Fluid Power World February 2019

Four tips on preventing compressed air waste p. 42

Smart solutions at Hannover Messe p. 58

bauma returns with record-breaking numbers p. 62

www.fluidpowerworld.com

February 2019

Hydraulic

motion system

tames rough seas

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FluidLines Mary C. Gannon • Editor

The power of connections Engineers and others working in fluid power understand the importance of connecting with their peers. This is especially true for those younger individuals just entering the field.

Fluid power is a technology that many (myself included) admit they “just fell into.”

Very few actually enter it intentionally (apart from those involved in family businesses, I am sure). How can we engage those individuals and make sure they end up loving fluid power as much as we do?

Mentoring, that’s how. Last year at our Fluid Power Technology Conference, our panel of women in fluid power all agreed on one thing — that mentoring is crucial to the industry’s future, as we work to not only get more women designing fluid power technologies and systems, but young people in general.

One organization that’s working towards this is the FPDA, said Bill Haley, FPDA Board of Directors Member from Force America, in a recent letter to members.

“Through its careful and deliberate pairing of aspiring future leaders (mentees) with accomplished managers and executives from other non-competing FPDA member companies (mentors), the FPDA’s mentorship program has fostered confidential, mutuallyconsultative relationships between transitioning generations of fluid power leadership,” Haley said. “That’s an impressive sentence, I know, but it’s as important as it sounds.”

The resounding complaint nationwide is that workforce development is a major challenge. This is no different at FPDA member companies, said Haley. Approximately 60% of FPDA member companies have fewer than 50 employees. These smaller companies may struggle to provide their staff training and guidance in the industry, leaving young fluid power professionals few opportunities to network with industry peers, and even fewer to engage with leadership of other fluid power distributors.

Haley said that mentees currently in the FPDA program have overwhelmingly agreed mentorship has been invaluable in their career development. Some mentees likened working with their mentor to having a personal coach or an unbiased advisor. “The fact that program mentors can offer different perspectives on fluid power distribution industry topics like ecommerce, HR issues, freight/logistics or CRM software has been especially useful to some,” Haley said. “Mentees say they trust their mentors and enjoy being able to bounce ideas — even the bad ones — off their mentor without doing damage to their reputation with their direct supervisor.”

But participation is key, said Haley. FPDA plans to expand its free mentorship program in 2019 and is encouraging its Young Executives and senior-level managers of member companies to get involved. FPDA members can find more information at fpda.org.

And the rest of us? Perhaps you need to begin mentorship programs at your own companies. Reach out to organizations where you belong and see how you can start a program there or get involved in one they may already have. Our industry’s future depends on it.

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From the Field

Making that human connection stronger At the last FPDA Industry Summit, attendees heard Tim David speak about human connections, something that is increasingly overlooked in today’s technology and social media-soaked world. He explained how research has shown that the more real, physical, in-person connections you have in your life, the better. And that means not just at home, but at work, as well.

Here are some of his top takeaways, which will hopefully inspire you to put down that mobile device and go speak with someone as soon as you finish reading this!

•

About 85% of your financial success is due to your personality, your ability to communicate, negotiate and lead. In other words, people skills. You won’t get that from electronic devices, you’ll only develop it over time through person-to-person interactions.

People are increasingly becoming addicted to their smartphones. David highlighted a survey which showed when people are willing to take out their phone and be interrupted by technology. 49% percent said during a meal, which probably wouldn’t surprise most people. But 24% said while in the bathroom. If you’re in a meeting, 22% are willing to do so. And an amazing 11% of people are willing to be interrupted by their cell phone during sex.

What you don’t focus on gradually disappears over time. This includes human empathy — the ability to know what other people are thinking and feeling. Ask yourself what that means for business? To provide any semblance of customer service, you need empathy … just as you do for sales and marketing. Plus, leadership is something that is improved with empathy. Studies have shown this, experience has shown this: life is improved with empathy.

Remember to use people’s names, early and often. Coke has recently used this magic word in their marketing, with people’s names on their cans. People are driven to make decisions by the sound of their own name. As Dale Carnegie said, “Remember that a person’s name is to that person, the sweetest and most important sound in any language.” When you’re writing, start every email with their name. When you’re addressing them face to face, to have the impact, use people’s names.

•

•

•

FPW

PEOPLE, PASSION & SOLUTIONS

Paul J. Heney

VP, Editorial Director pheney@wtwhmedia.com

On Twitter @DW_Editor 4

From The Field 2-19 FPW_v3.indd 4

FLUID POWER WORLD

2 • 2019

www.fluidpowerworld.com

2/19/19 11:31 AM

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FEBRUARY 2019 C ontents |

vol 6 no 1

|

fluidpowerworld.com

•

2

•

2019

F E AT U R E S

OFFSHORE TECHNOLOGY

Hydraulic motion system tames rough seas Active heave compensation uses proven technologies and components for safe positioning during complex offshore activities.

PNEUMATICS

Four ways compressed air systems waste energy (and what to do about it) Eliminating leaks, misuse, overpressurization and pressure drop can ensure efficient compressed air systems.

QUICK DISCONNECT

The benefits of custom quick disconnects Non-standard QDs often lead to a better system design and, surprisingly, lower overall costs.

SHOW PREVIEWS

Get smart solutions for smart factories at Hannover Messe 2019 Hannover Messe returns April 1-5 with its Integrated Automation, Motion & Drives (IAMD) show spanning 14 exhibition halls.

Record-breaking bauma descends upon Munich The largest trade fair for construction machinery runs April 8 to 14, bringing together more than 3,500 exhibitors from 55 countries.

34 42 62 D E PA R T M E N T S

51

02 FluidLines 04 From The Field 10 Korane’s Outlook

58

12 Association Watch 16 Design Notes 22 Fundamentals

62

24 Research and

Development 26 Energy Efficiency 28 Distributor Update 30 Training 66 Products

70 Component Focus 72 Ad Index A | S | B | P|E Fostering B2B editorial excellence

ON THE COVER

Next-generation active heave systems, such as the one used on this gangway, compensate for complex linear and rotary motions along several axes. | courtesy of Barge Master bv

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2 • 2019

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VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh

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

Videographer Graham Smith gsmith@wtwhmedia.com

Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane Contributing Editor Josh Cosford @FluidPowerTips Contributing Editor Carl Dyke @carlindustry CREATIVE SERVICES

www.MAINmfg.com/flg Phone: 800.521.7918 info@MAINmfg.com Grand Blanc, MI USA

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com NEW MEDIA/WEB/BUSINESS DEVELOPMENT Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Specialist Brian Furda bfurdar@wtwhmedia.com Multimedia Specialist Jaeden Froese jfroese@wtwhmedia.com SALES VP, Publisher Michael Ference 408.769.1188 mference@wtwhmedia.com

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Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com Garrett Cona 213.219.5663 gcona@wtwhmedia.com @WTWH_gcona Mary Ann Cooke 781.710.4659 mcooke@wtwhmedia.com Bill Crowley 610.420.2433 bcrowley@wtwhmedia.com Neel Gleason 312.882.9867 ngleason@wtwhmedia.com @wtwh_ngleason

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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.

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FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2019 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

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FLUID POWER WORLD (ISSN 2375-3641) is published seven times a year: in February, April, May, June, August, October, and December by WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Fluid Power World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

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2 • 2019

2/19/19 2:49 PM

Wind Energy Support GAT ROTARY JOINT & SERVO/PROPORTIONAL VALVE REMANUFACTURING

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•

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•

THE SLEEVES ARE “BORE GAGED” TO CHECK FOR ROUNDNESS OR WEAR SPOTS. THE FIT BETWEEN THE SHAFT “OD” AND THE SLEEVE “ID” IS CRITICAL. IF THE SLEEVES ARE BAD WE MAKE NEW ONES.

•

ALL BEARINGS AND SEALS ARE REPLACED WITH NEW VITON COMPOUND

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

Let’s play two!

Longtime baseball fans know well of the late, great Ernie Banks. The first African-American member of the Chicago Cubs, he played 19 seasons, was a 14-time All Star, won two league MVP awards and was a first-ballot Hall-of-Fame inductee. Noted for his boundless energy and passion, legend has it that on an oppressively hot summer day Banks rallied his teammates with the famous saying, “It’s a beautiful day. Let’s play two.”

Fans of fluid power might want to channel Banks’ enthusiasm and contemplate a visit to Germany this spring, as the Hannover Fair and bauma are running back-to-back.

With an easy train ride, one could hit both in the span of a week.

These massive, mind-boggling trade fairs are unlike any we see in the U.S. — combined, they are expected to attract more than 800,000 visitors from nearly every country worldwide — and fluid power will have an outsized presence at both. Virtually | Messe München every type of component, sensor, control, software and system imaginable will be found among 14 exhibit halls in Hannover. And it’s hard to find a mobile machine without hydraulics among the thousands that will be on display at bauma.

While one show leans industrial and the other to mobile and mining,

Finally, to address the shortage of skilled workers, fair both address common hot-button issues for fluid power. Consider digital organizers have arranged young-engineer events. Relatively new integration. It’s permitting more exacting control, better performance and graduates and university students can get free career-coaching higher efficiency in hydraulic and pneumatic systems across the board. sessions with industry experts, try out simulators and learn Industry 4.0/IoT is a ubiquitous theme at Hannover, with networked about internships, apprenticeships and non-traditional technical production, predictive maintenance and machine learning positioned as the professions. Special networking events for women target successful basis for “smart” factories. career strategies and novel work options.

At bauma, the trend is toward cloud-integrated construction sites

Well over 200 North American firms will be exhibiting, and machines equipped with sensors and communication interfaces that along with countless other European and Asian companies with improve precision, lower fuel consumption and emissions, anticipate a strong U.S. presence. To those executives attending: Consider breakdowns and manage entire fleets. Automated machine functions and bringing along one or two of your young engineers. From a careerexpanded use of driverless vehicles will drive productivity. development standpoint, the experience would be invaluable. It’s a

Likewise there’s electrification. Industrial fluid-power cylinders have unique opportunity to meet key players, suppliers and competitors, been fighting neck-and-neck with electromechanical drives for years. Now learn about the newest trends and see the latest innovations. electric construction machines, while still just novelties or prototypes, The impressions will be long-lasting, foster a more broad-minded are gaining momentum in the push for zero-emission vehicles. That could perspective and, ultimately, make them more-valuable employees. profoundly affect fluid power.

Hannover and bauma? Let’s play two!

Other areas of emphasis include everything from new materials and coatings to virtual reality for training and servicing. R&D clusters will For more details on these trade fairs, see our accompanying glean the future with topics like cognitive systems, bionic robotics and the stories on page 58 and 62. growing importance of artificial intelligence in production.

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ASSOCIATION WATCH

Edited by Mike Santora • Associate Editor

Nominations being accepted for Fluid Power Hall of Fame A special award has been established to acknowledge those individuals who have dedicated their careers — and have made significant contributions to —fluid power technology. The International Fluid Power Society is the 2019 Hall of Fame host and is now accepting nominations for the 2019 Inaugural Class of the Fluid Power Hall of Fame. Nominees and award recipients will be announced on June 19 – Fluid Power Professionals’ Day. The success of the Fluid Power industry, both in hydraulics and in pneumatics, is not in its hardware, pumps, valves, cylinders, and hoses – but rather the success is through the efforts of the dedicated individuals: innovators, researchers, application engineers, educators, as well as sales and service personnel who are keeping the industry alive and well. These people are the reasons that the industry continues to thrive.

Any person can nominate an individual, living or deceased, who demonstrated excellence within their 25-plus year fluid power career. Nominations are being accepted through April 15.

Eligibility for the award includes: • •

Verifiable 25 cumulative years in the field of fluid power industry.

Those nominated will be asked to complete a 13-question application.

A panel of judges will review and select the 2019 Inaugural Class.

Nominees will be recognized on a standalone website, which is under development.

FPW

To nominate an individual, visit ifps.org/hall-of-fame.

Cross-sector collaboration at the MPT Expo The 2019 Motion + Power Technology Expo will connect the top manufacturers, suppliers, buyers, and experts in the fluid power, mechanical and electrical industries. The biennial event will take place in Detroit, October 15-17, at the Cobo Center.

For three days, end-users will experience the latest technology, products, and services, while exhibitors will gain best practices and new ideas from like-minded colleagues and cross-sector collaboration. Exhibitors will conduct demos and host seminars as well as offer-up technical expertise. The event will also feature 30-minute presentation sessions with an additional 15-minute Q&A portion on topics like blockchain, cybersecurity, Internet of Things, and more.

FPW

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IF YOU USE HYDRAULIC FLUIDS

ASSOCIATION WATCH

ESA hosts Annual Convention in conjunction with FPTC For the second year, the Equipment Service Association in conjunction with the 2019 Fluid Power Technology Conference, will be hosting its Annual Spring Convention at the Milwaukee School of Engineering, May 13-15.

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From basic to advanced fluid power, sessions will target the “how to” on the following topics: • Properly size a system • Maintain control • Prevent and control contamination • Read schematics • Troubleshoot • Ensure reliability The Equipment Service Association is a proud sponsor of a Fluid Power Technology Conference speaker, and will also be showcasing the organization at a booth in the Exhibitor Hall, and hosting ESA Member Annual Convention events throughout the conference.

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ASSOCIATION WATCH

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DESIGN NOTES

Mary C. Gannon • Editor

Rota Engineering’s EL external and LA internal transducers are being used on Roadtec’s SX Reclaimer machines for road maintenance and repair.

Tough transducers ensure precise road maintenance while reducing machine downtime Roadtec manufactures a variety of road building and asphalt paving equipment, relying on hydraulics for the power density and precision control it provides in cutting, paving and more. The company’s soil stabilizers and road reclaimers are well balanced and constructed with a sealed box frame to make them as durable and versatile as possible.

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Used for road rehabilitation, cold recycling, or soil stabilization, different models feature hydraulically driven cutters, hydraulically driven suspension for precision cutting depths which is done easily via a push button, hydraulically adjustable doors to allow for easy access to the engine compartment, and hydraulically adjustable front and rear doors combined with optimal drum position in the cutter housing to provide sizing and material flow.

P

When servicing the magnetostrictive sensor buried inside the main lift of its SX model reclaimer/stabilizer machines became too difficult and time-consuming, Roadtec turned to Rota Engineering for a simpler solution. The company replaced all magnetostrictive transducers mounted on the main lift cylinder with Rota’s internal or external transducers where it was difficult to replace and maintain the transducer.

Rota’s external transducer allows for

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2/19/19 9:44 AM

DESIGN NOTES

fast on-site maintenance and minimum machine downtime. This is particularly useful when the cylinder is large and well integrated into the machine, said Michael Moore, Technical Sales for Rota.

“Prior to switching to Rota Engineering sensors in 2010, Roadtec had less than satisfactory experience with magnetostrictive sensors buried inside cylinders that turned out to be difficult and time-consuming to service. To service a sensor, they had to fully remove the hydraulic cylinder from the machine using a mobile crane or skid steer loader.

Servicing the sensor in the field turned out to be unfeasible in practice as the hydraulic cylinder had to be returned to a cylinder repair facility,” Moore said.

“Minimizing downtime was and still is a priority in terms of Roadtec competing for market share. Another aspect to minimizing downtime is sensor reliability. With Rota designs, Roadtec has met their service level expectations.”

Roadtec first installed Rota sensors on its SX models of its reclaimer/stabilizer, where hydraulic cylinders with linear sensors are used on elevation, cutter

door height and gate, and steering. Rota sensors were later retrofitted on its cold planers and material transfer vehicles (shuttle buggies).

The elevation cylinder supports the mass of the entire machine on its cylinder pins. As such, unpinning one end of the cylinder to gain access to the sensor was not practical as either a mobile crane or skid-steer loader would have to be used to relieve the force on the pin to remove it. For the elevation cylinders, Roadtec elected to go with the Rota external linear (EL) series sensor. The Rota EL sensor allows the user to replace the sensor element without touching the hydraulic cylinder at all. Protection of the sensor is afforded by the elevation support box beam, which surrounds the elevation cylinder and sensor.

Rota’s EL sensor is suitable for steering and long cylinder applications. It uses Rota’s non-contact, Hall-effect technology, which does not require gun drilling and

A look at Rota Engineering’s ELA transducer installed on Roadtec’s SX-4 elevation-cylinder.

allows for easy on-site replacement. In this design, an internal magnet communicates with the externally mounted sensor.

In other instances, Roadtec opted to use Rota’s LA series internally integrated sensors wherever possible as the cylinder tube provides best physical impact protection for the sensor. However, serviceability of sensors was also a priority, as downtime must be kept to a minimum.

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DESIGN NOTES

DESIGN NOTES

the best solution for accommodating both protection and serviceability requirements. Where the LA sensor is used on the machine, the hydraulic cylinder can be unpinned on one end to gain access to the sensor for service and/or replacement, which is easily supported in the field,” Moore said. “Rota’s Hall Effect sensor has flexibility in mounting design to accommodate this requirement. The other primary benefit to Roadtec was superior reliability of the Rota Hall Effect sensor compared to Roadtec’s prior sensor designs. Shock and vibration are virtually constant when the machines are in operation. Rota has field proven reliability in high shock, high vibration applications.”

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DESIGN NOTES

Mary C. Gannon • Editor

DESIGN NOTES

Environmentally friendly plug-and-play electrohydraulic braking system

Plug-and-play electrohydraulic braking systems from Dellner Brakes were introduced to the US market at this year’s International Workboat Show in New Orleans.

Dellner’s BUEL STL system provides a compact, self-contained solution for stopping, turning and locking ship propeller shafts on vessels of all sizes, as well as for industrial applications.

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Combining the very best of Swedish and German engineering from Dellner Brakes and sister company Pintsch Bubenzer, the new BUEL STL system provides a compact, self-contained solution for stopping, turning and locking ship propeller shafts on vessels of all sizes, as well as for industrial applications.

As the name suggests, the system combines elements from Dellner Brakes’ stopping, turning and locking (STL) systems with Pintsch Bubenzer’s patented BUEL electrohydraulic thruster/power package. According to Edgar Roca, VP for Dellner Brakes, “It functions as an HPU, but it requires about 70% less hydraulic oil than an HPU. It’s fully enclosed; therefore, we do not need to have any external hydraulic lines running to the system. And it allows us to power a complete stop, turning and locking system with a full enclosed hydraulic thruster.”

Because it needs no external piping, the system is compact, easy to install and, with the BUEL using only half a liter of high-performance synthetic oil (compared to as much as 30 l of hydraulic oil in standard hydraulic power units), it is cheaper to run and environmentally-friendly too.

“You don’t have to worry about any hydraulic fluid leaking. In the marine industry there’s a lot of concern — normally a lot of the brakes take their fluid from the water system — and there’s a concern there that they think the brake might take too much fluid and then you may have a steering problem,” Roca said. “So this eliminates that, cuts out the concern, and you have a fully enclosed hydraulic system directly to our braking.”

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DESIGN NOTES

At its simplest, the new system combines a Pintsch Bubenzer BUEL Model G, delivering up to 240 bar of pressure, with a powerful Dellner disc brake offering stopping force of up to 517 kN per unit. Customers can then choose to add a Dellner locking device that, available with hydraulic, electric or manual power, can deliver locking force of up to 1,300 kN. Customers requiring a full STL system can then also add a Dellner electrical continuous turning device, which uses an electric gear wheel to move the brake disc and attached shaft to any position – forwards and backwards – or turn the disc continuously, all with variable speed and turning force of up to 157 kN. A system with the above configuration and a 2.25 m diameter brake disc will provide 550 kNm stopping torque, 1,450 kNm locking torque and 155 kNm continuous turning torque (intermittent breakaway 233 kNm).

The stopping, turning and locking functions can be operated individually or as a fully automated system. There is also a wide range of options for the system interface, from manual hand operation to electronic control panels and even remote wireless operation through a smartphone or tablet — whatever the customer needs.

Roca said the BUEL STL is ideal for workboats, such as tugboats, icebreakers, and military vessels. “We really see it being a game changer for us on the work boats because of the fact they want small, compact shaft braking systems, yet they don’t want to do any modifications to the external hydraulic system,” he said.

“They want to have a fully enclosed system, without having to take fluid and pressure from the motor system.”

Dellner Brakes’ STL systems fit around the ship propeller shaft to enable faster directional changes with maximum maneuverability.

They also help lower fuel consumption, reduce the load on propulsion systems and make routine maintenance quicker, easier and safer. Securing the propeller prevents damage to the shaft and bearings if the vessel is drifting or buffeted by waves.

It also allows ROVs and divers to operate around the propeller blades in safety. When in the harbor, using the turning function to rotate the propeller can also help to reduce marine growth on the blades and lubricated shaft bearings. Roca said the BUEL STL can also be used in oil and gas, mining, port, and paper as well as any other type of industry that might require any type of emergency stopping, braking, turning solutions.

Dellner’s BUEL STL functions as an HPU but uses 70% less hydraulic oil than a standard HPU. The the self-contained system also eliminates leakage.

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FUNDAMENTALS

Edited by Mary C. Gannon • Editor

How does heat affect a hydraulic system?

Everyone knows that contamination can be catastrophic to a hydraulic system. But heat can also be detrimental to hydraulic fluid and the components within that system.

Heat contamination reduces oil viscosity, which in turn reduces the fluid’s ability to lubricate components. This thinning of the oil causes surface-on-surface wear. Without proper viscosity levels, as components rub against each other — such as a wear plate and the slippers on a piston pump — they wear at accelerated rates.

This wearing also softens metals, which in turn increases the rate of wear.

For example, anywhere there’s metal rubbing on and near to other pieces of metal (even if it’s two different materials such as bronze or stainless) as the metal heats up, it becomes softer and it wears away more quickly. This problem is exacerbated if other forms of contamination are present.

Additionally, heat can break down system seals.

As they break down, flecks of rubber can enter the system, causing internal contamination. And, if a seal fails, external contamination will easily enter through cylinder rods.

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Heat contamination also changes the chemical properties of hydraulic oil. It can reduce the additives in the hydraulic oils, increase sludge and also accelerate oxidation. It actually changes the nature of your oil, making what may have been a suitable oil a poor choice for your system.

Heat enters a hydraulic system in multiple ways. One culprit is ambient heat. For example, you may have a blast furnace dipping molten metal into a ladle. It is imperative that the hydraulic actuators and the oil used within them are designed for that type of environment.

Excessive system heat can cause hydraulic fluid to break down, resulting in lost viscosity, thinner fluid, and more damage that can cause catastrophic failure to internal components, such as this piston slipper pad or these pistons. | Image courtesy of Panolin

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Another thing to be aware of is internally generated heat; this often is generated from piston pumps, inefficient gear pumps or friction created by other internal components. For example, while useful in specific applications, low-speed, high-torque motors may only have a 60-70% efficiency rating. This means 30 to 40% of the system energy is wasted as pure heat. This internal heat reduces lubrication, increasing friction and reducing lubricity. This may eventually cause the motor to wear out.

So how to do you filter out or remove heat from a system?

First, you should try to design a system that doesn’t create it in the first place. Second, in regular maintenance, always keep an eye on the reservoir levels. You should have three times the pump capacity available in the reservoir. Ensure also that the reservoir is clean and not near heat sources (such as direct sunlight or machines that generate heat).

Finally, if there is any device that could be considered a heat filter, it would be a cooler or heat exchanger, which uses water or air to bring hydraulic fluid temperature down. Several types exist.

The first is a shell and tube heat exchanger, in which coolant water flows through internal system ports and tubing while the warmer hydraulic fluid circulates through others. The heat is transferred from one fluid to the other, thus bringing the overall fluid temperature down.

Shell and tube heat exchangers and brazed plate coolers use cooling water or fluids to bring hydraulic system temperatures down.

Upgrading to a brazed plate cooler helps increase efficiency, as these are extremely effective at removing heat from hydraulic systems. This design uses deep channels of aluminum or parallel plates with fins separating these plates. These channels create turbulence, with hot and cold liquids in alternation.

Air coolers can also be used. While not as effective, they are sufficient and often easier to use. These use a fan and radiator-type cooler, and often can be driven by hydraulic motors, simply to force cold air over the hot fluid inside.

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RESEARCH & DEVELOPMENT

Edited by Mary C. Gannon • Editor

Scandinavian International Conference on Fluid Power set for May

The AUT is spearheaded by the Faculty of Engineering Sciences. Fluid power automation is one of its main research areas. “We develop fluid power and automation technologies to minimize environmental impacts through automation and intelligent solutions. Our main research areas include sustainable drive systems and actuators, autonomous heavy machinery, and the robotic control of working machines,” Huhtala said. “In fluid power research we are following three principles: interdisciplinary research, the bridging of theory and practice, and cooperation with industry.”

Research papers are accepted from around the globe. Topics to be included in the conference include the following: Automation in mobile machines • • •

| Tampere Hall

The 16th Scandinavian International Conference on

Fluid power

Fluid Power – SICFP19, returns to Tampere Hall, May 22-24 in Tampere, Finland. The conference is organized and hosted by the Laboratory of Automation and Hydraulic Engineering (AUT) at Tampere University of Technology. It is co-hosted by is the Global Fluid Power Society. The organization and SICFP location alternates every two years between Tampere University of Technology and Linköping University in Sweden. The last event at Linköping featured more than 40 technical paper presentations under the theme, “Fluid Power in the Digital Age.”

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• • • • •

Digital hydraulics Displacement controlled systems High-pressure systems Pneumatic solutions Innovative components and solutions

Reliability and condition monitoring of fluid power and drives • • •

Aging modeling Fail-safe systems Life-cycle estimation

Sustainable systems and drives

This year’s conference will focus on various areas of fluid power automation. “As in previous conferences, the purpose of the conference is to provide delegates with a forum for sharing experiences with their colleagues and attend high-quality presentations that discuss the latest scientific developments in fluid power automation,” said Kalevi Huhtala, Professor Head of Laboratory and Chairman of SICFP19.

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Autonomous machines and vehicles Field robotics, teleoperation and remote handling manipulation Operator assistance systems

2 • 2019

• • • • •

Hybrid drives Energy storage systems Energy recuperation Renewable energy Environmentally friendly fluids

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2/15/19 1:04 PM

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ENERGY EFFICIENCY

Ron Marshall • Contributing Editor

False economy on air compressor purchase

A

A compressed air system used for engine start duty needed a new air compressor. The old unit had been troublesome and it was difficult to get parts. Purchasing was asked for quotes for a new unit and obtained three bids from various suppliers.

In comparing the prices for the replacement, the purchasing department representative saw that two of the bids were similar in price. One of these was the same lubricated screw compressor they had installed in another system — that had exactly the same application. But the third unit had a 20% lower cost, and the supplier had glowing references about the quality and long life their units provided. Purchasing felt it was a no-brainer, so they went with the lowest bid, saving $7,000 on the sale price.

About a year after installation, a compressed air auditor did some routine measurements to see how the systems in the facility were operating. Measurements revealed that the two engine start systems, one of which used the new compressor, had quite different operating costs. While one cost only about $2,000 per year in electrical consumption, the other, using the new compressor, consumed $25,000 per year in electricity.

Unknown to the purchasing department, the new compressor that had been purchased was stripped bare of any energy-saving features. This compressor, producing very little average air flow, ran constantly in a control mode called modulation and had no other operating regime except “constant run.” In modulation, this compressor runs constantly — and while doing so consumes no less than 70% of its full load power.

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This compressor was costing over ten times what it should have because it was missing a few important energy saving options.

The other system used a brand of compressor that runs in the more efficient load/unload mode, and these compressors were equipped with auto shutdown. This allows the compressor to completely shut down, using minimal power, between load cycles. As a result, the compressor spends most of its time turned off.

The purchasing agent had saved the company $7,000 in purchase costs, but his decision to buy based only on the initial price cost the company $23,000 in extra electricity costs for every year of compressor life.

This is false economy at its extreme. When purchasing air compressors, especially the lubricated screw variant, total life cycle costs need to be taken into account!

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www.fluidpowerworld.com

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DISTRIBUTOR UPDATE

Edited by Mary C. Gannon • Editor

The odds are good for a great NAHAD experience in April

N

NAHAD’s 35th Annual Meeting and Convention is taking over the Bellagio

Resort and Casino in Las Vegas, April 5-10, bringing together more than 1,000 hose industry professionals all under one roof. The event, geared towards both manufacturers and distributors, gives ample opportunities to network and learn from experts and each other through general sessions, organized and informal networking events, an exhibition, and social activities.

Saturday, April 6 The event will be kicked off Saturday with Ken Gronbach, demographer, futurist and author who writes about how countries’ age curves interact to create opportunities and challenges today and in the future. Gronbach’s presentation, “The Open Secret of the Demographic World” explores how waves of generations redetermine our fortunes and futures.

Gronbach determined the complex ways that America’s Baby Boomers, Generation X, Generation Y — and other generations in other countries — interact to shape the world’s societies. He will also talk about 28

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| Courtesy of MGM Resorts International

what the future will bring for people, profits and the planet.

Saturday’s highlights include an expanded speed networking program and an Emerging Leaders session led by Randy Disharoon, “Leaders Are Not Born. They Are Built.” Designed for company executives and sales/branch managers, this interactive course introduces the four phases of leadership development – Build Within, Build Around, Build Up and Build Out. The evening continues with a firsttimers happy hour and concludes with the popular Opening Reception, which

provides an excellent opportunity to network, meet old friends and colleagues, as well as meet new people while enjoying live entertainment, beverages, and food outdoors on the Bellagio terrace.

Sunday, April 7 Sunday morning affords companies a chance to host sales meetings on-site. The first general session begins at 10 a.m. with Sara Lebens’ talk, “How Women Will Boost Your Bottom Line,” which is sponsored by Women in NAHAD (WIN). She’ll provide tips on developing the most effective strategies

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During the Members’ Luncheon, The Carver Award will be presented and Mike Staver will present on “How to Stay Calm Under Pressure.” In this session, participants will learn what it takes to stay calm and focused even if they don’t like the circumstances. The final general session on Sunday will be a Distribution Workshop by Dirk Beveridge, “INNOVATE! How to Create Relevancy in the Age of Rapid Change.”

In this inspiring workshop, attendees will learn how how to create a culture of innovation. The evening concludes with manufacturer and associate hospitality suites.

Monday, April 8 In addition to tours, free time to have fun on your own, and more company meeting opportunities, Monday includes a general opening session with Denise Keating, “The Amazon Effect,” which will look at the Amazon Effect and offer insights on how and why disruptors are targeting traditional channels. Keating, President of DATAgility, will provide lessons that can be leveraged by distributors and manufacturers, so the industry can adapt and thrive in the age of disruption to remain the channel of first choice for their customers. www.fluidpowerworldonline.com

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Afterwards, attendees can choose from one of two UID Workshops on human resources or sales. Pam Krivda, will present “Dealing with Difficult HR Decisions” while Joe Ellers will present “New Processes of Distribution Sales Management.”

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Tuesday, April 9 Tuesday kicks off with the ever-popular Showcase of Hose Solutions, a five-hour opportunity to visit the exhibition floor and meet with leaders in the industry with direct purchasing power. The day ends with the Closing Casino Party from 5 – 7 p.m.

Optional tours throughout the week include Culinary Adventures, Hoover Dam and Boulder Brewery, Las Vegas City Tour and Neon Museum, and Cork and Thorn – Wine and Floral tour.

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2 • 2019

FLUID POWER WORLD

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1/17/19 PMAM 2/19/192:01 8:54

TRAINING

Mary C. Gannon • Editor

Robotics, automation headline Fluid Power Technology Conference 2019 The 2019 edition of the Fluid Power Technology Conference is slated for May 14-15 at the Milwaukee School of Engineering’s Kern Center.

The conference will open both days with exciting keynote presentations highlighting how fluid power manufacturers can be leaders in robotics and automation technologies.

On May 14, Dan Kara, Vice President, Robotics at WTWH Media, will kick off the conference at 9:30 a.m. with this talk, “Robotics Solutions for Smallto-Medium Manufacturers.” He is a recognized thought leader in robotics, with extensive businessdevelopment and analysis experience.

A large percentage of small-to-medium manufacturers have missed out on the many benefits of robotic industrial automation such as increased productivity, improved quality and enhanced competitiveness. Rapid change, however, is underway.

Both traditional industrial robotics companies, as well as a number of new vendors, are providing products and services specifically designed to satisfy the requirements and support the culture of the sizable and underserved small-to-medium manufacturer market. In this session, attendees will learn about these new products and services. Real world case studies will be presented to illustrate salient points.

Topics covered include: • • • • • • • • • •

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Collaborative robotics Bench-top systems Grippers and gripping systems Application specific systems Mobile robots Robotics-as-a-service Non-traditional manufacturing and novel application areas Flexible automation Rapid deployment and simplified programming What’s next

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Pre-conference workshops return to the FPTC. Here, the IFPS’ Tom Blansett presents on advanced hydraulics in 2018.

As VP, Robotics at WTWH Media, Kara is chartered with driving the company’s robotics and intelligent systems initiatives.

Prior to joining WTWH, he was Practice Director, Robotics at ABI Research and Chief Research Officer for Myria RAS, both research and advisory services firms focused on automation, robotics and intelligent systems. He served as President of Robotics Trends, the producer of Robotics Trends and Robotics Business Review online news, information and analysis portals, as well as a number of robotics business development events. Kara is a widely known research analyst and well-respected thought leader who has extensive business development experience with nascent technology markets that are poised for rapid growth.

Donna Ritson, President of DDR Communications, will open day two of the conference at 8:30 a.m. with her presentation, “The Evolution of Advanced Automation.” Attendees will learn about the advancements in Automation and the influence of technological breakthroughs that are impacting the industry for years to come. The presentation will review the role of

www.fluidpowerworld.com

2/19/19 1:49 PM

0030_F

pneumatics in automation, the reasons driving embedded intelligence, and the growth of smart machines on the plant floor.

Donna Ritson founded DDR Communications more than 30 years ago. DDR’s business is based on a direct response methodology that delivers market research, business development, strategic alliance and actionable market intelligence for companies in virtually every B2B industry.

DDR has been a partner with PMMI for more than 12 years reporting on the trends that help members gain a deeper insight into key markets and customers.

Ritson is a certified business communicator with a BA and MSMC in Marketing Communications.

All-day workshops, IFPS certification testing available on Monday

Now in its fourth year, the Fluid Power Technology Conference is continuing to add more technical programming for its attendees.

Back by popular demand will be a full day of pre-conference workshops on May 13, presented by MSOE and the International Fluid Power Society (IFPS). New this year will be IFPS certification testing.

MSOE’s Tom Wanke will once again be offering his “Fluid Power Basics Workshop.”

This introductory level workshop will cover the benefits and challenges of using fluid power systems for power transmission and motion control. Physical laws that govern how and why fluid power systems function will be discussed. Individual components that comprise a fluid power system; including Dan Kara VP, Robotics design, construction, operational performance at WTWH Media and efficiency characteristics will be presented.

ISO symbology used for representing individual components will be covered. The workshop will conclude with a brief overview of circuit architectures.

Wanke is the Director of the Milwaukee School of Engineering’s Fluid Power Industrial Consortium and Industry Relations. He’s one of the industry’s most popular trainers, with more than three decades of fluid power courses to his credit.

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TRAINING

IFPS’ Tom Blansett will once again present an eight-hour long course, “Advanced Hydraulics Mashup,” in which he will cover the following:

Donna Ritson, founder DDR Communications

Systemic Contamination Control — By evaluating an entire hydraulic system and its duty cycle, it is possible to systematically select the type and placement of contamination control components to enable a more reliable and cost-effective solution to avoid system downtime. Contamination control will ensure that the maximum life for components is achieved as long as the components are operated within the manufacturer’s specified operating parameters.

Pump Controls — Pump controls will be addressed as to the theory of operation along with some examples, such as when a specific type of pump control is more appropriate to use than other options to maximize energy efficiency. Along with common pump controls such as pressure compensation, load sensing, and torque limiting, less understood control options such as constant tensioning and electronic displacement controls will be explained.

Proportional Control Theory / PID Control — Proportional, Integral, and Derivative (PID) control theory is explained and how this relates to tuning an electrohydraulic system for maximizing accuracy of control. A thorough understanding of PID control is essential to operating a system with high cyclic rates to minimize instability issues.

Blansett, CFPS, CFPAI is the technical director for the IFPS. He has been working in the fluid power and motion control industry for almost 40 years. Blansett has contributed as a subject matter expert on numerous IFPS technical subcommittees and has been a technical consultant for the IFPS. He holds the Fluid Power Specialist (hydraulics and pneumatics), Industrial Hydraulics Technician, and Connector & Conductor Certifications; he is also certified by the IFPS as an Accredited Instructor and Authorized Job Performance Proctor.

Pre-Conference workshop requires separate registration. Visit www.fluidpowertechconference.com for more details.

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Finally, IFPS will be offering all of its certification tests, including: • • • •

Specialist – Electronic Controls Specialist (ECS) Hydraulic Specialist (HS) Pneumatic Specialist (PS) Mechanic and Technician tests (MHM, MHT, IHM, IHT, PM, PT) both written and job performance

Candidates should register at www.ifps.org/certifications-offered.

There, they should select the certification they are interested in. Once a certification is selected, the candidates should use zip code 53202 and test date May 13, 2019 when selecting Test Location & Date on the Test Application.

Individuals who register for IFPS certification tests will also receive 25% off their registration for the Fluid Power Technology Conference.

Visit www.fluidpowertechconference.com for more details and to register.

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E D I L -G A R E T K 6 B H

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Hydraulic motion system

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Parveen Gupta • Director – Sales, Production Machinery, Bosch Rexroth

Active heave compensation uses proven technologies and components for safe positioning during complex offshore activities.

Safely moving heavy loads from ship to sea floor is a basic requirement in the offshore industry. Undersea work of this type is common in the oil and gas industry. It typically includes tasks such as pipeline construction and repair, placement of oil and gas well heads, installing subassemblies on drilling rigs, as well as maintenance and repair activities. Similar operations entail building and maintaining offshore wind turbines, underwater salvage, geotechnical surveys, and dredging.

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These applications frequently involve large and expensive parts and require a high level of control, particularly when being placed with or linked to other components on the seabed. A major risk, in heavy seas, is the load acts as a destructive hammer to itself or nearby structures.

Such activities would be exceptionally hazardous to people, equipment and the environment if it were impossible to compensate for ship movements caused by wave action. Thus, there is a growing need for advanced heave compensation systems because of increasing activities on and below the sea.

Active heave compensation The systems compensate for the movement of a ship as a result of wave action. Rexroth has decades of experience in developing, commissioning and maintaining active heave compensation (AHC) systems. Engineering is based on a large portfolio of proven components, control systems and software. Designs range from a single 5 metric ton winch to some of the world’s largest working vessels that lift loads of nearly 50,000 metric tons.

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AHC systems rely on actively controlled devices which can operate in various modes depending on the required characteristics.

They maintain the constant vertical position of a free hanging load or a constant tension to a supported or fixed load.

Three variants have been developed: linear AHC (LAHC), rotating or secondary regulated AHC (RAHC) and primary regulated AHC (PAHC). All work by measuring vessel movement by means of Motion Reference Unit (MRU) acceleration sensors, and relaying that data to the main controller. Based on this data, the control software calculates the necessary counter motion and directs the hydraulic system to make adjustments in real time. Depending on the type of AHC, that can involve a hydraulic motor connected directly to a winch (RAHC), a variable pump (PAHC), a proportional valve (LAHC), or even an electric motor.

These components power the winch so the load hangs idle relative to the fixed world (such as a drilling rig or seabed). When the ship moves upwards, the winch pays out and when it comes down again, the winch hauls in. This makes it possible to position loads accurately and lets ship personnel work safely even in rough weather. By compensating for more than 90% of a ship’s movements, it’s possible to realize unparalleled precision operations at virtually any depth.

Primary AHC The latest development in AHC systems is primary active heave compensation.

PAHC systems are based on standard Rexroth hydraulic pumps and motors. This involves regulating speed and direction of the winch by varying the swivel angle of an axial-piston pump and thus regulating the volume flow rate. The MRU sends data to a digital controller, such as Bosch Rexroth’s type HNC 100, which calculates the set point and, in real time, controls the hydraulic variable pump that is connected to a fixed motor. To change the winch’s rotation direction, the hydraulic pump swivels over center and works as a motor.

Thus, the PAHC is a closed-loop hydraulic system.

Active heave compensation systems permit safe movement of personnel and equipment even when a ship is buffeted by large waves.

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Next-generation gangway

AHC systems rely on actively controlled hydraulics that sense motion and maintain a constant vertical position of a free hanging load or a constant tension to a supported or fixed load.

The main advantages of this primary system are lower investment costs and compact construction. Primary rotary active heave systems integrate into the winch drive system and require minimal space on deck. And Rexroth can adapt the software to meet customer-specific requirements.

Another characteristic feature of PAHC is that this type of heave compensation is suitable for recovering energy.

Among other things, the energy released by easing the load (when the ship moves upwards) can be stored in a hydraulic accumulator. This energy becomes available again when the ship comes down and the load must be taken up. This energyefficient system uses a modular kit with safety components, a brake and the required accumulators.

Secondary rotary systems Rexroth has also developed a rotating system that uses energy-efficient secondary control. It is based on use of a secondary regulated motor connected directly to the winch.

In the RAHC system, the winch is fitted with adjustable hydraulic axial-piston motors, the size of which is determined by the required winch capacity. The speed and torque capacity of the motors can be adjusted to vary the speed and direction of the winch.

Barge Master and Bosch Rexroth have teamed up to engineer and produce a next-generation gangway. The system is designed for the safe and efficient transfer of personnel and cargo from ships to drilling and offshore production platforms, wind turbines and other ships.

Barge Master specializes in the development and fabrication of motion-compensating systems for use on ships while offshore. The technique counteracts ships’ movements so that ship-mounted cranes and multipurpose platforms remain stable and cargo can be transferred and positioned without problems, even in rough seas.

For the safe transfer of personnel from a ship to wind turbines or production and drilling platforms at sea, the company developed the Barge Master Gangway in close collaboration with Bosch Rexroth. The design of the gangway has been assessed and approved by global quality assurance and risk management company DNV GL (DNVGL-ST-0358).

According to Ron van den Oetelaar, managing director of Bosch Rexroth’s Benelux unit, the development of the Gangway presented an engineering challenge. “Due to the simultaneous linear and rotary motions along several axes, which are moreover accompanied by large forces, the active motion-control technology applied in the system is extremely complex,” he said.

The gangway mounts on a small diameter pedestal with a hinge and a luffing cylinder to compensate the roll motions of the vessel. Hydraulic motors let the gangway translate and rotate (surge and yaw) in the horizontal plane around the pedestal. Telescopic sections with winches in the bridge ensure smooth translation in sway direction. Extremely fast sensors and controls for the Barge Master Gangway translate the ship’s movements into counter-movements for the gangway. The system can compensate for vessel motions despite wave heights of more than three meters. In addition to the gangway system, customers can add modules such as a height-adjustable pedestal with an integrated elevator.

This option ensures stepless trans-shipment of pallet trolleys between vessel and platform.

The development, fabrication and timely delivery of the system involved close collaboration with engineers from Bosch Rexroth, says Martijn Koppert, CEO of Barge Master.

Although some parts were custom built, most were standard components, he said. “The fact that Bosch Rexroth has an extremely wide product range helps enormously in this respect.” The result was lower costs and faster delivery in addition to a small footprint, light weight and modular design.

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150 ton shipboard AHC

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A 150-ton active heave compensation system from Bosch Rexroth enables an SBM diving-support vessel to position sensitive equipment at depths down to 3,000 m. The AHC system compensates for heave caused by ocean swell, and allows loads to be placed on the seabed gently and under full control. At the same time, it protects the hoisting cable from potential breakage due to internal resonance caused by wave motion. It handles wave amplitudes of up to Âą3 m and compensates for load movement by more than 90%.

The linear active heave compensation system operates continuously based on measurements made by the Motion Reference Unit that track the vertical movements of the ship. An advanced controller processes this data and uses it to control a hydraulic cylinder. The cylinder extends or retracts to tighten or relax

the hoisting cable, such that the load is suspended nearly motionless in relation to the seabed.

The system mounts below deck and includes a specially-designed compensation cylinder, which combines both a pneumatic and hydraulic cylinder. The pneumatic compartment bears and compensates for the static load, while the hydraulic compartment provides the dynamic forces to almost entirely compensate for movements of the load. Thanks to this unique combination, the required hydraulic capacity is only a fraction of the theoretical peak capacity that would otherwise be required from the winch if no heave compensation was installed. This results in considerable energy savings.

To ensure reliable operation under harsh conditions at sea, the hydraulic cylinders are treated with Enduroq

2200 surface technology, an extremely wear-resistant and corrosion-resistant cylinder rod finish. In addition, essential system components are dual or multiple-redundant. For example, the Bosch Rexroth CIMS measuring system integrated into the cylinder is equipped with three sensors.

From design to commissioning, Bosch Rexroth developed the entire system for SBM and supplied the required components. These include the drive section including the hydraulic power unit and the hydraulic cylinder, the air supply unit, all pipework, plus the controls and software, control cabinets and operator panels.

unit and tanks, as well as lower ship fuel costs and reduced exhaust emissions.

More than one hundred RAHC systems from Rexroth are in service in cranes and winches, safely positioning loads of hundreds of tons.

The company also offers electric rotary AHC systems that work similarly to RAHC, in that they also recover, store and reuse energy. The hardware controls are identical to the hydraulic variants, simplifying operation, diagnosis and spare parts management. The portfolio of acservomotor drives ranges from 11 kW to 4 MW of power, and the electromechanical drives are adapted to the special requirements of the maritime and offshore industries.

Linear AHC measures heave motion where the winch rope leaves the vessel, then compensates for it with a special cylinder.

A sheave assembly attached to the cylinder moves cable back and forth, counteracting ship movements and maintains nearly steady position at the lift point.

In this configuration, the primary load and wave-motion oscillations are managed and compensated by a secondary control system. During operation, the cable load and ship movements are constantly monitored with fast and accurate sensors, which serve as the basis for dynamic control of the secondary motors, and active control of the load in real time.

The design offers an additional advantage of using an integrated energy recovery system based on hydraulic accumulators. The principle is much like in the PAHC: during upward movement of the vessel the drive unwinds the winch cable and the hydraulic motor acts as a pump, converting motion energy into hydraulic pressure that is stored in the accumulators.

In the subsequent downward movement, the drive works like a motor, reusing the stored energy from the accumulator.

Thus, the AHC system can operate with far less installed power capacity versus a system without energy regeneration. Energy savings of up to 65% are reported. Other advantages include smaller footprint for the hydraulic power

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Linear compensation LAHC systems are suited for standard winch-driven cranes and hoists. The system fits with nearly every existing winch system as an add-on, and it consumes considerably less energy than other activeheave systems.

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Bosch Rexroth designed an AHC system that lets SBM’s Normand Progress diving-support vessel position sensitive equipment at depths to 3,000 meters.

In LAHC, the MRU measures heave motion where the winch rope leaves the vessel, then compensates for it with a special cylinder that combines both active and passive compensation capabilities. (A passive heave compensation unit acts as a springlike device and typically consists of a hydraulic cylinder and a gas accumulator.) The passive part accounts for the average load while the active part compensates for the wave-induced load variations.

The cylinder stroke determines the length of the winch cable and, thus, the load position. This cylinder pays out wire rope when the vessel lifts up, and retracts the wire when the vessel lowers. The control system uses the MRU output to calculate the required AHC cylinder movement and follow the desired movement as accurately as possible. A sheave assembly attached to the AHC cylinder moves the cable backQRAM andPRINT forth, the ship7 movements.

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results in nearly steady position of the lift point (at the location of the overboard sheave) and thus maintains a near-steady load with respect to the fixed world.

Based on closed-loop force control, LAHC requires only a simple mechanical interface for the vessel structure. The LAHC is designed to be modular, making it easy to integrate into nearly every vessel arrangement. It consists of four main modules: the cylinder-based integrated cable-actuation system, hydraulic power supply, high-pressure air system, and an integrated control system, including the MRU.

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“The technique counteracts ships’ movements so that cranes and platforms remain stable.”

The next-generation gangway developed by Barge Master and Bosch Rexroth relies on active motion-control technology to compensate for complex linear and rotary motions along several axes.

Mastering multiple degrees of freedom In recent years Rexroth has been a pioneer in developing motion-compensation systems that handle six degrees of freedom. First used in simulators for aviator training, the company revised this concept to fit maritime and offshore applications. It has already been applied to helicopter decks on ships and to cranes on flat-top barges and supply vessels.

For example, one motion-compensating platform for crane applications was developed in close collaboration with marine company Barge Master, Rotterdam, The Netherlands.

To prevent the crane-carrying platform from moving, the dominant three degrees of freedom — heave, roll and pitch — are compensated, while the other degrees of freedom — sway, surge and yaw — are restrained. Motion is compensated by a trio of hydraulic actuators.

The first platform was installed on a standard flat-top barge, carrying a standard crawler crane with a maximum lifting capacity of 400 to 600 tons. It’s an economical, selfsufficient system that is ready to be installed with its own controls, software and power supply.

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WHAT Connect with thousands of DO engineering YOU design THINK? professionals

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Four ways

compressed air systems waste energy (and what to do about it)

Eliminating leaks, misuse, overpressurization and pressure drop can ensure efficient compressed air systems.

Bradlee Dittmer • Product Marketing Manager, Norgren, Inc., An IMI Precision Engineering-branded company

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Are your energy dollars vanishing into thin air? According to U.S. Department of Energy estimates, 10 to 30% of all energy consumed by the average industrial facility is used to generate compressed air. And a third of that air may be wasted. The potential for energy savings is clear. Making sure the compressor is performing efficiently can prevent a lot of waste, but another — often overlooked — opportunity for energy savings is the compressed air delivery system. This article describes the four most common ways air is wasted after it leaves the compressor and how to fix them.

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Problem 1 – Leaks Leaks are the main cause of energy waste in compressed air systems. The U.S. Department of energy estimates that as much as 20 to 30% of compressors’ output is wasted due to leaks.

How much are leaks really costing you? Use this formula recommended by the U.S. Department of Energy1 to find out: (Number of leaks) x (Leakage rate in cubic feet per minute) x (Compressed air generation requirement in kilowatts per cfm) x (Number of hours per year) x (Energy cost per kilowatt hour) Small leaks are the most common, so the following very conservative example starts with the assumption of 10 leaks at a size of just 1⁄32 in. At a pressure of 100 psig, the leak rate would be 1.55 cfm2. Other assumptions are that the compressor requires 18 kW to generate 100 cfm of compressed air at an average cost of $0.1 per kW hour. Finally, assuming 7,500 hours of operation in a year, the potential savings are calculated: (10)(1.55)(0.18)(7500)(0.1) = $2,090.50

Connection points are a common location for leaks, which can be easily detected using leak detection fluid.

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That’s over $2,000 a year for just ten leaks totaling only about one third of an inch! And the cost goes up at an exponential rate as leak size increases. Since most leaks can be repaired in a matter of minutes, most in less than an hour, the payback is nearly immediate and substantial.

So how should maintenance professionals look for leaks?

Use an ultrasonic leak detector or simply listen for escaping air, starting at the compressor and walking down the line.

Leaks near the compressor are typically the costliest because that’s where the pressure is highest, but leaks there are fairly rare. More common leak sites are pipe joints, quick disconnects, flanges, condensation traps, fittings, filters, regulators and valves. Large leaks often occur at connection points in the main distribution system and in off-takes. Worn snap connectors and poorly jointed pipe work can allow leaks.

Leak detection fluid helps pinpoint the location by producing bubbles where air is leaking.

Air can escape through damaged or deteriorated hoses and couplings. Older pneumatic components like cylinders and regulators might have worn internal air seals that leak.

Condensate drains that are stuck or left open allow large amounts of air to escape.

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Finally, systems that are left pressurized when they are not in use can leak. Some subsystems like presses or drop hammers that must be kept pressurized have leakage that cannot be avoided, but waste can by minimized by isolating them from the air supply when they are not in operation. Shut-off valves or electrically operated soft start dump valves are cost effective ways to isolate leaky systems or unused areas of a plant. And don’t forget to disconnect obsolete equipment from the air distribution system if it is not moved after being retired.

Besides wasting energy, leaks affect productivity when they cause system pressure to fluctuate. Increasing the pressure from the compressor to compensate just drives up energy use and can shorten the equipment’s service life. So, finding and repairing leaks pays off in more ways than just energy savings.

Use a regulator to set the pressure of air going to the tool at its rated setting, not the mainline pressure.

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Problem 2 – Misuse The second most common waste of energy is using compressed air just because it is available, even when there are more efficient power sources for the application.

Some examples of potential misuse are creating vacuum, ejecting faulty products from assembly lines and removing water, dirt or powder. Some processes need air, but not compressed air. Dedicated air blowers or vacuum pumps may be more energy efficient. If compressed air is required, choose the correct equipment and control systems to keep usage to a minimum.

Where air nozzles must be used, for example to remove dust or powder from products moving down a conveyor, make the distance between the nozzle and the target as short as possible to keep the air pressure as low as practical. Nozzles should only be directed at the specific point where air is needed. Fit control valves and sensors to ensure that flow only occurs when the product reaches the nozzle, with no flow during gaps between the items on the conveyor or when the conveyor is not running. Air saver nozzles entrain and accelerate the air, producing higher outputs at lower supply pressures. They can reduce compressed air usage twenty-fold.

Problem 3 – Over-pressurization Many plants run their compressed air systems at full line pressure, regulated only by the pressure switch on the compressor.

But every pneumatic component or tool has an optimum operating pressure and flow. Operating all of them at mainline pressure will waste energy and shorten equipment life by increasing loading and wear.

Pressure regulators allow air to be delivered to each tool at its rated pressure.

If there are no pressure regulators distributed throughout a system, it is likely that excessive pressure is being used and energy wasted. Even when pressure regulators are present, they should be

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checked to see that they are actually regulating the pressure. If the outlet pressure is the same as the inlet pressure, regulators are not helping save energy.

Reducing pressure on double-acting cylinders can save energy. These cylinders usually only do work on the out- or work-stroke, so the return stroke can be accomplished at a lower pressure. Using a pressure regulator to reduce return stroke pressure can have a fast payback, especially where large bore, long stroke or multiple cylinder systems are used.

To save energy with valves, reduce the applied pressure to the rated conductance of the valve. Be sure to note the valve operating duration to ensure optimal flow savings. The potential savings are small but for multiple valve installations or rapidly cycling valves with long pipe runs they can add up.

An industry rule of thumb is every reduction of 2 psig in system pressure will reduce operating costs by approximately 1%.

Problem 4 – Pressure drop Pressure drop is the loss of power available to do the work required. Operators often compensate for this loss by increasing the pressure from the generator or by turning up regulators, but this drives energy costs up without

addressing the underlying problem. The best way to save energy is to find and eliminate the cause of pressure drop at its source.

The potential energy of compressed air dissipates through friction as the air is pushed through all the components of the distribution system. In most cases, 15 psig (1 bar) of unnecessary pressure drop increases generating costs by up to 7%.

The two main areas where pressure drop occurs are pipework, including tubing, and filtration.

Friction occurs between a pipe’s surface and the air molecules that pass through it. If the pipe is too small for the volume of flow, the velocity of the air will be higher, resulting in more friction and a loss in the power potential of the compressed air. Piping also causes energy loss when there is a change in flow direction, such as at elbows, junctions and shut-off valves.

Simplify pipework to avoid using elbows and fit low resistance valves. A low resistance full flow ball valve creates less resistance than a gate valve. Another

Using an actuator with integrated valves, controls and tubing eliminates pressure drop between the valve and the actuator. The unit is also more energy efficient and reduces the risk of leaks.

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A filter with a pressure drop indicator makes it easy to tell when the filter element needs to be serviced so that adequate pressure can be maintained for optimum energy efficiency.

way to prevent pressure drop between a valve and actuator is to use an integrated valve/actuator unit. These integrated components combine the valves, flow controls, cushioning and sensors in the same package as the actuator. This reduces or eliminates multiple valve islands, external components, tubing and accessories, so not only is pressure drop avoided, but less energy is required and there are fewer points vulnerable to leaks.

Filtration is essential to conditioning compressed air and protecting equipment from water, particles and degraded

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compressor oils, but a filter can impact the flow, causing pressure to drop. There are three ways to minimize pressure drop caused by filtration. First, correctly size the filter unit. As with pipework, if the filter unit is too small for the flow required it will cause a larger pressure drop. Second, use the right level of filtration. A very fine filter will create more flow resistance than a coarser filter. Most air tools only require filtration to a particle size of about 40 microns. If finer filtration is required, say, 5 microns, place the filter as close as possible to the tool requiring it rather than

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filtering the whole main or branch line to this level. Delivering air that is cleaner and dryer than it needs to be wastes energy.

Maintaining filters also helps prevent energy waste. After some time in service, the filter element will be blocked by particles, reducing pressure. Operators sometimes turn up the regulator to restore the pressure, but this increases energy consumption. Simple pneumatic or electrical pressure drop indicators can show when pressure is dropping, signaling that the filter element needs to be changed. Changing elements when indicated or on a regular filter maintenance schedule reduces energy consumption and ensures that the correct quality of air reaches the tool or machine.

An ounce of prevention Good design and regular maintenance can help prevent energy waste before it happens. Properly sized pipework, filters and components like valves and cylinders make the most efficient use of compressed air. Keeping the air flowing by maintaining filters saves energy. Inspecting systems for leaks and repairing them quickly can really pay off in energy savings. And not using compressed air when other energy sources or air delivery mechanisms can do the job will cut energy use as well.

References: “Minimize Compressed Air Leaks,” Energy Tips – Compressed Air Tip Sheet #3, August 2004, U.S. Department of Energy, Office of Energy Efficiency & Renewable Energy, http://energy. gov/sites/prod/files/2014/05/f16/ compressed_air3.pdf

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custom quick disconnects Non-standard QDs often lead to a better system design and, surprisingly, lower overall costs.

Joe Engel • Nick Goenner Specialty Manufacturing Co. St. Paul, Minn.

Most quick-disconnect coupling manufacturers focus on offering standard products in dozens, if not hundreds of different sizes and types. Many times, off-the-shelf QDs work fine for a given task. They meet the necessary performance requirements and tend to offer ready availability and a reasonable price.

But often a standard product is not the best choice, especially when a fluid-power engineer must make compromises to the overall machine design to accommodate a stock QD. In such cases, a custom design can often improve equipment efficiency, reduce space requirements and lower the total system costs.

Quick couplings are fittings used to mate fluid lines with equipment that requires repeated connections and disconnections. Their design is straightforward: a male end is inserted into a female socket to make a secure, leak-tight seal — and the assembly can be quickly undone with minimal effort. The products are designed for easy hand operation in countless hydraulic and pneumatic applications, such as in mobile and industrial machines, hydraulic and pneumatic tools, food and packaging equipment, analytical instruments, and medical and dental devices.

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Consider custom Unfortunately, most QD manufacturers see custom designs as either an afterthought or a nuisance; or the producers lack customization capabilities altogether. A handful of fluid-power companies tend to take a different approach.

For example, SafeWay, a division of Specialty Manufacturing Co. based in St. Paul, Minn., offers a catalog of standard agricultural and industrial quick couplings along with a mix of ISO and non-standard versions. In addition, SafeWay takes a collaborative approach to solving quick-disconnect application challenges. The company designs and manufactures couplers to fit the specific need, so the design engineer is not forced to choose an off-the-shelf part that may be over- or under-built. This also allows them to be more flexible on the design of the rest of the hydraulic system.

Our experience in both our standard product line and solving issues with our customer’s custom applications provides us with a deep pool of knowledge that can be applied to avoid the unforeseen challenges and pitfalls that those less experienced in the industry may fall into.

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Custom Machined Twist Lock Adapter Metal or Plastic

This oil-change adapter features a custom twist-to-lock connection.

By sharing ideas and concepts with our customer, a design often emerges that suits the customer’s performance requirements while also fitting our manufacturing capabilities to minimize the cost as much as practical.

Adapting them to particular applications tends to require a different approach, because virtually every aspect of a quickcoupling can be altered and refined to better serve a customer’s application. Such criteria can include:

Quick-coupling options Quick-couplings are much more complex than they seem on the surface, so it is important to work with a supplier that understands every aspect of the product.

The connect/disconnect action: Different connection styles are available to suit a variety of applications. One-handed, pushpull connections make coupling as quick and easy as possible. Threaded connections eliminate excessive wear caused by side-loaded or high-impulse applications.

Sometimes the locking mechanism is removed entirely because another mechanical device is used to couple the QDs and maintain them in that state, as in multi-coupling or “rack-and-panel” applications.

Color Coded Lubricant Dispensing and Processing

Custom Color Coded Anodize Finish

Dry-Break Connection

Custom Keyed Locking To Prevent Cross Contamination

Size: Size is closely related to the amount of flow that the coupler will accommodate.

Larger sizes will allow more fluid to pass with less pressure loss through the coupling. Internal features also matter — sometimes a smaller coupling is feasible if the flow passages are designed to minimize pressure loss.

This dry-break coupling for lubricant handling is color coded for easy identification, and custom key locking prevents cross contamination.

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Beverage Dispensing Flow and pressure capability: Important considerations related to size, these parameters can definitely be tailored to the design. Generally larger couplers will flow more freely, but typically struggle to contain as much pressure as their smaller counterparts.

Vacuum capability: Vacuum adds additional considerations to the design, but capable engineers can easily accommodate this capacity into a QD. Shape: Shape and geometry are somewhat dependent on the coupling’s features. For example, a “dry-break” style coupling will have a different appearance than a traditional “agricultural” style coupling due to its nature.

However, outside of these features, shape can be adjusted to fit the needs of the application, usually for mounting or user-friendliness reasons.

Machined Stainless Steel Body

Custom Hose Barb Ends

Custom Thread Design Facilitates Sanitation A quick disconnect for beverage dispensing applications has a sanitation-friendly design made of stainless steel.

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onto the coupler eliminates the need to add an adapter to an off-the-shelf coupler, saving weight, cost, and eliminating potential leak paths.

Coatings and finishes: Various coatings are available to increase corrosion protection, reduce friction, harden surfaces to resist wear, or apply color coding as the application demands.

Valving: The type of valve will affect the performance and functional characteristics of a coupling. The valve type can be tailored to achieve extreme durability, flow performance, or minimize spillage upon disconnect, to name a few considerations.

Sometimes customers request no valving at all to maximize flow through the coupling.

Type of threads: An experienced manufacturer can offer much more than just standard pipe or O-ring boss threads, such as metric and British options.

Designing the preferred connection right

Seals: It is very common to select seals appropriate to the application, typically to suit the media and temperatures.

Offerings include Buna, Viton, EPDM and more exotic compounds such as Aflas and

Diagnostic test equipment & data logging

perfluoroelastomers. Seals can also be crimped or bonded into place to suit demanding applications.

Environmental extremes: Engineers can design the QD to handle temperature extremes or operate under rugged environmental conditions. This is closely related to the seals and materials discussed previously.

Additional considerations: Other customizable design parameters include color, sleeve lock (prevents accidental disconnects) and interchangeability, or lack thereof, with other designs.

Cost-effective manufacturing Customers should expect that any QD

Flow condition monitoring

Flow, Pressure, Temperature or Speed Sensors & Transducers Factory Calibrated = Fast Installation

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Flow & directional control valves, pumps and motors. Custom versions available

Toll Free: 800-932-8378 - Phone: 414-769-6400 - Email: sales-us@webtec.com

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Custom coupler simplifies assembly and installation Today’s data centers, gaming and many other electronic systems operate with increased processing speed and graphic quality — with the added challenge of increased thermal management. More and more manufacturers are looking for alternatives to traditional air cooling to disperse the heat generated by their highpower electronics systems. A reliable, safe and passive two-phase cooling system can provide a low-cost, efficient and effective alternative to air or water cooling.

QuantaCool, Chadds Ford, Pa., helps solve the cooling challenges of the electronics industry with its Microchannel Heat Pipe (MHP) technology. The system passively circulates refrigerant instead of pumped water, and cools more efficiently while minimizing the risk to both electronics and personnel. Compact high-flux heat absorbers (cold plates) rely on phase-change principles (boiling and evaporation) to remove and dissipate large quantities of heat from high-intensity sources. The heat is passively rejected to the outside surroundings.

Secure and leak-free couplers are critical components in this two-phase cooling design. QuantaCool needed a unique refrigerant coupler to meet the demands of their new electronics cooling system. Off-the-shelf component options were too large and expensive, and many manufacturers were not interested in producing the short-run couplers that the application required. QuantaCool approached the engineering team at SafeWay to design a unique coupler that fits the size and material requirements, at a cost-effective price. The new coupler not only met the demands required for thermal management in the reduced footprint of QuantaCool’s PolarBox and PolarRak systems, it also simplified the assembly process.

Application requirements For the new cooling system, QuantaCool required a quick-disconnect coupler with unique requirements for size, material and pressure—beginning with smaller production runs. These included: • • • • • • • • •

Dripless and leak-free performance 200 psi pressure rating Lightweight aluminum construction Size less than 0.75 in. in diameter Quick disconnect functionality Coupler ends that match preferred tubing and fittings Materials, seals and lubricants compatible with refrigerant Color coding for easy assembly Sleeve-lock to prevent accidental disconnect

QuantaCool required an economical, dripless QD that is color coded for easy assembly and with a sleeve-lock to prevent accidental disconnect.

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While other manufacturers were not interested in developing a new product with initial low volume production runs, SafeWay’s flexible, collaborative approach to product development made it possible to green light the project.

Based on the application requirements, SafeWay’s design engineers developed initial product drawings, and a collaborative team of SafeWay and QuantaCool experts enhanced the product design. SafeWay then produced 3D prototypes, initiated a small pilot run and qualified performance. Additional on-site testing led to enhancements in the lubricants and seals, creating a final readyfor-production coupler solution.

Installation advantages The new dripless couplers let QuantaCool easily precharge the products with refrigerant before shipping to customers.

And at customer installations, the colorcoded, quick-disconnect couplers make it simpler and easier to install QuantaCool’s products on-site.

SafeWay added a locking collar for a more-secure connection, to prevent accidental disconnects during assembly or operation. Customized ends allow the couplers to connect to tubing or be panel mounted. And the specialized design ensured the couplers operate in an environment where the media does not lubricate the coupler components. Finally, with a critical eye on the bottom line, SafeWay provided QuantaCool with the small production runs they needed, at a cost-effective price.

QuantaCool now has an electronics cooling system that is leak free, modular, flexible, and efficient. Their custom coupler solution from SafeWay helps them assemble products more efficiently, while helping their customers install QuantaCool’s products more easily.

QuantaCool quantacool.com

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Engineers at Specialty Manufacturing designed special compact, leak-free couplers to handle refrigerant in QuantaCool’s electronics cooling system.

manufacturer has a clear understanding of the many performance attributes needed for a given application, and should be willing and prepared to discuss the unique characteristics and the QD options, materials and cost elements to optimize the long-range performance of the device in their application.

Users should also look for a high quality manufacturing partner that has a history of successful innovation. Specialty Mfg., for example, is ISO 9001:2015 certified, which demonstrates a strong focus on tight controls in manufacturing and assembly processes. One of the most unique aspects of the company is that production facilities include seven distinct manufacturing disciplines and engineering specialists. These include: metal machining, wire EDM, plastic injection molding, stamping, grinding, assembly and quality control.

Unlike manufacturers that heavily rely on subcontractors, these disciplines are vertically integrated at Specialty Mfg. Vertical integration permits tight control of an entire process, project management and costs. In rare instances some secondary operations are outsourced. These are mapped into the production cycle of a given project to streamline coordination, so the customer only needs to deal with a single point of contact—rather than facing the headaches of juggling multiple vendors and purchasing agents.

Customers should also expect a reasonable turnaround time from order to delivery. Six months is the typical window for a project from initial engineering consultation with a vendor to the delivery of a pilot run. Projects can be sped up in situations where the base design is proven for functionality and the natural iterative process is minimal.

Finally, there’s the overall economics of a custom design. Manufacturers who are strong adherents of designing for manufacturability generally offer products with lower costs and better consistency and reliability. While costs for customized solutions are very volume-dependent, a focused and efficient producer can be very competitive outside the commodity market.

By truly understanding the customer application, the design-for-manufacturability process often eliminates unneeded features of an off-the-shelf coupler, ensures intelligent choices in the materials used, reduces the overall footprint of the system being designed, and ensures dimensional optimization—while applying the most appropriate manufacturing disciplines to optimize efficiency and overall cost.

FPW

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Slow down to speed up

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Get smart solutions for smart factories at

Hannover Messe 2019 Edited by Mary C. Gannon • Editor

Hannover Messe returns April 1-5 with its Integrated Automation,

O

Motion & Drives (IAMD) show spanning 14 exhibition halls.

One of the world’s largest industrial trade shows opens April 1-5 at Hannover Messe, this year with the motto “Integrated Industry – Industrial Intelligence.” Hannover’s Integrated Automation, Motion & Drives (IAMD) — a mega-show spanning 14 exhibition halls — will highlight smart sensors, intelligent drives, modular production, automated logistics systems and holistic solutions for intelligent manufacturing. IAMD covers everything to do with industrial automation, industrial IT, power transmission, and fluid power technology — from mechanical engineering and robotics to process automation.

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The motto reflects the organizer’s desire to show how the close integration of automation, power transmission and fluid power and software and IT can supercharge industrial production.

In 2019, the integration, digitization and interconnection of industrial technologies will transform the world’s manufacturing industries more than

“The motto, ‘Integrated Industry - Industrial Intelligence,’ reflects how close integration of automation, power transmission and fluid power, and software and IT can supercharge industrial production.”

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ever before. In recognition of this, the IAMD show will feature the full range of products and solutions for the factory of the future, including intelligent hydraulics and pneumatics systems, factory and process automation systems, industrial IT, robotics, and smart drives. All of the exhibits will share one unifying theme: “Industrial Intelligence.” Artificial intelligence and

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machine learning are helping to eliminate production downtime, boost efficiency and ensure the seamless integration and operation of all the different parts that make up smart factories.

“Automation solutions for the digitization and smart integration of industrial technologies will be the focus of the upcoming IAMD show,» said Arno Reich, Global Director IAMD for Hannover Messe.

“IAMD will also showcase the best power transmission and fluid power technologies the world has to offer, as well as serve as a central forum for debate on the latest market and technology trends.”

A large number of fluid power manufacturers will be among the more than 2,000 exhibitors highlighting 9,000 products throughout the week. Key fluid power exhibitors include: Argo-Hytos, Aventics, Bansbach, Bosch Rexroth, Bucher Hydraulics, Continental, Eisele Pneumatics, Festo, HAWE Hydraulic, Hunger Hydraulics, Hydac, IMI Precision Engineering, Intertraco, KTR, Mindman Industrial, Oleotec, O+P, Parker Hannifin, Piab, Scanwill Fluid Power, Stäubli, SUCO, Trelleborg, and many more. Visit www.hannovermesse.de for a complete exhibitor list.

Automation and AI take center stage Apart from the exhibits, supporting forums and special presentations will include the Hannover Messe Pump Plaza, Wireless, M2M & IoT display; the Application Park showcase for robot manufacturers, systems integrators and image processing specialists; and a new SME Pavilion where small and mid-sized companies will present their Industry 4.0 solutions. Among Hannover Messe’s many platforms for learning, knowledge sharing and lively debate on the latest trends and developments will be the new Motion & Drives Forum and the wellestablished Automation and Industry 4.0 forums within the IAMD show.

P R E V I E W

The theme of Hannover Messe 2019 underlines the growing importance of artificial intelligence and machine learning in the production and energy industries, including such areas as energy efficiency and use and autonomous production processes as well as challenges in terms of interfaces, protocols and security.

Finally, visitors to the event will see a focus on this year’s chosen Partner Country of Sweden. Collaboration, innovation and digital transformation will be at the center of Sweden’s presence, with the country’s main objective to promote networking, trade and investment with partners from around the globe.

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Record-breaking

bauma descends upon Munich

The largest trade fair for construction machinery runs April 8 to 14, bringing together more than 3,500 exhibitors from 55 countries.

Mary C. Gannon • Editor

More than 3,500 exhibitors from 55 countries will descend upon Messe München for bauma 2019 in April, with almost 100 more exhibitors than in 2016. Set for April 8 to 14, the event is a reflection on a strong construction market. In addition, show organizers have added new elements, including bauma PLUS which allows even more companies to present their products and services; and virtual reality, which will bring the construction site into the trade fair hall. The event attracts hundreds of thousands of visitors every three years, with more than 600,000 expected this year.

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“The industry is booming, which is also reflected in the growth of bauma. We’ve taken account of the rise in demand and expanded our site in eastern Munich to 614,000 m2, 9,000 m2 more than 2016,” said Klaus Dittrich, Chairman and CEO of Messe München.

The willingness to invest in the construction machinery industry is on a very high level globally and continues to be regarded cautiously optimistic in the coming years. This is one of the findings of the “bauma Industry Barometer,” a representative study that polled approximately 10,000 industry experts over a period of two months (June-August 2018). 44% of the respondents are planning to increase the investment volume for their company in the future.

“The majority of the respondents assume that investments will remain at a high level. This illustrates the extraordinarily positive mood with regard to the economic development of the construction machinery industry. But it also shows that an aboveaverage willingness to invest is necessary in order to remain competitive in the long term,” Dittrich, said.

New and expanded exhibits For the first time, visitors to Hall B0 will be able to experience the industry virtually — thanks to virtual and augmented reality. This is made possible through a combination of images, sound, or sensor feedback, such as wind. “The booths have size limits, the digital area is limitless. With new virtual offerings, we’re bringing the construction site into the trade fair and expanding our digital portfolio,” said project manager Mareile Kästner.

Already today, construction machines can be equipped with a wide range of sensors and communication interfaces. The collected data can be used, for example, to monitor work performance, consumption and location, define predictive maintenance intervals or determine operating costs.

Entire vehicle fleets can be managed by telematics. Moreover, digital tools help to automate workflows.

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“Many companies in the construction industry have already recognized the relevance of digitization, but are still investing with caution. From a trade fair point of view, my appeal is: Dare to drive more digitization! To remain fit for the future, we must permanently incorporate digital processes and systems in our events and organization. I don’t think that is any different for the companies in the construction machinery industry,” Dittrich said.

Another new feature are the bauma Plus models that bring more exhibitors to the fair. With bauma Plus Onsite exhibitors can present their company on a compact area. bauma PLUS MOVE is a flexible co-working area where visitors can meet exhibitors.

Expanded to 18 halls, the event will include five halls for component manufacturers, with more than 150 fluid power manufacturers on site. Key manufacturers include: ARGO-HYTOS GmbH, Axiomatic, Bondioli & Pavesi, Bosch Rexroth, Bucher Hydraulics, Carlisle Brake & Friction, Casappa, Concentric, Continental AG, DANA Inc., Danfoss Power Solutions, Eaton, Gefran, HansaFlex, HAWE, HBC-Radiomatic, HED Inc., HUSCO International, Hydac, Hydraforce Hydraulics, Hydraulik Nord Fluidtechnik, Hydreco Hydraulics, Linde Hydraulics, Lisk Ireland, Magnet-Schultz, Marzocchi Pompe, MTS Sensor Technologies, Parker Hannifin, Roquet Hydraulics, Rotary Power, SAI Hydraulic Motors, SIKO, Sun Hydraulic, Thomas Magnete, Walvoil, Wandfluh, and Weber Hydraulik, and more.

In addition, the largest sector construction machines and attachments area is expanded from four to five halls as well as by an additional area outdoors, directly adjacent to the hall complex.

Another key stat from the “bauma Industry Barometer” indicated that more than half of the respondents (58%) regard the shortage of skilled workers as the greatest challenge for the industry. To combat this, bauma organizers have made its “Think Big!” exhibit larger. Previously www.fluidpowerworld.com

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located in Hall B0, the special “Think Big!” exhibit will move to the ICM – International Congress Center Munich to show students career opportunities in the construction and building material machine industries.

Learn from the experts at the bauma Forum Finally, the bauma Forum is where exhibitors, trade associations and partners present the latest product developments, trends and market analyses in presentations, press conferences and/or panel discussions.

The bauma Forum is embedded directly into the fair’s activities in Hall C2. Forum events are free of charge for visitors attending bauma. Topics include additive manufacturing in construction, digitization, updates on research and innovations, highlights from various markets and countries, and more.

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PRODUCT WORLD

Solenoid-operated relief valves Sun Hydraulics sunhydraulics.com

New to Sun’s cartridge portfolio and to the FLeX series family, four new solenoid-operated relief valves feature a 2-stage, field-adjustable design. These RVC valves offer precise and dependable pressure regulation with up to 25 gpm (100 lpm) flow rates. They offer fully adjustable, ventable and blockable relief functions for both mobile and industrial functions.

They reduce complexity by combining the functionality

of two valves into one body and one cavity, reducing materials and creating a compact and efficient system. They also improve reliability because the main stage orifice is protected by a 150-micron stainless steel screen for extended product life.

A leak-free adjustment screw improves safety because its mechanical stop prevents the screw from backing out, offering safe, reliable field adjustment.

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Hyde Industrial Blade Solutions

Solutions You Can Count On! TM

Phone: 800-872-4933 www.hydeblades.com

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

New range of vacuum cartridges Coval coval-inc.com The new CVPC series combines for the first time a pilot-operated solenoid valve and a single stage venturi, all in the form of a cartridge weighing no more than 22 g. Performance is achieved through the combined solenoid valve and single stage venturi in an ultra-compact unit. The cartridges can be placed close to the suction cups, eliminating any loss of vacuum pressure and guaranteeing an instantaneous grip. Flexibility of implementation is achieved with a cartridge designed to be easily integrated into any type of tool. The CVPC series is also maintenance-free, thanks to the venturi’s single-stage construction which makes the cartridge dust-resistant.

Additional Features: •

Size 1: nozzle Ø 1.2, 1.4 and 1.6 mm generating a suction flow rate ranging from 41 to 90 NI/min. Max. vacuum 85%

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Size 2: nozzle Ø 2.2 and 2.7 mm generating a suction flow rate ranging 160 to 215 Nl/min. Max. vacuum 85%

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Integrated pilot-operated solenoid valve reduces response times

4.3-inch displays Danfoss danfoss.com The DM430E series display will provide OEMs and operators a modern machine interface with increased outdoor screen viewability, an environmentally robust design, simple screen set-up, and a range of flexible features.

The optically-bonded and anti-glare coated 4.3-in. color display is

optimized for usage in all lighting conditions, providing better sunlight viewability and wide viewing angles. In darker settings, the light sensor automatically adjusts screen brightness and switches between day and night display themes.

Through the updated Engine Information Center (EIC) application,

OEMs can directly set up the display without any programming. The application connects more than 4,000 J1939 engine signals with a set of pre-defined screen graphics, saving development time and resources.

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PRODUCT WORLD

Vacuum pump for automated industrial procedures Piab piab.com The piPUMP23 is a powerful vacuum pump aimed at automated industrial procedures involving packaging, sheet metal, and wood products. The pump offers the same vacuum ejection performance and energy-efficiency as piCOMPACT23, the company’s all-in-one vacuum generator. However, not included are the advanced integrated controls, resulting in a less expensive vacuum pump for users who might not require these specialized functions.

Fully configurable, piPUMP23 is available with one or two COAX

Off (ABO) feature, resulting in a more efficient, powerful and energy-

SX12/SX42 multistage vacuum ejection cartridges and can be supplied

saving blow-off. By closing the flow-path of the ejectors during blow-off,

with or without cleanable and replaceable filters in two optional sizes.

the ABO feature ensures that 100% of the compressed air is channeled

The pump can be configured for up to three vacuum connections,

through to the cups during blow-off. This feature is also useful for

making it suitable for a variety of applications and industrial settings.

floating suction cups while positioning them in ergonomic lifting aids.

Retained from the piCOMPACT platform is Piab’s Amplified Blow-

Visual level indicator and transmitter in one package Gems Sensors & Controls gemssensors.com Mini LED SureSite indicators are suited to environments

where zero and low ambient light make visual indicators

safe and durable stainless steel process fluid containment, while

These mini indicators feature all the benefits of a SureSite, like

difficult to read. They make it easy to see tank level in

combining a continuous output transmitter with a bright LED channel.

low light and dirty environments where traditional units

The LED indicator assembly integrates a continuous level transmitter.

might get covered or be invisible. They can be used as an

A variety of signal conditioners provide the required output. They

oil level gauge and oil level indicator as well as for water.

feature a 270° viewing range and are built to withstand constant

They are available with 4-20 mA or voltage output and

vibration and shock while operating. They can withstand freezing

can be mounted in four ways: top and bottom, side and

temperatures, rain storms and washdown.

side, top and side, and side and bottom.

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

Environmentally acceptable synthetic hydraulic oils Chevron U.S.A. chevronlubricants.com Clarity Synthetic EA hydraulic oils are designed to give maximum protection in hydraulic equipment used on vessels and in environmentally sensitive areas. They are used in hydraulic systems as recommended

by ISO 15380, HEPR in mobile and stationary hydraulic vane-, piston-, and gear-type pumps.

They have a viscosity index of 180, which

ensures good temperature fluidity for lowtemperature operations. They are formulated with synthetic base stock and an ashless, zincfree additive system that provide exceptional oxidation stability, water separability, foam suppression, and protection against wear, rust and corrosion. The synthetic base stock withstands oxidation at high operating temperatures and results in maximum service life for the oil relative to vegetable-based readily biodegradable products.

They meet the requirements of

the EPA Vessel General Permit (VGP) for biodegradation, low toxicity and low bioaccumulation.

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COMPONENT FOCUS

Todd Degler • Product Manager • Eaton Hydraulic Motors

When should you use high-pressure motors?

High-pressure motors are able to accomplish more in a smaller package compared to medium-pressure technology.

When it comes to enhancing performance of both mobile and stationary hydraulic systems, high-pressure technology can be used to reduce package size, improve starting torque, and reduce system costs. At the end of the day, this means that skid steer loaders (SSL and CTL), drilling equipment, grinders and mixers, material handling and other mobile equipment can get more done, generate less emissions and use less fuel.

Switching from medium to highpressure models is typically driven by three factors: •

• •

Equipment size: as machines become more compact and nimble, higher pressure products allow the same capability in a smaller envelope.

Capability gains: applications where more capable motors yield more productive or efficient machinery Future compatibility: supporting future upgrades and changes

With a design to handle high backpressure, high-pressure motors such as Eaton’s HP30 can be used in series circuits without limitations on duty cycle or pressure ratings.

Key advantages of high-pressure motors There are many factors that impact the decision on the type of motor to select. New high-pressure motor technology is delivering benefits across a variety of aspects, making high-pressure motors the right choice for a range of hydraulic systems.

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COMPONENT FOCUS

Smaller package design High-pressure motors are more compact than medium-pressure models, upwards of 1.5 to 2-in. shorter. With improved mechanical efficiency, high-pressure motors require less cooling space. By generating less heat, high-pressure motors need less fuel over the life of the equipment.

High-pressure motors with a two-speed capability are optimized for reduced no-load pressure drop. This can reduce heat build-up, improving operating efficiency when traveling fast with low engine speeds when cooling is critical.

Flexible design

Weighing in less than larger, lower pressure technology Weight is an important consideration during machine design and typically impacts a range of performance parameters, including lifting capacity, ground compaction and towing requirements. Extra weight wastes fuel, requires stronger machine frames and often takes up valuable space.

High-pressure motor designs are enhanced through computational fluid dynamics (CFD) and fluid element analysis (FEA), so that material is placed where it is required and minimized elsewhere. These latest design methods are yielding motors that are stronger in more targeted and effective ways, reducing unnecessary weight in castings and reducing overall package size. Ultimately, today’s innovative motor designs are yielding lighter and smaller motors that can do more work.

High-pressure motors can provide some additional design capabilities in terms of series circuits, speed sensing and open- or closed-loop capability. With a design able to handle high backpressure, highpressure motors such as Eaton’s HP30 can be used in series circuits without limitations on duty cycle or pressure ratings. Further, highpressure motors can sense motor speed for real-time machine control. With an HP30 Design code 003 motor, an open-loop motor configuration can be changed to a closed-loop arrangement (and a closed-loop configuration can be altered later to an open loop) quickly and easily.

FPW

Eaton | eaton.com

Improve performance With higher motor pressure capability, high-pressure motors can perform more work. High-pressure motors have been shown to deliver an 8% increase in starting torque efficiency.

This means that high-pressure motors can perform more work than lower-pressure technology. Further, a high starting torque efficiency provides more power to the output shaft at start-up and reduces pressure and flow requirements to initiate rotation.

Additionally, high-pressure motors with two-speed technology can help accomplish some tasks faster and more cost-effectively. A high-speed low-torque mode (HSLT) can reduce motor displacement, which can yield a significant increase in rotation speed and reduce pressure and flow requirements to start rotation.

High-pressure motors have been shown to deliver an 8% increase in starting torque efficiency.

Minimize losses Heat and friction losses increase the need for cooling and overall costs. CFD (Computational Fluid Dynamic) models are helping to reduce fluid losses through disc valves with large flow passages; this means less heat is generated as the fluid travels through the motor. With less heat, cooling system requirements are reduced and the cooling system itself can be less costly and smaller. Further, finite element analysis is driving innovation in the design of built-in motor balance rings, so they are able to maintain high volumetric efficiencies at high pressures.

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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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