crop rows.
www.fluidpowerworld.com
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DESIGN NOTES
LA transducers are versatile, too, he added. “This design allows for sensor installation at the cylinder manufacturer, at the OEM factory floor or in the field by a dealer technician when the feature is desired,” Hoffman said. “The sensors can also be installed after wash down and painting process thus avoiding water ingress or ESD issues on an electrostatic paint line.” LA transducers are ideal for agricultural machinery, too, Hoffman said, because they use the latest version of compact electronics that are compatible with mobile equipment electronics. And, an optional 5-Vdc powered transducer gives 4.5 Vdc output, allowing the user to upgrade from resistive type transducers to Rota’s noncontact Hall Effect without upgrading the mobile equipment electronics. The LA transducers are packaged in a high-tensile aluminum enclosure rated to 325 bar (4,750 psi) operating pressure. Their costeffective design makes them a perfect fit when replacing limit switches, brackets and the associated cables, potentiometers, etc. where the 5-V supply option is ideal.
Rota Engineering’s LA transducers feature an aluminum enclosure.
FPW
WHAT Connect with thousands of DO engineering YOU design THINK? professionals
Rota Engineering Ltd. | rota-eng.com
online.
LA transducers are compact, allowing for easy, internal mounting inside the hydraulic cylinder.
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DESIGN NOTES
Edited by Mike Santora • Associate Editor
Portable filter device for off-line filtration Most failures in oil systems (up to 80%) are related to oil contamination. Failures like this are a common problem in large industrial applications and mobile machines as well as systems powered by small hydraulic power packs. Effective off-line filtration — continually or temporarily during filling and cyclic service inspections — significantly improves oil purity, minimizes operating costs, and extends machine lifetime. ARGO-HYTOS Fluid Management (FMA) products are designed for servicing systems with relatively large oil tanks of 60 to 5,000 l capacity. But what if users are dealing with a small-sized reservoir or its installation position makes it difficult to access larger service units? The CFP 03 is a portable filter device for off-line filtration that acts primarily as a service unit for off-line filtration. This type of filtration seems evident in systems with easy tank access, where the installation of two independent hoses (suction and pressure) is not a problem. The real challenges are small systems where oil is poured through one tiny available port. What about off-line filtration in such systems? The CFP 03’s suction-return set helps users handle this specific configuration. The problem of oil cleanliness is not only related to large devices. The question is how to improve the service of smaller devices such as compact power packs. Unfortunately, these types of systems are often filled in the wrong way, without the use of professional equipment. As a result, oil poured into the tank
Compact filter pack (CFP 03).
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Filling of the small power pack with the use of CFP — one of the possible ways of use of the aggregate.
does not meet the basic purity requirements. Even new oil’s cleanliness class is worse than recommended by manufacturers of hydraulic components. The filling of a system with such media results in faster component wear and frequent failures. In case of small tanks (volume up to several
dozen liters), it is not possible to fill and provide off-line filtration with standard service units. Even a small nominal flow of 8 or 16 lpm can lead to spillage. Moreover, most compact power packs have limited possibilities for connecting external hydraulic hoses. Usually there is only one port in the oil tank (after removing the ventilating filter) which is too small for parallel installation of a suction and return hose. Without the possibility of oil sucking
and then pumping it via a separate hose, off-line filtration cannot be performed. To solve this problem, ARGO-HYTOS developed the compact filter pack CFP 03, which has a nominal flow of 3 lpm for filling of small machines. With such a low nominal flow, the risk of spilling or overflowing is minimal. Even in the case of a tank with a capacity of several liters, oil can be filled in a controlled manner.
Off-line filtration in small hydraulic power pack with CFP, connected to the tank via suction-return set.
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DESIGN NOTES
DESIGN NOTES
Installation of the suction-return set in a plastic tank.
Suction-return set.
Securing of the end of the hydraulic hose with a plug.
The whole configuration consists of an aluminum body, suction and pressure tube and a quick couplings kit. Additionally, it is equipped with a small ventilating filter which provides air exchange between the external environment and the tank inside. With the magnet attached to the body, the installation of the set in the steel tank is fast and efficient. In the first step, the original ventilating filter must be removed from the tank. Then the suction-return set can be placed in the released port and rotated to any desired angle. The strength of the magnet provides a reliable connection. After the connection of the suction and pressure hose, the entire installation is ready for off-line filtration. The same set can also be used in power packs with plastic tanks. This is possible thanks to an additional adapter made of steel. The adapter screwed into the air filter port is the base for inserting the suction-return set. The compact size of the CFP 03 makes it suitable for use in installations where other units do not work — specifically, systems with an inaccessible oil tank where the connection of a bigger service unit is not possible. FPW
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8/14/18 9:42 AM
DESIGN NOTES
Edited by Mary C. Gannon • Editor
DESIGN NOTES
Parker’s Virtual Engineer tool delivers a custom specification report, CAD models, and seamlessly creates a ready to issue “request for quote” (RFQ).
Virtual Engineer design tool simplifies pneumatic component selection A new motion control design tool for engineers from Parker Hannifin Corp. aims to help with the proper selection of electromechanical and pneumatic linear motion. Dubbed Virtual Engineer, the free online tool is an intuitive interface where users can easily enter their application specifications, (for example, speed, load, external forces) and then quickly navigate to accurately sized product options.
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The tool delivers a custom specification report, CAD models, and seamlessly creates a ready to issue “request for quote” (RFQ). By connecting directly with Parker motion control experts, Virtual Engineer takes collaboration to a whole new level, and by doing so, helps to increase efficiency of engineering resources. Parker’s Jeremy Miller, Product Manager – Linear Mechanics in the Electromechanical & Drives Div., said there is no other tool like this on the market for specifying either pneumatic or electromechanical technologies. This tool actually simulates how Parker’s products will work in a user’s specific application; it doesn’t just give rated data. “It can be challenging for our customers to get from an application through to a final product because there’s a lot of technical calculations” that must be considered, Miller said.
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“There’s a trend of manufacturers, machine builders, and OEMs trying to offload their engineering complexity and their engineering work onto their suppliers. So we thought, how do we streamline that process and save some of the cost that is incurred every time we have a design engineer have to go through that process while also minimizing design time,” he continued. Miller added that requiring engineers or anyone who may be specifying a product to review catalogs, online configurators and other sizing tools makes it difficult to understand how the product is really going to work in their application. There’s also a confidence factor of knowing whether the customer has selected the right component. “We need to solve this problem,” Miller said. “The goal is to provide something that is extremely simple and extremely intuitive. We have taken all those complicated calculations and built them into the software so now you don’t have to think about how I do convert a force to a moment or calculate my total time of travel, you’re just looking at simple questions as you go through and we’re thinking about every single potential variable.” Virtual Engineer includes many customer-focused features including product life estimation, “Compare” function for multiple products, CAD model availability, and a “My Projects” area. My Projects allows engineers to create, save, and share projects. The simple graphical interface allows the user to input details on attached mass, external forces and moments, plus axis orientation, motion details, filter by key attributes, or explore all solutions with minimal required inputs. As application parameters are applied, a list of possible solutions is presented on your screen. If any specification exceeds a solution’s capability, it is eliminated from the available options in real time. After completing all specifications, Virtual Engineer’s “Compare” feature will display clearly the differences between the most suitable products, including expected life and relative cost. This information can then be saved, downloaded, or submitted to Parker for a price quote. Essentially, it reviews thousands of products and finds the best fit according to your specific inputs and requirements. Virtual Engineer currently supports Parker Electromechanical and Pneumatic products.
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8/13/18 3:53 PM
ENERGY EFFICIENCY
Ron Marshall • Contributing Editor
Why your compressor: makes water
Water condenses when air is compressed and cooled.
You may have noticed water coming out of your compressor. Some people ask where does it come from and why is it there? But it’s also important to ask: how well is it being removed? Atmospheric air contains water in vapor form, the amount depending on the temperature and relative humidity of the inlet flow. For example, air at 70° F and 70% relative humidity contains about 0.1 gal of water per 1,000 cubic feet. When this air is compressed, the moisture carrying capability of the compressed air reduces — and some of the water drops out. The same air at 100 psi pressure and 70° F can hold only about one-fifth of the amount of water as it did at ambient pressure. This extra water needs to be removed from your system — or it will travel downstream, contaminating your compressed air consuming tools and equipment. 26
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A typical compressor has some method of removing this water, usually located after the air cooler, on the bottom of a centrifugal water separator. You should be aware that not all compressors have water separators and drains at this point; therefore, to avoid moisture problems, some method of removing the water must be added. A good check to always incorporate to your maintenance rounds is to see if water is being removed at this point—a surprising number of compressors have failures of the drains, allowing water to pass downstream. If this point is dry, you may have problems. How much water is formed? At the previously mentioned conditions, every 10 hp of fully loaded compressor capacity produces about 2,500 cubic feet of compressed air per hour. This would condense about 0.2 gal per hour, or about 5 gal
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of water per day for every 10 hp of compressor power. At different inlet conditions, the amount of water in the compressed air would go up or down; every 20° F increase in temperature roughly doubles the amount of water in the air. Want to avoid problems? Always make sure your compressor drains are working and you have a backup location where water can be captured and removed. A good location is a well-sized wet receiver, through which the air passes before going downstream. And, if you want to avoid water problems altogether, make sure your system has an air dryer that would reduce the dew point of the compressed air at least 10° lower than the coldest point at which the system piping is exposed. Refrigerated dryers, which produce dew points of about 35° F also have drains that must be working to expel water, so this is an additional maintenance item. A desiccant dryer would be used if the air is subject to freezing temperatures — these would have drains on the inlet filters. In case of dryer failure, make sure your piping system is designed with a slight slope away from the compressors, with automatic drains located at any low point. Drains should be selected and set so they waste a minimal amount of compressed air, expelling only water. There are many varieties of “airless” drains that can do this. Lastly, make sure that you tap the air drops to equipment from the top of the pipe rather than the bottom, lest free water flow into your expensive machines. FPW
Ron Marshall is a compressed air energy efficiency expert at www.compressedairaudit.com. Join us at the Compressed Air Efficiency discussion group at https:// www.linkedin.com/groups/12065406
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8/14/18 8:58 AM
DISTRIBUTOR UPDATE
Paul J. Heney • VP, Editorial Director
A Q&A with NAHAD’s new Executive VP
A
At this year’s 34th Annual NAHAD Convention at the JW Marriott in Marco Island, Fla., I had the chance to sit down with Molly Alton Mullins, the new Executive VP of the association. Here’s our exclusive interview with Mullins, which covered her vision for the group, her thoughts on how the Convention has evolved, and what she believes the future will bring. FPW: Tell us a little bit about how you first got involved with NAHAD. MM: Sure, I’ve been with NAHAD for about two and a half years now. I was brought on as Executive Vice President to really create a succession plan for NAHAD with Joe and Christa Thompson’s pending retirement. It gave me a great opportunity to work with them and see how they had done things— and see what we could do to make NAHAD even better, as we continued to move forward. So that was a great opportunity, and it culminated here at the convention, which was the last of their NAHAD activities. FPW: It seems like there have been a few changes from last year’s conference to this year’s. How much of that was your team? How much was feedback or simply trying new things? MM: We really encourage people to complete our convention surveys and to provide us with feedback, and after last year’s convention, three very distinct points came out of the survey. People wanted
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more time in the showcase to meet with distributors and manufacturers. People wanted the convention to be shorter; it was too much time out of the office. And people wanted more time for business meetings. We started offering space for company meetings a few years back. Then, in addition to all the other things they were doing here at the convention, people could hold their company sales meetings, they could do their strategy plans, their forecasting, etc. So, we sold out with more than 40 company meetings during the course of this year. There were no open time slots, and people really responded to it. Will we do the same thing every year? No, but one of my biggest visions is I want to try new things, so I can see where we can succeed and where we fail.
FPW: What is your vision for NAHAD moving forward? MM: My goal is to provide services that directly impact business, so how can I increase your bottom line? How can I provide you with tools that help you benchmark how you’re doing against others in the industry? What kind of networking do you need, face-to-face? What kind of education do you need—webinars? What kind of training do you need? What are the issues around workforce development and finding and recruiting the right people? I even struggle with that at our company, so what kind of tools can I provide so that you can not only attract someone to this industry, but you can keep them and retain them. I’m trying to evaluate the services that we offer and see what we’re missing, and really discover what the members need.
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FPW: Do you see the membership changing much in the coming years? MM: The heart and soul of our membership is distribution, I think, and it always will be. But, distributors aren’t traditional like they once were. I’ve had members with both manufacturing and distributor memberships, because they want to be able to exhibit and showcase product, but they also do distribution. I think that’s only going to increase more and more. We’re going to see more and more companies that fit a multi-channel profile, and I think NAHAD needs to adapt—and figure out what’s best for the members and best for the industry. I want the exhibitors here that they want to do business with, so if they’re changing, tell me. FPW: How did this year’s event turn out? MM: This was our second highest convention in history. We had about 1,060 registered attendees. We rented out all space in the hotel, that’s how good our numbers were. It’s a good economy; that makes a difference. Everyone’s business is good; for the most part, with every member I talked to, they cannot keep up with demand—so there’s an economic edge that helps a convention like this. We tried to offer attendees different opportunities here, whether it was company meetings, whether it was networking-specific times. We didn’t want them to feel like they missed anything, so we planned education so you could attend. We planned networking so you could go. We planned open times so you could have it. These people still want to enjoy a beautiful location like this. FPW: For sure. And then next year? Talk a little bit about next year, Las Vegas, and the rumors of the Bahamas in 2020. MM: Next year we’ll be in Las Vegas. Vegas is one of the cities that works really well
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for some, and others, not as much; they don’t like it as much. So, you’ve got to make a program that works for that particular city, and a lot of that will be based on feedback from what people want. Do you like more education? Do you want more time for networking? What can I do to keep you from the casinos and all the other attractions of Vegas? So we know what’s ahead of us. Then, we will be at the Atlantis in the Bahamas on 2020; I think the dates are the 24th through the 29th of April. Attendees like to go to warm places; we’ve heard that from our members. In 2021, I’ll probably look back on the West Coast. We’re going through that process right now. I do want to make sure my manufacturers know that for 2020, we’ve looked heavily into shipping rates to make sure that [rates to the Bahamas] are comparable to anywhere else that they’re going to be going, so your fee shouldn’t increase just because we’re going into international waters. FPW: Why should a NAHAD member come to a future convention? MM: At this show, you really see people coming here to get business done, and I think that that’s a huge value for our members. People come back year after year, and I think there’s a reason for that. But I’d love to hear what it is that they want from us and what they want from NAHAD— so that we can keep trying to evolve it as we move forward.
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SAFETY
Mary C. Gannon • Editor
Temperature fuse devices completely discharge the nitrogen in an accumulator in case of fire. HYDAC offers two different kinds of temperature fuse. In addition to the temperature fuses pictured below in carbon steel and stainless steel, which are suitable for bladder accumulators, HYDAC also offers a temperature fuse of the type GMP6 (pictured on the next page), which is approved according to the European Pressure Equipment Directive. It is made of stainless steel and has a CE marking.
How do you ensure accumulator safety? Accumulators are pressurized vessels that hold fluid under pressure. This stored energy can be called upon to boost energy to a system when needed, then recharged to store it again. This stored energy can be dangerous; proper care should be taken to ensure pressure and temperatures are kept under control. Several small yet critical accessories can be installed on accumulators to prevent the release of this stored energy and to ensure temperatures remain in their safe operating range. Burst discs, temperature fuse plugs and relief valves are all safety devices for use on gas-loaded accumulators. Overseas, the European Pressure Equipment Directive (PED) offers statutory regulations to ensure safety in the workplace. Fundamental risks affecting hydraulic accumulators are: • Excessive pressure and • Temperature increase (e.g. in the event of an external fire).
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When selecting safety equipment, consideration must be given to the material (elastomers and housing material) in terms of material compatibility in the application. This means that the safety equipment must not exceed the maximum permitted operating pressure of a hydraulic accumulator. If pressure exceeds the maximum level on the gas side, a burst disc is designed to burst, permanently opening the port. This reduces the gas pressure by discharging the nitrogen completely. Burst discs are designed for different response pressures and are supplied with a declaration of conformity. Bursting discs are made either entirely of stainless steel, or from an alloy based on stainless steel and nickel. Temperature fuse plugs are used to release the gas pressure by discharging the nitrogen completely when an increase in temperature reaches unacceptable levels (e.g. in the case of fire). Gas safety valves protect the hydraulic accumulator by
A
Ca
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reducing the pressure in a controlled way if pressure exceeds the permitted level unexpectedly. They are preset on the pressure side and load-sealed by an authorized representative. Mounted on a hydraulic accumulator on the gas side, they can be fitted with various pressure devices, charging equipment, safety valves, and other safety components. The fluid side of an accumulator must be protected from pressures exceeding the permitted operating pressures by installing approved and appropriate unloading valves. FPW
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8/15/18 12:32 PM
MAINTENANCE
Josh Cosford • Contributing Editor
What does maintenance mean to you?
Waiting for a component to fail before replacing is reactive maintenance and an expensive method of maintaining machinery. Here, scuffing isn’t just a problem for pump performance; the little filings created will cause valves to jam. Image courtesy of CD Industrial Group
I once had a walk-in customer bring with him an old, rusty spin-on filter, which I believe was originally colored white below the now orange and brown soup of rust and oil. He needed a replacement filter for his vacuum truck, a machine he said he bought used eight years ago. I grabbed a stock filter head to confirm thread and seal fitment, and casually asked him when the last time this filter was replaced. I was horrified when he responded with, “this is the first time.” Maintenance means different things to different people. Just as some people visit the doctor only if and when they develop severe gout, when a daily maintenance plan of diet and exercise prevents the condition to begin with, so too did my customer practice reactive maintenance. I can’t help wondering how many other hydraulic components on that vacuum truck were ailing 32
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while its lifeblood was essentially circulating with no kidneys! When it comes to maintaining your hydraulic machinery, you can subscribe to one of four plans; reactive, planned, preventive or predictive maintenance. The level in which you adhere to any of these tiers will directly and proportionately correspond to your machine uptime and productivity. Although each plan comes with an increasing commitment of time and money resources, so too does the equivalent payback. Reactive maintenance — is the most stressful plan, although I should drop the word plan from the previous clause. A plan is a thoughtful collection of tasks for future completion, but reacting to your maintenance needs only when a component fails is not much of a plan. Reactive maintenance is more a result of a lazy
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MAINTENANCE
and ignorant approach to machine care; generally not caring or knowing how and when to maintain your hydraulic machinery. Reactive maintenance is far more common than anyone would like to admit, but the manufacturers of spare parts and the shops replacing those parts are glad their customers would prefer a $2,000 pump repair bill than the sale of a $100 filter element. Oil suppliers are happy you want to change out your 200 gallons of tank fluid rather than invest in a couple hundred dollars worth of desiccant breather caps per year. If you’re on the reactive maintenance plan at work, read on … you may want to upgrade. Planned maintenance — pays respect to the sensibilities of maintenance personnel, and ensures the hydraulic system gets regular attention … whether it needs it or not. The planned maintenance technique follows a calendar, and on regular days on typical months, the machine will have its filters changed, oil replaced or cylinders serviced. In many ways, planned maintenance is the superior way to keep the machine as close to new as possible. The issue with planned maintenance is the exorbitant investment in time and money. Sure, your machine is “always new,” and rarely experiences breakdowns, but the cost to maintain can be higher than the cost of failures. Where absolute, no-option production uptime is the driving factor, planned maintenance is the way to go (think automotive). However, for the average user, the resources just aren’t there to justify it. Although I’d love to have a new hydraulic machine every three months, it’s just not practical. Preventive maintenance — is a method to maintain equipment as required just before components fail or are close to failure. For example, a machine operator may notice leakage from the D03 valve stack on their machine. Given time, the seal may blow out completely, leading to a catastrophic fluid loss. Upon recognition of the leakage, a “PM” can be planned for the machine, when 34
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IoT connected devices, like Des-Case’s IsoLogic desiccant breather, allow users to establish more predictive maintenance routines. Sensor technology within the breather provides a digital reading of remaining breather life, saturation direction and breather temperature.
the valve seals will be replaced during scheduled machine downtime. Preventive maintenance sometimes involves replacing components based on known service life and hours of operation. For example, if a pump is known to provide 100,000 hours of service life, it could be replaced at the next scheduled PM as it approaches the end of its life. This method allows components to be replaced prior to failure, providing longer service life and lower cost than planned maintenance. However, unexpected failures still occur, and conversely, what if your pump could have lasted 150,000 hours? Predictive maintenance — tries to head failure off at the pass. By using tactics to predict when a maintenance event is required — and only when — you can save both time and money. For example, most hydraulic filter assemblies have a differential pressure port providing a reading of the back pressure being created as fluid flows over the filter element. As the filter becomes clogged, the backpressure rises as fluid finds it more difficult to sidestep the increasing number of particles. The pressure port can be fitted with a simple popup indictor, a pressure gauge or even an analog transducer. Each of these options allows you to compare backpressure to the bypass valve rating built into the filter. The bypass valve will open when pressure in the filter exceeds the valve’s rating, allowing fluid to flow freely (and unfiltered) to prevent collapse of the element. By comparing bypass valve pressure rating to the actual backpressure across the
filter, you have datum to see how close the filter is to becoming clogged. As differential pressure approaches bypass pressure, then and only then do you replace the element. Predictive maintenance avoids the unnecessary cost and time of needless replacements, but also prevents failures related to neglected practice. The Industrial Internet of Things, and the Industry 4.0 umbrella it falls under, are changing the way we maintain our machinery. What is being used on a plant floor today doesn’t always mirror what is potential with Industry 4.0, but the early concepts are promising. Imagine instead of changing a pump at 100,000 hours, you change it within a day of failure. The technology already exists to monitor the temperature and flow of the pump’s case drain line, of which acceleration of flow and temperature occur as the pump wears. Adding vibration sensors to the pump’s bearings will fill you in if they’re about to blow. Now imagine if instead of dumb sensors, the case drain and bearings were monitored by Bluetooth enabled smart devices programmed to interpret its parameters and send a lifespan doomsday clock directly to your phone. I could spend an entire article on predictive maintenance, especially with all the exponentially increasing technology flooding in with Industry 4.0. I want to be there the day the maintenance supervisor asks of his team member, “Hello, Aiden. I’m going to need you to go ahead and change that pump on Press 8M. It’s going to fail on Thursday morning, so if you could change it by Wednesday afternoon, that would be great.” FPW
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8/15/18 11:21 AM
FUNDAMENTALS
Mary C. Gannon • Editor
What does pressure really mean? Images courtesy of Noshok
Pressure is simply the force applied perpendicular to the surface of an object per unit area over which that force is distributed. However, there are many ways to reference and identify pressure, which is largely dependent upon the application. In many applications, there is a common misconception that all pressure measurement needs to be absolute. While there are certainly applications in which absolute pressure measurement makes sense, most applications only require gauge pressure. Understanding the details of an application can make selecting an appropriate pressure sensor easy. Here are a few of the most commonly referenced types of pressure. Gauge pressure (psig) references the atmosphere around the sensor, or ambient air pressure. Simply put, it is the absolute pressure minus the atmospheric pressure. The sensing element has a 36
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deflection due to a pressure change, and therefore a reference point is required to identify exactly the pressure that is being measured. Pressure sensors that use gauge pressure (usually psig, barg, and kpag) include a vent. This vent can be built in to the sensor itself, or through a tube in the electrical connection. The vent is positioned to use atmospheric pressure as a reference point for the sensor to measure the media, so when the pressure port is exposed to the atmosphere, the sensor will read 0 psig. Using gauge pressure ensures that at any location in the world, the sensor will always reference the location in which it is installed. While gauge pressure is measured from atmospheric, absolute pressure (psia) is measured from absolute zero pressure,
so when the pressure port is exposed to the atmosphere the sensor will indicate atmospheric pressure (approx. 14.7 psia). Absolute pressure uses a full vacuum as its reference — it is the gauge pressure of the media plus the pressure of the atmosphere. In different locations and elevations, the reference point can change because of atmospheric pressure variations. The atmospheric pressure varies with temperature and altitude above sea level. An absolute pressure sensor eliminates the reference to varying atmospheric pressure and relying on a specific pressure range for reference. Sealed pressure (psis) is referenced to the prevailing atmospheric pressure which is hermetically sealed in the chamber within the sensor. No venting is needed because the reference point is pre-determined.
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When the pressure port is exposed to ambient atmosphere the sensor will indicate 0 psi when the ambient atmosphere is identical to the sealed atmosphere. These sensors are useful in applications where it is not possible to provide a vent path, such as a depth sensor used inside a submersible vehicle with no surface vent tube, in which the sensor needs to measure depth relative to atmospheric pressure at the surface. A sealed pressure sensor can also be used to provide additional containment for high-pressure safety in case the diaphragm bursts. Differential pressure (psid) simply indicates the pressure difference between two pressure measurements. A differential pressure sensor is used to identify the difference between two separate pressure input ports. For example, differential pressure is used to monitor the pressure drop (or loss) from one area of an object to the other, such as pressures outside and inside a pipe, levels within a pressure vessel, before and after a barrier in a flow path, or even between two points along any flow path. Units of pressure psi (pounds per square inch): The unit of measure for one pound of force applied to one square inch of area — psi is the traditional unit of pressure in the imperial and US customary systems and is not part of the International System of Units (SI). bar: One bar equals the atmospheric pressure on the Earth at sea level, which is exactly equal to 100,000 Pa. The bar unit is a
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FUNDAMENTALS
metric unit of pressure, but not part of the International System of Units (SI).
“millimeter of mercury.” The torr is not part of the International System of Units (SI).
Pa (Pascal): One Pascal is the International System of Units (SI) derived unit of pressure. One Pascal is defined as one newton per square meter.
in.H2O (inches of water): The pressure exerted at the base of a column of water exactly 1 in. high, at gravity and 4°C (39.2°F). The in.H2O is not part of the International System of Units (SI). 1 in.H2O = 0.249082 kPa. It is typically used for a differential pressure measurement or in low pressure water applications.
In.Hg (inches of mercury): in.Hg is defined as the pressure exerted at the base of a column of mercury exactly 1 in. high, at gravity and 0°C (32°F). The in.Hg is not part of the International System of Units (SI). 1 in.Hg = 3.38638 kPa. In.Hg is typically used for barometric pressure.
FPW
Noshok | noshok.com
torr: A unit of pressure based on an absolute scale and is defined as exactly 1⁄760 of a standard atmosphere. Historically, one torr was intended to be the same as one
Differential pressure gauge
The Mobile Hydraulic Experts. Kraft Fluid Systems is the leading industrial distributor of hydraulic equipment and provider of mobile drive solutions in the Midwest US. With more than 45 years of experience, Kraft is the preferred distributor when seeking hydraulic components, power transmission equipment and electronic controls for mobile OEM integrated solutions.
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How to use
hydraulics in machine tools Josh Cosford • Contributing Editor
The machine tool is a machine that uses a guided tool for the shaping of materials, typically by cutting, grinding, drilling, boring or forming, etc. As opposed to hand tools, which require the operator to be fully in control of the metal shaping, a machine tool uses one or more fixed or rotating tools to move along an axis to shape metal. The machine may be electrically, hydraulically or manually traversed, but the machine tool uses guides and balls screws to feed the tool along its axis.
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Hydraulics improves lathes Manual lathes of every generation use a chuck to clamp the workpiece down for machining. A manual chuck uses a scroll and pinion to adjust and tighten the jaws. A keyed wrench is used for the tightening, and if the process isn’t done with sufficient force, the workpiece can slip during machining. Machinists must often hammer on the wrench to achieve sufficient clamping force, which can be tiring in a production environment.
The hydraulic (or power) chuck was developed to improve performance in the areas of speed and repeatability. Hydraulic energy can close a hydraulic chuck in a fraction of a second, which obviously improves cycle time compared to hammering on a wrench. And because hydraulic pressure is easy to control with relief or reducing valves, the clamping force can be accurately and repeatably achieved, preventing over- or under-clamping, which can damage the workpiece.
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The hydraulic chuck uses an annular actuator to push a tapered collet, forcing the jaws down on the workpiece. Obviously, provisions must be made so that stationary plumbing allows a rotating cylinder to receive flow, although this can be easily overcome with sealing technology allowing for both axial and radial movement. With a through bore chuck, features can be added so bars of raw material are fed into the machine hydraulically, rather than the operator pulling or pushing the bar through the machine by hand. The draw bar cylinder can clamp and draw the material through the chuck, enabling the operator or machine to part off the material and then begin creating a new finished piece without resetting or restarting the machining process. Realistically, lathes with hydraulic chucks and draw bars find themselves in CNC machines rather than manual lathes. The speed and power of a CNC machine almost requires the same from the work holding equipment of the lathe. Why machine a complete component in ten minutes, only to spend five minutes setting it up and removing it from the machine? Simplifying work holding Work holding is the primary function of most hydraulic components used in the machine tool industry. For milling applications, clamping vices are used for the fixturing of work pieces held onto the work table. Just as with a standard bench vice, those inside a CNC machine must be manually opened, closed and tightened. The same difficulties of lathes exist with mills, in that you risk either loose workpieces with under-clamping or damaged workpieces with over-clamping. Hydraulic fixturing provides the easily controllable clamping force with speed and repeatability. The advantage to hydraulic fixturing on mills compared to lathes is that mills can be outfitted with the components from the aftermarket quite easily. A lathe must usually be ordered with hydraulic chucks and drawbars, as upgrading after can be difficult. However, hydraulic fixtures for mills can easily be added afterward through third party suppliers. Hydraulic clamping for mill tables are offered in many configurations, but the most popular is the swing clamp. Part
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rotary actuator, part hydraulic cylinder, the swing clamp mounts with rod upwards and pivots at the same time as it retracts. As it bottoms in retraction atop the workpiece, it clamps the piece securely to the bed. Conversely, the swing clamp extends to release the material as the rod rotates and the clamp bracket moves out of the way, allowing the operator to easily remove the workpiece. Any CNC mill can be upgraded to use hydraulic fixturing and it is usually just a matter of adding a small power unit with control valves. Often, these valves can be operated by the computer controller of the CNC machine, making an upgrade simple. The hydraulic actuators are powered by an external power unit, often a very compact unit which can be tucked out of the way. Sizing down with the HPU Hydraulic power units for the machine tool industry are unique to the segment, and they employ techniques not used in other environments. Their miniature size is often the primary consideration, as they must fit into a tiny area of real estate within the machine, especially if the machine is outfitted with a power unit from the factory. Of all the fluid power topics covered in schools, machine tool hydraulics seemed to be left out more often than not. It’s not that
CNC power units for the machine tool industry must be compact to fit within the machine. Image courtesy Daikin.
“Workholding is the primary function of most hydraulic components used in the machine tool industry.” 42
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they’re overly complicated or intricate, but it seems that they have just flown under the radar. The world of the CNC machine tool is increasingly competitive, which has resulted in machine pricing dropping drastically over the past decade. Those reduced costs began with less expensive components, of which the power unit price was reduced as well. The result of this stiff competition led to a handful of compact power unit suppliers being able to produce the components required for a CNC machine. The pump/motor group must be efficient both in dimensions and energy usage, but able to perform well when asked. The pump is often close-coupled to the motor to save space, which means one component must have a custom female shaft. The close-coupled pump/motor
The draw bar cylinder, like this one from Kitagawa, can clamp and draw the material through the chuck, enabling the operator or machine to part off the material and then begin creating a new finished piece without resetting or restarting the machining process.
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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. Go to yatesind.com to try out our cylinder configurator today.
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is one reason few manufacturers build systems for the machine tool industry. After the pump/motor group is mounted to the tiny reservoir, the remaining accoutrements must be attached. These components include coolers, filtration, plumbing and sometimes valves. The power unit occasionally has advanced control, like a remote pressure compensator allowing the operator to change pump pressure on the fly. Coolers are often just radiators plumbed into the case drain line of the pump, and if you’re lucky, the motor’s cooling fan will aid in heat dissipation. If valves are mounted to the power unit, they’re almost exclusively compact stack valves on a manifold. Custom compact manifolds with cartridge valves are becoming more popular, especially as suppliers become more flexible in their manufacture.
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The room for the independent hydraulic shops in the machine tool hydraulic market is limited, as least from a Tier 1 perspective. The compact hydraulic packages designed for CNC machines are OEM specific, specialized and required in high volumes. You may get lucky to service or replace an old or obsolete power unit, but if anything, a local hydraulic shop will be best suited for custom upgrades, such as with material handling applications which support the primary function of the machine. However, because of the size of the machine tool industry, the proverbial pie is very large. Even a hose supplier working with some of the big OEMs can secure a significant part of the hose market in this industry alone. If you’re a fluid power component manufacturer, your best bet is
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to start small and supply ancillary components, such as fixtures or replacement parts. This market will only continue to grow, especially as Industry 4.0 expands to every corner of manufacturing and old, manual forms of manufacturing fall to the wayside. FPW
WHAT Connect with thousands of DO engineering YOU design THINK? professionals online.
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IMTS
features 7
co-located conferences
Annual manufacturing conference and exhibition returns to Chicago’s McCormick Place September 10-15.
Edited by Mary Gannon ● Editor
The IMTS 2018 Conference, a platform for manufacturing education at IMTS – The International Manufacturing Technology Show, will feature 69 sessions over four days, September 10-13, at McCormick Place. The exhibition and conference covers information for all manufacturers: manufacturing process innovation, alternative/additive manufacturing, plant operations, systems integration, Industry 4.0/lloT, and quality/ inspection/metrology. The IMTS Conference is organized into 55-minute sessions to emsure that visitors can easily attend sessions without taking too much time away from the show floor.
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W Integrated Automation, Industrial IT, Power Transmission and Control. Located alongside IAMD USA will be the Fluid Power special display area, with about 50 exhibitors of key fluid power technologies including hydraulic and pneumatic pumps and cylinders, sensing technologies, filtration, and more. A full exhibitor list accompanies this article. Seven co-located conferences IMTS also hosts seven co-located conferences ranging from half to two-day events. • Integrated industries Presentations at the 2018 Integrated Industries Conference (IIC) will tie in closely with technologies on the show floor of Hannover Messe USA. IIC offers three tracks: Track A – Motion, Drive & Automation; Track B – IIoT/Industry 4.0 and Track C – Integrated Industries. Global industry experts and thought leaders will share advanced manufacturing insights, best practices and new methods to help introduce new tech- nology onto the factory floor.
Session abstracts submitted by exhibitors are evaluated to ensure that they provide non-commercial insight and best practice information from credible experts, industry leaders and technical professionals. “Contracted exhibitors present on a variety of topics that cover industry needs and breakthroughs,” said Bill Herman, Director of International Exhibitions and Sponsorship for AMT – The Association For Manufacturing Technology, which owns and produces IMTS. “These aren’t product pitches. Conference sessions are technical deep dives that apply directly to the daily activities of engineers. That said, CEOs and shop owners often attend process-oriented sessions so they can keep an eye on industry direction, notably as it relates to additive manufacturing and Industry 4.0.” All IMTS Conference sessions will be held in the West Building – Level 1 of McCormick Place. IMTS will feature increased space for Hannover Messe USA’s co-located shows, with 130,000 ft2 for its newly branded North American industrial technology co-located trade show. Hannover Messe USA is organized and managed by Hannover Fairs USA (HFUSA), the U.S. subsidiary of Deutsche Messe, organizer of Hannover Messe. Hannover Messe USA will feature approximately 500 exhibitors in the East Building. Level 3 will feature its Integrated Automation, Motion & Drives USA (IAMD USA), North America’s trade show for 50
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• GAMS (Global Automation Manufacturing Summit) The Global Automation Manufacturing Summit (GAMS) will highlight the industry’s journey to operational IIoT systems, a game-changer that is poised to help manufacturers every- where measure, manage and analyze plant floor data to optimize operations. Presentation topics include IIoT in discrete manufacturing, maintenance and IIoT, “Embrace your robot: a guide to the future” and cybersecurity. • Additive Manufacturing Conference Held on-site at IMTS during show years, the Additive Manufacturing Conference focuses exclusively on the hottest industry trend today: additive technologies for industrial part production. The event will include technical sessions, business networking, receptions and sponsor displays that offer a practical, applications-based look at the machines, materials and methodologies being used to grow end-use tools and components. • AppliedAM – Where Additive Minds Meet Hosted by EOS, AppliedAM is a half-day, Additive Manufac- turing (AM) applications-focused symposium where profes- sionals will discuss how AM is being employed today and why AM is a cornerstone of true digital manufacturing and Industry 4.0. Panels and presentations will feature experts from Boeing, Siemens, UDRI, EOS and many others.
www.fluidpowerworld.com
8/13/18 4:51 PM
Production Downtime Doesn’t Stop the Clock. Failure to Deliver Does!
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• Top Shops Workshop The Top Shops event provides best practice information in a variety of business areas, including the machining floor, the front office and human resources. Manufacturing facilities and job shops will learn about areas where they can improve business, from the machining floor to the front office. • Industrial Laser Conference Learn about the many industrial applications of lasers and how to incorporate them into manufacturing processes to improve efficiency and profits. Hear best practices about applying lasers for applications such as additive manufacturing, cutting, welding, marking and more. FPW
(Exhibitors list, page 54)
IMTS | imts.com
Positions Sensors for Hydraulic Cylinders - say goodbye to drilling pistons!
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Watch the video http://bit.ly/2CqxUpT 8 2018 FLUID POWER WORLD 52 SIKO Products Inc., Phone +1 (734) 426-3476, www.siko-global.com
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MAKING THE MOST OF YOUR
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© 8.2018 Schroeder Industries.
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■ Easy contamination level measurement of mineral oils and phosphate esters in bulk storage, transfer and dispensing applications ■ Fluid condition measurements are recorded, stored and easily recovered via WiFi or Bluetooth® wireless technology with our FluMoS mobile App
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I M T S
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2018 IMTS Exhibitors Advanced Machine & Engineering
P R E V I E W Booth Number
2018 IMTS Exhibitors
2018 IMTS Exhibitors
Booth Number
121117, 432423
Festo
Ametek
135642
Flourten
135070
API Heat Transfer
135089
Gradient Lens
135333
Prevost
121021
Argo Hytos
134975
H.B. Hydraulics
135255
Quaker Chemical
431949
Balluff
134062
Hirschmann
134812
Rosedale Products
121436
Bimba
134825
HYDAC Technology Corp.
135062
Schunk
432010
Settima USA
135067
Buy Fittings Online
121588
ifm effector
121828
SIKO Products
134245
Canfield Industries
121558
ITT Enidine
121051
Smalley
236300 121238
215128, 134357
Nachi America
432024
National Filters
135177
Caplugs
121282
J.W. Winco
121441
SMC Corp. of America
Deublin
121003
Lexair
431322
SUCO Technologies
134979
Dura-Bar
431272
236914
Sunnen Products Co.
Elesa U.S.A. Corporation
121265
Liebherr Gear Technology and Automation Systems
432216, 237400
Sunsource
121657
Enerpac
431426
Milwaukee Cylinder
431426
Techno Summer
134352
Faster
121595
Mindman Industrial Co
135162
The Lubrizol Corp.
121493
Tolomatic
134436
Diagnostic test equipment & data logging
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Booth Number
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Time-honored process embraces pneumatics Food-safe pneumatics automates traditional cheese production.
Bill Oliver • Sector Head Food & Beverage/Industrial Automation John Bridges • Head of Marketing AVENTICS Corp.
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Most everyone who enjoys a good bowl of pasta is familiar with Parmigiano-Reggiano and Grana Padano, the well-known Italian cheese varieties famous around the world. These types of parmesan cheese have been produced in the Po River region for more than 800 years, and the traditional production process has essentially stayed the same for centuries. Most people are less aware, however, that crafting these products involves back-breaking manual work. The Italian company Progema Engineering has now automated much of the cheese-making process without compromising traditional methods. A key to mechanized production and handling is the use of pneumatic cylinders and valves from AVENTICS, with headquarters in Laatzen, Germany and U.S. operations based in Lexington, Ky.
| istockphoto.com
Automation meets tradition Automation technology is increasingly used to ease this difficult task because these cheese varieties not only need a great deal of time, but above all meticulous care. Ingredients are blended based on proprietary recipes and pressing out the whey is a strenuous job. The cheese mixture must first rest for two to three days in round forms called “fascere.” Subsequently, the resulting wheels are repeatedly dipped in brine over the next three weeks. They are then warehoused for at least one year in air-conditioned storage rooms until complete maturity. During the months of this maturation process, the cheese wheels must be carefully and repeatedly turned, cleaned and inspected. “Often, these tasks are still carried out manually. With the help of our new Forma4 machine, however, producers can automate the process,” explained Alberto Boceda, head of mechanical engineering and co-owner of Progema Engineering S.R.L. The company, located in Borgo Virgilio southeast of Milan, has 15 employees and specializes in innovative dairy equipment, in particular the design, development and manufacturing of special equipment used to automate cheese production.
www.fluidpowerworld.com
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IF YOU USE HYDRAULIC FLUIDS
You NEED Flow Ezy! Flow Ezy Filters, Inc is the leader in supplying filters, strainers, and accessories for hydraulic applications. If you need it, we have it. Our product line includes: • Sump Strainers • In-Line Filters • Tank Mounted Strainers • Tank Breathers • Suction Screens • Flow Diffusers • Lube Oil Filters • Spin-On Filters • Cartridge Filter Housings • Interchanges for Parker, Marvel, Schroeder, Vickers, and many others...
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AVENTICS ISO CleanLine cylinders close the round molds and apply appropriate pressure. The air cylinders feature a smooth profile that ensures easy-to-clean hygienic surfaces.
This includes automatic storage and cleaning systems that meet Cleaning in Place (CIP) principles for process-engineering systems in the food industry. CIP basically involves equipment and processes that permit cleaning without dismantling equipment and with minimal operator involvement. The goal is to clean product-contact surfaces of processing machinery, vessels and piping. It often involves highpressure sprays, chemicals and sterilizers, and elevated temperatures. It ensures that equipment is free of dirt, organic contaminants and microorganisms, resulting in high plant hygiene and product safety. Founded 25 years ago, Progema Engineering has gained extensive expertise with dairy applications and understands that cleanliness and safety are critical. “All components used for our systems have to meet the high standards of the food industry. In addition, we always guarantee that our machines are food-safe, despite customizing them to individual customer’s needs. That’s why we decided to use pneumatic components from AVENTICS when configuring our Forma4 machine for automation,” said Daniele Barbieri, co-owner and head of electrical engineering.
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The CL03-EV valves regulate cylinder movements. The IP69K-rated units have no indentations that could trap particles and are specifically designed to handle high-pressure washdown applications.
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Machine forming and turning The Forma4 machine adapts 21st-century methods to the forming and turning of Grana Padano and Parmigiano-Reggiano cheese wheels. Pneumatic units built to high hygienic standards perform essential handling functions. Specifically, corrosion-resistant, double-acting AVENTICS cylinders from the ISO CleanLine (CCL) series close the round molds and ensure that the whey is pressed out by applying the appropriate pressure. Later, when the cheese wheels are turned, the cylinders keep the molds under tension. AVENTICS CL03-EV valves regulate movements and mount directly on the cylinders. The CL03-EV valves are ideal for such applications due to their tailored design and the high IP69K protection class. AS5 series maintenance units—modular filterpressure regulator-lubricator combos that round out the complete, installed pneumatic system— provide 5 µm filtration and ensure proper compressed-air preparation for efficient production.
Optimized for OEM requirements at a lower price. PHD, Inc. is setting a new standard in pneumatic actuators. PHD Optimax® products are designed and tested to meet the demands of the industrial market for optimum price savings. These economical, efficient and reliable actuators complement PHD’s option-rich product lines.
Food-friendly pneumatics “The Clean Line concept from AVENTICS immediately convinced us,” confirmed Boceda. He also lists the consultation and integration of the pneumatic
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8 • 2018
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specialists during the construction phase of the new system as deciding factors in the selection process. “In cheese production, all components must comply with premium standards and endure countless cleaning sequences. Therefore, the right choice of components and their materials is just as important as the use of hygienic components that are easy to service, clean, disinfect and maintain,” he said. AVENTICS long-term expertise in the design of hygienic components plays a key role, demonstrated by the special features of the “best-in-class” components, which have been especially designed for optimal food safety. This means: no indentations or sharp edges, use of food-grade materials and lubricants, as well as high resistance to chemicals and corrosion. The overall design facilitates cleaning, disinfecting, and sterilizing of the machine, thus reliably preventing the risk of microbial contamination. Series CCL CleanLine air cylinders meet ISO 15552 and ISO 21287 standards and feature a smooth profile that ensures easy-to-clean hygienic surfaces. The design minimizes potential pocket areas where dirt and contaminants can collect, making them ideal for washdown applications and other packaging or handling operations. They are available in two versions. Standard CCL-IS series cylinders (ISO 15552) come in bore sizes from 25 to 125 mm bore and maximum stroke of 2,800 mm (double acting) and 1,500 mm (through piston rod). They’re built with anodized-aluminum end covers and tube, stainless steel piston rod and tie rods, a polyester scraper, and use ISO 21469 (NSF-H1) lubricants. They have a rated operating pressure of 1.5 to 10 bar (22 to 147 psi) and temperature range of -20° to 80° C (-4° to 176° F). A magnetic piston is standard. The CCL-IS cylinders also feature “Ideal Cushioning” capability that minimizes both deceleration time and end-ofstroke impact, and as a result helps increase equipment productivity and reduce maintenance requirements. Related CCL-IC cylinders (ISO 21287) come in 16 to 100 mm bores and maximum strokes to 500 mm in double-acting versions and 16 to 63 mm for single-acting products.
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It used to skew and chatter.
Now it runs like a Swiss watch. This press applies up to 3000 tons to form composite automobile panels. Delta’s RMC does multi-axis control of position and pressure to keep every moving part in perfect synchronization.
Look to Delta RMC motion controllers and graphical RMCTools software to make complex motion design easier, smoother, and more precise. Call 1-360-254-8688 or visit deltamotion.com Find case studies like this about Wuxi LANLI Machine Tool Co., Jiangsu, China, and many others. Watch training videos to see how Delta motion can make everything work in perfect, precise harmony. Delta RMC Motion Controller Family
1 to 32 axes
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The Forma4 machine, built to rigid Cleaning in Place standards, replaces manual forming and turning of Grana Padano and Parmigiano-Reggiano cheese wheels.
The CL03 Clean Line series of pneumatic directional control valves are specifically designed to handle high-pressure (100 bar) washdown applications. The units are designed such that there are no indentations that could trap particles. The cover and base plate are made of fiberglass-reinforced polyamide to resist detergents and aggressive chemicals. A hydrogenated acrylonitrile butadiene rubber (HNBR) seal prevents ingression between cover and base. This material handles higher temperatures than do nitrile rubbers and has excellent resistance to many chemicals, steam, hot water and ozone. CL03 (Clean Line) directional valves have a zero-overlap spool design. Working pressure is up to 10 bar and they handle ambient temperature from 0° to 50° C (32° to 106° F). The units are available as standalone single valves (CL03-EV version) with nominal flow of 700 lpm; or in manifolds of up to 16 valves that, depending on the size, can handle flows of up to 1,100 lpm.
Imagine a 90% reduction in size and weight. The patented Cyclone Hydraulic Reservoir is designed to rapidly remove air from hydraulic fluid. The result? Weight and size reduction, along with corresponding savings in fluid expense.
cyclonehydraulics.com 62
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The American Champ Dump Pump
Paving the Way The American Champ Dump Pump is built in America with quality globally sourced parts
1500 Frost Road Streetsboro, Ohio 44241 | 330.626.2801 | www.permco.com PERMCO 1-18.indd 63
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Typical switch time for the CL03 is 16 msec on and 25 msec off. The valves are available with multipin electrical connections, or can be configured to support various fieldbus protocols. Serial communication options for industrial networking permit advanced diagnostic capabilities. Customized systems Thanks to their protection against high-pressure water and steam jet cleaning and a hygienic design, Progema Engineering can install the individual CL03-EV in decentralized locations. Mounting them directly on the actuators, rather than remotely in a protective control cabinet, reduces the lengths of the compressed air lines and minimizes the volumes to fill each cycle. That, in turn, means lower air consumption and pressure losses and faster cycle times, thus increasing machine efficiency and throughput. Progema Engineering uses individual valves in the Forma4. “The modular valve system offers 17-1864_Kaw_Horz_9x5.25.pdf
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countless possibilities, and this solution corresponds exactly to our requirements in the standard machine. However, depending on the need and specific end-use in a dairy, we can easily expand the CL03,” said Barbieri. The mold-turning device equipped with AVENTICS pneumatics is one of the components of the automatic warehouse system that Progema Engineering offers its customers. The modern system with several storage levels requires significantly less space, facilitates access to the molds, and creates ergonomic workplaces with individual height settings. As an optional supplement to this modular, expandable concept, customers can use the Forma4 device for further automation. In the production of Grana Padano and Parmigiano-Reggiano, the Forma4 machine is used on the first day to remove the excess whey and form the cheese shapes.
In further steps, the cheese is repeatedly immersed in brine for 21 days, followed by seasoning in the last phase. “The regular turning of the approximately 40-kilogram cheese wheels is not an easy task and can quickly lead to back pain in employees. Instead, our automatic turning device takes over this monotonous, heavy-duty work and completely eliminates that problem,” emphasized Barbieri. This makes the Forma4 turning device a sensible investment—especially considering that about 3 million wheels of Parmigiano-Reggiano and about 5 million wheels of Grana Padano cheese are produced in the region of origin each year. FPW
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PRODUCT WORLD
Collaborative Robot Vacuum Tool (CRVT) launch Bimba bimba.com The new Collaborative Robot Vacuum Tool (CRVT) offers a plugand-play end effector option for collaborative robots. Developed to meet the versatile nature of collaborative robots, the CRVT comes off-the-shelf as a complete solution — no external valve required. Although designed to support a variety of applications with minimal configuration, a wide array of pump options enable users to meet the vacuum requirements of their application.
grippers. They only require access to one side of the work piece. In addition,
Collaborative robots are making it easier than ever before for
Vacuum end effectors offer many advantages over mechanical
manufacturers to implement automation. The CRVT is designed
vacuum grippers can handle a variety of part sizes, shapes, and weights
to be controlled using the I/O connection built into the robot. No
without making changes to the robot’s settings. As part of Universal
additional software or controls are required. That means simply
Robots’ UR+ program, the CRVT is tested and approved to integrate
connecting the tool to the robot and supplying an air-line to it.
directly with UR robots, ensuring set-up, programming, and operation
Once that’s done, the user is ready to program.
can all be accomplished with ease. Compatibility with additional robotics manufacturers will be available in the future.
Multi-purpose hydraulic hoses for replacement market Gates gates.com The new Gates MXT family of hoses is a lighter weight and more flexible solution that meets or exceeds a wide range of industry standards, and addresses both replacement market and original equipment manufacturer needs. It is designed for applications across industries such as agriculture, mining, construction and other end-markets with demanding performance requirements. Features • Meets or exceeds multiple industry standards, covering
• More flexible with an average of 40% decreased
force-to-bend (compared to similar Gates products),
allowing for faster and more ergonomic installation
approximately 90% of the hydraulic wire braid product applications
• Up to 30% lighter weight for improved fuel efficiency,
• Tested to exceed 600,000 impulse cycles — three times
easier handling and reduced shipping costs
greater than industry standards
• Compatible with Gates extensive line of hydraulic couplings 66
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(crimp specifications available)
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8/14/18 11:57 AM
40 Years of Innovation. Winco.
Air preparation products
Breathers and Strainers
Emerson emerson.com The ASCO Numatics series 653 air preparation products are available
JW Winco offers special valves for no-mess oil changes and components for safe container ventilation and breathing.
in ½, ¾ and 1-in. port sizes. This allows users to power more products
■
from the same filter-regulator or lubricator (FRL), or reduce pressure
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drop across the system, both of which enable potential energy and
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cost savings. The range of the series 651, 652, and 653 products
Controlled draining of the medium No pollution of the environment Compact design for universal use Long service life
consists of filters, regulators, filter regulators, lubricators, soft starts, quick exhausts, diverter blocks, and shut off valves. With the industry’s highest flow characteristics, related to size, the ASCO Numatics series 651, 652, and 653 products are suitable for use in any application that requires high volumes of air or where space is limited. Original equipment manufacturers will benefit from the wide temperature range (–40° to 80°C), and ATEX and CUTR certification.
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Explore our full product line online or contact us with your application requirements. J.W. Winco, Inc. Phone 800-877-8351 Fax 800-472-0670 Email sales@jwwinco.com www.jwwinco.com
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PRODUCT WORLD
Vacuum gripper for collaborative robot Piab piab.com The Kenos KCS gripper enables a collaborative robot (cobot) that can handle just about anything, anywhere, at any time. This makes it a suitable "co-working" tool, especially for small businesses, where flexibility is essential. Originally developed together with a leading cobot manufacturer as a tailor-made automation tool for one customer, the resulting vacuum gripper cobot proved so successful that Piab decided to offer it more widely.
Combining air-driven COAX technology for vacuum ejection with an easily
replaceable technical foam that molds itself around any surface or shape, the Kenos KCS gripper can be used to safely grip, lift and handle any object. Standard interface (ISO) adapters enable the whole unit to be attached to any cobot type on the market and, with a body made in a lightweight 3D printed material, it can be easily moved to perform different jobs in different parts of a production site, warehouse or other setting.
It’s not a web page, it’s an industry information site So much happens between issues of Fluid Power World that even another issue would not be enough to keep up. That’s why it makes sense to visit fluidpowerworld.com and stay on Twitter, Google plus, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the hydraulics and pneumatics community.
fluidpowerworld.com FPW house ad 8-18_half horizontal_use.indd 1
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For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com
Miniature LVDT position sensors
Open circuit axial piston pump
NewTek newteksensors.com
Danfoss powersolutions.danfoss.com
This miniaturized series of AC-operated position sensors has a
The D1 pump is a high-pressure, high-flow variable displacement axial-
lightweight and compact ⁄8-in. diameter size for reliable linear
piston pump, developed specifically for open-circuit systems in the
position feedback in rugged industrial applications with tight
most extreme application environments. Its design makes it a suitable
space and weight restrictions.
solution for mining, heavy-duty construction, forestry, material handling
and marine, oil and gas markets.
3
Resistant to harsh and high-pressure environments,
the M-375 series miniature AC LVDTs provide high response
dynamic measurement for machine operations such as
portfolio to include higher hydraulic power options — up to 160 gpm
robotics, automatic inspection equipment, plastic injection
[600 lpm] — for OEM customers. Working seamlessly with the new PVG
molding, hydraulic cylinder and valve positioning, downhole
128/256 high flow valves, OEMs have the ability to extend hydraulic
drilling, and dimensional gaging. In addition to performing in
support for all their high flow system needs. The pump’s open-circuit
the aerospace, oil and gas and manufacturing industries, these
control options make it suitable for drill rigs, artificial lift systems,
compact LVDTs serve as components within medical devices
harvesters, mulchers, wheel loaders, dumpers, pipe-handling systems
with tight space restrictions and high accuracy requirements.
and more.
The addition of the D1 pump expands the Danfoss open circuit
With a corrosion-resistant, nickel-iron alloy housing
and core, the environmentally-robust sensors operate in
Features:
temperature extremes of –65 to 275° F (–55 to 135° C), with
•
Four displacement options from 13,0260 cc
optionally extended ranges of –65 to 400° F (55 to 204° C ). A
•
Pressure, load sense, power limiting and displacement controls
vented design exposing the interior coil assembly equalizes
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Output pressure up to 350 bar [5,075 psi] continuously, 400 bar
pressure inside and outside the LVDT, enabling greater
[5,800 psi] intermittently
endurance to high pressure and temperature as well as shock
•
An integral charge pump allows the D1 pump to run at speeds
and vibration.
up to 2500 rpm
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PRODUCT WORLD
Load-holding valves ensure safety Valvole America valvoleamerica.com Load holding valves from Valvole America are available in a wide range of cartridges or assembled into valve blocks. They secure the last commanded position of an actuator by preventing fluid from escaping work chambers, with “zero” leakage. They ensure low leakage when closed, with less than 5 drops/min when the valve is closed with 85% of set pressure applied to load holding port.
They are rated for standard maximum operating pressure of 350 bar
(5,000 psi), and optional maximum working pressure of 420 bar (6,100 psi). They offer reliable and stable hydraulic performance over full temperature range of –30° to 100°C (–22° to 212°F).
With system cleanliness level recommended at ISO 4406 19/17/14
for all high-pressure components, they offer a high level of contamination resistance. The critical components of the load holding valve are hardened and do not sustain performance degrading damage with normal levels of fluid borne contamination.
Electric-operated variablepriority flow divider Webtec webtec.com The new VFD120E electric-operated variable-priority flow divider was designed specifically for use on mobile machinery. It allows the speed of hydraulic motors on trailed agricultural attachments and on mining and construction machinery to be controlled remotely. The 420 bar rated VFD120E will offer greater levels of efficiency than previous generation products when it is launched in the third quarter of 2018.
As a three-port pressure-compensated variable-priority flow divider with an
electric drive motor, the VFD120E can provide constant flow to a primary system while still powering a secondary system. To explain in more detail, priority-type flow dividers split a single input flow into a ‘priority’ (regulated) flow and a ‘bypass’ (excess) flow that can be returned directly to the oil reservoir or used to power a second system. This capability is possible thanks to the valve’s adaptive pressure compensation characteristics, meaning both the priority and bypass flows can be used to drive separate circuits, even under fluctuating loads. In many instances, this functionality eliminates the need for another pump to operate a second system. 70
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Edited by: Paul J. Heney • VP, Editorial Director
COMPONENT FOCUS
When should you change your compressed air filters? The short answer to when you should replace air filters is when the cost of operating with clogged filters exceeds the cost to replace them. Compressed air filters are important to the quality of air produced by the air compressor and dryer, and the condition of these filters can also affect the energy efficiency of the system. The worst type of filter is one with no installed pressure differential gauge and no indication of any past maintenance date. The condition of a filter like this can be easily ignored, leading to downstream pressure problems — sometimes incorrectly blamed on the compressor. Eventually, the pressure problems will disappear when the filter fails internally, leading to air quality problems. Filters like this need to be changed on a time schedule. Once done, the date of change should be added to the maintenance tag. The frequency of change depends on how much the filter is used; that is, how much air is flowing through it, but the manufacturer’s recommendations should be followed as a minimum. Your best bet is to have an accurate differential gauge installed across a filter, or a set of filters, to be used in detecting when change due to pressure differential is required. Care should be taken in reading these measurements. The pressure differential of a filter varies exponentially with the flow through it, as a square function. Thus, the reading shown on the differential gauge only really shows the true condition of the filter when the flow is near the filter rating, sometimes only occurring during short duration peak flows. Sometimes, coalescing filters will never develop excessive pressure differential across the element, but they will stop working properly as they age, allowing lubricant mists downstream to contaminate equipment. For this reason, pressure differential should not be the only criteria in changing a coalescing filter. A typical clogged filter on a fully loaded 100-hp compressor could cause additional compressor power consumption of about 0.5% for every psi across the filter. This would consume about 4 cents/hr (at 10 cents per kWh electricity cost) or about $3,700 per year in extra energy for every extra psi of differential. Thus, replacement of this filter might be wise once differential reaches 5 psid or above. Additional costs would be incurred if the pressure differential also affects the control of the compressor, such as restricting the flow to a
downstream main storage receiver. Further costs might be added if the filter has a drain installed that wastes compressed air. Note that the main system filters are not the only important filters in a compressed air system — the filters inside the compressor and ones installed on compressed air operated machines must be maintained, too. It is possible for a $20 filter element problem in a small critical machine to force the main compressor pressure setting to rise significantly to compensate, causing thousands of dollars in additional electricity costs. It is also important to ensure the filter actually needs to be there in the first place. Quite often, routinely installed compressed air filters are not actually required in a system, but have been placed as part of an installed assembly or as part of a plant-wide standard. Maintaining unnecessary filters is the worst waste of time and resources of all. Consider assessing your filtration system for appropriateness and removing redundant filters.
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WHAT Connect with thousands of DO engineering YOU design THINK? professionals online.
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AD INDEX
Kawasaki Precision Machinery ... 64 Kraft Fluid Systems ..................... 38 Lillbacka USA, Inc. ........................ 9 Main Manufacturing .................. 27 Marken Manufacturing .............. 39 MP Filtri USA Inc. ....................... 11 O+P SrL ......................................... 4 OEM Controls ............................. 67 Permco, Inc. ............................... 63 PHD Inc. ...................................... 59 Price Engineering ....................... 62 Prince Manufacturing Co. ............ 6 RYCO Hydraulics ......................... 44 Schroeder Industries .................. 53 Servo Kinetics ............................ IBC SIKO Products ............................. 52 Smalley Steel Ring ........................ 5 Super Swivels ............................... 2 Tompkins Industries ............. IFC,27 Veljan Hydrair ............................. 43 Webtec ....................................... 54 Yates Industries .......................... 45 Zero-Max, Inc. .............................. 7
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LEADERSHIP TEAM Co-Founder, VP Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memic Co-Founder, Managing Partner Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson
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Hydraulic Servo &
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Servo Kinetics (SKI) has been in business for 40 years, before many of the competitor’s even existed. Our capacity for servo and proportional valve repair far exceeds any of our competition. SKI serviced the NASA Houston Shuttle Simulator for 25 years, through three major upgrades of the Electro-Hydraulic, closed loop motion system.
The shuttle used 12 servo valves on “closed Loop” precision actuators. We suggest you visit our website for further details on our complete services, there are reference letters there you can read from FedEx, L3, Cedar Point, Fidelity and Delta Airlines. If you want/need a vendor that can meet any hydraulic challenges you have, SKI can do that for you. We know how to meet your needs.
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