FLUID POWER WORLD JUNE 2019

Managing rod-seal friction in hydraulic applications p. 38 The evolution of construction equipment p. 46 A primer on hydraulic maintenance p. 34

www.fluidpowerworld.com

June 2019

Why pneumatic actuators are the workhorses of industry PAGE 52

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Over the course of two weeks, I heard several industry experts echo a fascinating trend as they discussed the future of manufacturing. The factory of the future is going to have to be flexible and fast, using IoT and AI, to deal with customized products and designs.

The first person to describe this trend was Donna Ritson, during our Fluid Power Technology Conference in Milwaukee last month, where she gave a keynote presentation on the future of pneumatics and automation. Here she stressed the importance of four key components of smart technology that are going to redefine the smart factory — efficiency, safety, flexibility and connectivity. And machine learning or AI and the use of digital twins will be core to all of these, she said.

For example, she noted how custom manufacturing is a thing — cars are being built to the buyer’s specs.

“Any components that you want, any frills that you want on it, you get your car made going down the manufacturing line. Well, that same concept is coming into the CPG market … maybe you want to get a beverage and you don’t want to buy a 12-pack of one beverage. You want to have every flavor in that package,” Ritson said. “And that’s what’s driving a lot of this change in this ‘manufacturing of one’ now is to be able to accommodate that efficiently where they don’t have to send that out to now a secondary warehouse for it to be broken down and repacked into multiple packs or variety packs.”

Just a few days later, I had an opportunity to tour Bosch Rexroth’s Factory of the Future Experience at its Hoffman Estates, Ill., facility, where the company has developed an exhibit to highlight how it is using its various technologies to embrace this concept. Rexroth experts echoed Ritson’s words.

According to Heiko Schwindt, VP Automation & Electrification Solutions, USA for Bosch Rexroth, “Our customers are requesting more customization, there’s one-piece production.

Higher productivity is clear — our machine builders want to increase productivity and save costs, with smaller batch sizes. And to support this we need a massive technology shift.”

This shift will include the need for an investment in higher connectivity, flexibility, intelligent systems, safety integrated into the automation system itself, and transparency.

Rodney Rusk, Rexroth’s I4.0 Business Leader – USA, drilled down further, adding that distributed intelligence will have to come down to the device level.

“That will allow us to have the ability to have mobile devices, where we can move machinery around, and begin to move the factory floor to accommodate what we need to build.”

It’s a far cry from where manufacturing is today, Rusk noted, adding that the use of digital twins will help make this possible.

“We are going to see more and more of that merger between the physical and cyber world here,” Rusk said. “It has to be a smart manufacturing floor and that smart manufacturing floor has to be open to change.”

FPW

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From the Field

Can the Amazon effect be overcome?

| iStockphoto.com

One of the speakers at NAHAD’s Annual Meeting & Convention in Las Vegas in April was Denise Keating of DATAgility, who spoke about “The Amazon Effect” that many companies, from manufacturers to distributors have been experiencing. Is it possible for a company to keep its sales channels intact without being overcome by the multibillion-dollar behemoth from Seattle?

Keating warned attendees that Amazon is not going away. In fact, the company’s incredible growth shows no signs of slowing down. In the last two years, Amazon has had 30% growth — a number that’s hard to fathom for a company of its size. Plus, while the company has been focusing more on the b2c market, the b2b market is five times larger, meaning that Amazon executives surely have a lot of the industrial in their targets.

Here are some of her main takeaways: •

•

•

•

Often times, innovation is about taking an existing product (or sometimes a newer product or service) and making it better, faster, and cheaper. It’s about making incremental improvements in your business processes, as well as in your manufacturing and distribution processes.

When she recently surveyed 300 manufacturers and distributors across multiple verticals, two-thirds felt that Amazon was some level of threat to their business. But she feels that the threat by another company or threat of disruption really comes not from what the other company is doing, but by our own lack of action and our own lack of understanding of the customer.

Customers have come to expect an easy-to-use platform with a broad selection of products, with robust and trusted content — all to help them make informed buying decisions. They want to be treated as an individual, so that they receive a personal and consistent experience.

And Amazon has taught buyers to become dependent on fast, reliable, on-time, low-cost or no-cost shipping. You don’t want to ignore those changing expectations.

Virtually all Americans own a smartphone — and the use of the smartphone runs across all demographics, so a mobile app can be an important tool. She explained how Home Depot ended up creating two totally different apps for typical consumers and their pro customers, because they saw enough differences in their needs and their behavior. Keating said that when you’re building either your app or your website, take multiple perspectives into account — say, both loyal customers who are familiar with you, as well as customers who are totally new to your company.

•

•

Include technical specifications on your site to help your buyers make informed decisions. Let them do faceted search on physical performances and attributes. Provide all of the content that supports the customer — not just in text form but with images.

Create a visual representation of that information, as that really resonates with many customers. Amazon doesn’t focus on the post-sales support sites based on products, so make sure to also include details such as warranties. Maybe you offer 30-, 60-, and 90-day, as well as 1-, 5-, and 10-year warranties. All of that information might be important to the customer; don’t limit their ability to filter the products on your website by that sort of information.

Don’t forget to include all delivery options on your website. Let customers know what products are available for same-day shipment and whether you have the inventory available.

FPW

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

On Twitter @DW_Editor 4

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JUNE 2019

C ontents |

vol 6 no 3

fluidpowerworld.com

•

6

•

2019

F E AT U R E S

SEALING TECHNOLOGIES

Managing rod-seals friction in hydraulic applications Advances in rod seal design, materials and test methods help improve the efficiency and reliability of hydraulic systems.

MOBILE HYDRAULICS

We’ve come a long way baby: the evolution of construction equipment

38

46

46 D E PA R T M E N T S

PNEUMATIC ACTUATORS

Pneumatic actuator control options Pneumatic actuators are essential workhorses for machine and equipment motion. Here are some pointers about different styles for control and monitoring.

52

02 FluidLines 04 From The Field 10 Korane’s Outlook 12 Association Watch 16 Design Notes 28 Distributor Update

30 Fundamentals 32 Energy Efficiency 34 Maintenance 57 Products

63 Component Focus 64 Ad Index

A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e

ON THE COVER

Understanding control and monitoring options for pneumatic actuators is critical in selecting the right component for your application. | courtesy of AutomationDirect

6

2019

SILVER SILVER NATIONAL NATIONAL AWARD AWARD 2018 asbpe.org

FLUID POWER WORLD

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Quality – The standard of something as measured against other things of similar kind, the degree of excellence of something.

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If quality and reliably high performance in your pneumatic automation applications matter to you as much as they do to us, then Fabco’s pneumatic cylinders are your only choice.

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JUNE 2019 • vol 6 no 3 • www.fluidpowerworld.com

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EDITORIAL

VIDEO SERVICES

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

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VP, Publisher Michael Ference 408.769.1188 mference@wtwhmedia.com

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Contributing Editor Josh Cosford @FluidPowerTips

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Contributing Editor Carl Dyke @carlindustry CREATIVE SERVICES

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EVENTS

Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison

Digital Production/ Marketing Designer Samantha King sking@wtwhmedia.com SALES

DIGITAL MARKETING

Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane

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

FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 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, June, July, 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.

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E D I L G A R E T K 6 HB

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

Komatsu’s small electric excavator runs much quieter and matches the speed and productivity of an equivalent diesel-powered PC30.

Pre-production units are currently working at customer sites in Japan.

Mobile hydraulics gets an unwelcome jolt One unmistakable take-away from this year’s bauma show was the buzz surrounding electrification. The idea of massive mobile machines running only on batteries may seem far-fetched, but for smaller equipment it has become a reality. At every turn, major manufacturers like Cat, Kobelco, Komatsu and Volvo to niche players like Ecovolve and Giant featured electrified excavators and loaders.

Why the increasing focus on electric construction machines? “There are different reasons. Some people are interested just from an ecology green perspective,” said Caterpillar’s Elie Abi-Karam.

“For others, regulatory issues — in Europe especially — are driving people to lower their emissions. Electrification is the next step, creating a machine that effectively has zero emissions.”

Bobcat is specifically addressing indoor applications such as demolition and basement construction with its new E10e battery-powered, 1-ton mini-excavator. The industry is definitely moving in this direction, said Product Line Director Jarry Fiser. “In developing the E10e, we are not just demonstrating technology for the sake of it. We are providing a product that offers clear customer benefits.” As well as indoor projects, many other sites will require low-noise, zero emission machines, he said, including urban/citycenter developments, night-time work and quiet zones such as hospitals, cemeteries and schools.

All of the machines at bauma were firstgeneration — basically engine out, batteries in. At this initial phase of electrification it’s still about powering existing hydraulics. “In the first step, OEMs don’t want to completely change 10

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the architecture of the machines,” said Bosch Rexroth’s Bernd Schunk. “They just want a plug-and-play solution. And, to be honest, they are all a little bit reluctant to change everything at the same time.”

Next-generation machines, however, may bring modifications such as electric drives replacing hydraulic rotary drives on excavators, he said.

Schunk said his company’s engineers are working to further optimize the design, performance and efficiency of products like axial-piston pumps specifically for electrification. “It makes a huge difference whether you use a diesel engine or electric drive, and it’s even more challenging if you have batteries inside.” That’s because the load cycle and battery life play a major role in whether a machine is successful in the market or not, he explained.

One such development specifically targeting this market is the new AX piston pump from Bucher Hydraulics.

The 24-piston, load-balanced unit claims extremely high efficiency over a wide speed range, making it ideally suited for use with

variable-speed electric drives. Low power losses conserve valuable battery capacity.

Fluid power engineers need to step up their game because there are rumblings about fully electric machines with no hydraulics whatsoever. Wacker Neuson’s Klaus Allerstorfer, for one, can foresee electromechanical actuators as the future.

“I definitely think so; the hydraulic system on an excavator is not a given. In the end, it depends on where the industry is going and what suppliers are developing,” he said.

“We only use components in our electric machines that are proven for hard applications and can sustain dust and vibration conditions.” For production machines, that currently means hydraulics, but they’re exploring new technologies in different areas of the excavator, he explained. “It’s always a mix of performance, sustainability and the expectation of long lifetime for the customer. In the end, we want to deliver the best quality, the best performance for zero-emission products as we do for our regular machines.”

FPW

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ASSOCIATION WATCH

Edited by Mike Santora • Associate Editor

NFPA’s 2019 Industry & Economic Outlook Conference August 12 – 14 Hilton Chicago/Oak Brook Hills Resort, Oak Brook, Ill.

The Industry & Economic Outlook Conference (IEOC) returns to the greater Chicago area in August, once again offering hard data and expert analysis for everyone in the fluid power supply chain. The 2019 conference provides attendees several new opportunities to network, learn, and get the most out of the event.

In addition to a new location, this year adds new topics to the usual IEOC lineup to offer a different level of technological insights in addition to a co-located event with the American Gear Manufacturing Association (AGMA).

These include: Robotics and IoT in the Industrial Marketplace – Donna Ritson, DDR Communications LLC The Future of Technology and its Impact on Manufacturing – John Ellis, Ellis & Associates Co-Located AGMA Marketing & Forecasting Conference — Tom Runiewicz of IHS Markit will share his insights on the U.S. economic conditions surrounding the gear industry. The IEOC offers several opportunities to make connections with other attendees.

12

Tuesday Networking Breakfast or Special Pre-conference Networking Breakfast and Presentation – Enjoy breakfast while talking with colleagues or while listening to a special presentation on solutions to industry issues.

Networking Lunch – Choose from three networking lunch meeting options on Tuesday, August 13: • Future Leaders Lunch – Open to NFPA members 45 years of age or younger who are currently on a leadership path, this option features networking and a short presentation.

• NFPA Technology Roadmap Forum and Lunch – Open to all attendees. Enjoy lunch while discussing the latest fluid power technology challenges and solutions with your industry peers.

Highlights:

• Networking Lunch for All Attendees – Open to all attendees.

NFPA Foundation Invitational Golf Tournament – This modified “scramble”-formatted tournament appeals to golfers of all levels and offers fun, casual competition.

Registration is open at nfpa.com. The room block at the Hilton Chicago/ Oak Brook Resort is available until July 12.

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ASSOCIATION WATCH

More IoT resources coming this summer Many of the presentations at the past few NFPA events, including the NFPA Annual Conference, Industry & Economic Outlook Conference, and Regional meetings have focused on the Internet of Things and how it relates to the future of fluid power.

Planning and building around fast-moving, shifting, and often unclear IoT trends can be tough without the right information, so NFPA will continue work to bring more resources for members to use moving forward at their companies.

Coming soon, NFPA has signed on with IHS Markit to provide NFPA members a report that assesses the IoT readiness, capabilities, and emerging requirements based on key industrial markets for fluid power, such as automotive and power generation.

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ASSOCIATION WATCH

The report is based on a survey that looks at six key areas of IoT readiness: Data handling and processing – how well companies are collecting, storing, and analyzing data?

Governance – to what extent do IoT capabilities appear ready to support new business models?

Networking – to what extent do companies have suitable infrastructure for collection and storage of data?

The report will be available to all members, and at the same time, IHS Markit analysts will present key conclusions and additional insights at the 2019 NFPA Industry & Economic Outlook Conference this August in Chicago.

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DESIGN NOTES

Hydraulic actuators bring the power to the HyQReal quadruped robot Edited by Mary C. Gannon, Editor

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DESIGN NOTES

Researchers from Moog and IIT-Istituto Italiano di Tecnologia recently completed the design, assembly and testing of the new version of the hydraulic quadruped robot HyQ, called the HyQReal. Its capabilities were demonstrated by pulling a 3,300-kg (7,275 lb) airplane for more than 10 m (394 in). The compacte HyQReal is just 1.33 m (52 in.) long, and stands only 90 cm (35 in.) tall and weighs 130 kg (287 lb), even with hydraulic infrastructure and batteries onboard. The robot has customized rubber feet for high traction on the ground and is protected by an aluminum roll cage and a skin made of Kevlar, glass fiber and plastic. A 48-V battery powers four electric motors connected to four hydraulic pumps. The robot has two computers on board: one dedicated to vision and one to its control.

The new design was tested in the Genova Airport, with the support of Piaggio Aerospace, to demonstrate the power of HyQReal by pulling a Piaggio P180 Avanti, a small passenger airplane weighing more than 3 tons, with a length of 14.4 m (567 in.) and a wingspan of 14 m (551 in.).

Moog partnered with IIT, a research institute that promotes excellence in basic and applied research fostering Italy’s economic development, in 2016, when both created the joint lab to develop the next generation of hydraulic legged robots. The partnership combines IIT’s knowledge of designing the hardware and software of legged robots, with Moog’s expertise in miniature, highperformance actuation solutions.

The HyQReal robot is developed to support humans in emergency scenarios. These hydraulically powered quadruped robots have been under development by researchers at the IIT since 2007. The long-term goal of the project is to create the hardware, software and algorithms for robust quadruped vehicles for rough terrain that can be tailored to a variety of applications, such as disaster response, agriculture, decommissioning, and inspection. Compared to the previous versions, HyQReal is completely power-autonomous with onboard hydraulics, batteries and wireless communication. Furthermore, the robot features a higher ruggedness, reliability and energy efficiency.

The hydraulic HyQReal quadruped robot from Moog and IIT-Istituto Italiano di Tecnologia. Its capabilities were demonstrated by pulling an 3,300-kg (7,275 lb) airplane for more than 10 m (394 in). www.fluidpowerworld.com

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DESIGN NOTES

“Pulling a plane allowed us to demonstrate the robot’s strength, powerautonomy and the optimized design. We wanted to achieve something that has never been done before, and we succeeded last week,” said Claudio Semini, project leader at IIT’s Dynamic Legged Systems Lab.

For the HyQReal, Moog developed the majority of the hydraulic actuation system, including the hydraulic pump units, smart manifolds, fluid rotary unions and Integrated Servo Actuators (ISA). The Integrated Smart Actuator is a lightweight hydraulic actuator with integrated servovalves, control electronics, sensors and bus communications designed for mobile robotic applications. Moog has specifically developed these components for the HyQReal and will offer this

technology to equipment builders in the mobile robotics market where energy efficiency and high performance are critical.

According to Burkhard Erne, manager for Growth & Innovation at Moog Inc., “Small, mobile robots typically use electromechanical motion control solutions.

HyQ-Real is larger and more powerful than many other mobile robots, and it

The HyQReal quadruped robot is powered by hydraulics from Moog. The company partnered with IIT-Istituto Italiano di Tecnologia in 2016, to design and now test the newest HyQ.

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DESIGN NOTES

is designed to master unstructured terrain, outdoors. For high-power dexterous motion control, hydraulics has numerous advantages including: substantially lower “unsprung” mass (weight of suspension and components connected versus supported by the suspension), higher power density, better drive transparency, integral cooling and lubrication. These advantages help the robot to move faster, to walk more dynamically in unstructured terrain and to be more robust when hitting obstacles.”

IIT has led the overall development of the robot’s hardware and software. In terms of hardware, IIT focused on the design of the torso, legs, electronics, hydraulic hoses, and fall protection and sensing technology. Additionally, it coordinated the integration of the actuation subsystems developed by Moog. In terms of software, IIT adapted its locomotion control framework that it has developed over the last decade.

“Thanks to IIT and Moog’s complementary expertise, we managed to enhance our control software with increased safety and modularity,” said Victor Barasuol, who is in charge of HyQReal’s control technology.

The HyQReal team at IIT is international, composed of 14 people from Italy, Switzerland, Brazil, England, Canada, Egypt, the Netherlands, and Mexico. The development of HyQReal was funded by the Istituto Italiano di Tecnologia and Moog Inc. with the support of INAIL – the National Institute for Insurance against Accidents at Work and the European Union under the framework of project ECHORD++.

FPW

To see a video of the HyQReal robot in action, find this article at fluidpowerworld.com.

Moog Inc. | moog.com/industrial 6 • 2018

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Hydraulic accumulator system helps new blow molding facility Edited by Mike Santora, Associate Editor

There were significant challenges when Roth Hydraulics needed to design and install a large new blow molding plant for plastic products at its production site in Watertown, N.Y. The project connected the manufacturer’s skills in two fields — hydraulics and plastics processing. The design of the new hydraulic accumulator system now permits high-speed production, ample power reserves, and substantial energy savings.

Weighing in at 125 tons and with a clamping force of roughly 300 tons, the blow molding plant is equipped with three extruders. The production plant is also fitted with three sensor-controlled piston accumulator systems for various hydraulic functions in the production process. Roth chose this configuration because hydraulic energy is required to open and close the nozzles, to extrude the plastic tube, and for all movements that the blow molding plant undertakes.

The hydraulics facilitate movement in the plates, the two-part 20

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mold, the blow pin and blow needles for letting in air, the mold closing mechanism during the blow molding process, and the control of the wall thickness of the plastic. Both halves of the mold can be moved separately, allowing them to move both in and out of synch and at different speeds. Cylinders fitted with locking devices at the four corners of each mold half regulate the clamping force. Clamping cylinders support the mold as it closes to a precise fit while withstanding blowing pressure of up to 87 psi.

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The mold itself weighs 15 tons (7.5 tons per half) and can open by up to 9.84-ft at a speed of 11.8-in./sec. Each piston accumulator system has a working pressure of 2,600 psi and a maximum pressure of 3,100 psi. Proportional valves control how the two mold halves close and how the plastic tube feeds into the blow mold. www.fluidpowerworld.com

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Blow molding plant for plastic products at Roth Hydraulics USA in Watertown, N.Y.

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DESIGN NOTES

John Pezzi, V.P. Operations at Roth North America, explained, “The piston accumulator systems have allowed us to reduce the electrical load of our hydraulics by around 75%. This reduction covers the load from our pumps, motors, and heat exchangers. Cutting energy consumption to a minimum improves our environmental footprint and helps to conserve resources.”

The piston accumulators for machinery and systems come in sizes ranging from 0.026 to 396 gal. Standard systems are available with a maximum operating pressure of 5,100 psi, while customized designs can handle up to 17,500 psi with variable pre-load pressure.

Depending on their field of use, increases in capacity are possible by installing auxiliary gas bottles to be used

DESIGN NOTES

Roth Hydraulics pressure vessel plant with a customer-specific screw joint system.

with the piston accumulators. Even compact, large-scale systems with a total volume of well over 26,400 gal can be manufactured and supplied, ready for connection — by coupling together any number of piston accumulators and auxiliary gas bottles. The accumulator systems are suitable for use in temperatures ranging from 14 to 176 °F with versions available that can handle larger extremes: as low as –76 °F and as high as 392 °F. Roth designs fluid connections and sealing systems for the piston accumulators to order based on its customers’ requirements. It is not possible for any gas

to escape suddenly on the fluid side.

With its large new blow molding plant, Roth now has five production sites located throughout the world that use blow molding processes to create plastic products. All of them are equipped with Roth Hydraulics piston accumulator systems.

FPW

Roth Hydraulics roth-hydraulics.de

Monnier, Inc. and Fluid Air Controls Holdings, Inc. have merged to form

The Monnier Companies will maintain our brand names Monnier, Flairline and Hydronic, but all will be under the same corporate structure. Learn more @ themonniercompanies.com.

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DESIGN NOTES

Tube forming assembly machines can be easily monitored in future via a cloud connection. Software updates and new parameter sets can also be installed in this same way.

Documentation and evaluation of the orders completed is also simplified by the cloud connection. | Courtesy - Walter Stauffenberg GmbH & Co. KG

Cloud-connected assembly machinery simplifies predictive maintenance Edited by Mary C. Gannon, Editor The latest generation of machines for the pre- and final assembly of cutting rings (Type SPR-PRC-POC) and forming machines for Stauff Form (SFO-F) now come with a built-in connection to the cloud.

This offers users significant advantages — for instance with software updates. Up to now, Stauff Service had to contact the user of the machine and agree to a time at which a network connection could be established and an update installed. Or, alternatively, the software was updated in situ using a laptop with a network connection. In future this can be done online. Stauff Service simply needs to agree to a time with the user at which the machine is online and not in use.

Updating the machine for new uses will also be made easier. Stauff experts can now also relatively easily transmit new parameter sets if the user of the machine is working with different tube materials for which the requisite parameters were not supplied when the machine was delivered.

This addition provides the customer with a new benefit: the machine documents online in detail the assembly processes performed and enables them to be called up online. They can then be printed out and used as evidence of correct assembly.

A further benefit also comes from the option of viewing the machine’s history and parameters via an online service. According to Dipl. Ing. Oliver Wagner, Electronics Developer at Stauff, “We can now analyze data 24

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together with the user and optimize the machine’s settings if we need to.”

One example of this is if the parameters show that the cylinder pressure in a certain process is always at the limit of a defined and stored threshold value. “We can then specifically counteract this and so maintain the quality of cutting ring installation or forming at a high level,” Wagner said. “And if the machine were to malfunction, the cause can be quickly identified, as all the relevant data for the machine as well as for the individual tools can be accessed in the cloud.”

Requisite data security is guaranteed in all the use cases presented here, as all data is exchanged encrypted with the cloud and vice versa. The data is therefore protected against unauthorized access, misuse and manipulation.

This cloud connection means that Stauff is manifesting key functions — and benefits — of predictive maintenance in its machines. This solution is achieved through the use of a built-in SIM card, which can be used in all industrial regions of the world. Existing machines can be simply and easily retrofitted with the module.

FPW

Stauff | stauff.com

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Electrification exposes hydraulic-pump shortcomings Ken Korane, Contributing Editor Heightened concerns over climate change and global warming are key reasons for the growing interest in zero-emission vehicles.

Battery-electric mobile machines, while still mainly in the prototype stage, may require hydraulic-pumps and variable-speed drives to evolve to suit future applications.

Typical forces in an axial-piston

Hydraulic pumps are high-performance components. However, according to engineers at Bucher Hydraulics, Klettgau, Germany, they have some fundamental flaws that highlight a considerable need for improvement in the face of new demands.

Technically mature and well-proven hydraulic pumps and motors work to their full potential in mobile machinery, traditionally designed and engineered for use in combination with diesel engines. They were invented for such applications, have been continuously improved over decades and are suitably efficient in this combination today. Having said that, these mature solutions are clearly reaching their limits in new applications involving electrification of the drive train, particularly where battery-powered machines are concerned. This is evident in almost all the application-critical factors: from starting behavior and installation envelope to noise level and efficiency.

Battery capacity is expensive and it therefore needs to be used efficiently, but the extent to which this can be achieved depends largely on individual components in a system. Recent electrification projects clearly confirm the high efficiency of electric drives. The efficiency of hydraulic systems is lagging behind in comparison, and is not ideal for these applications. Using a simple, low-cost pump results in high power losses at the expense of the battery. Valuable battery capacity is needed just to make up for the power losses, and it is inevitably converted into useless heat.

Power losses The efficiency of a hydraulic pump and its power losses directly affect costs and emissions. Consider the example of a pump with 26

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pump can lead to issues in battery-powered equipment.

an 80 cc/rev displacement operating at 250 bar pressure and 1,500 rpm. Pump efficiency ηp = 0.85 and power losses at the shaft = 8.8 kW.

The power lost at the hydraulic pump must also be supplied by the electric motor, which means electrical efficiency ηe (e-motor + inverter) = 0.92, which equates to a power loss = 9.5 kW at the incoming electrical supply. After a running time of 1,000 hours, this equals 9,500 kWh.

Using the German Environment Agency’s CO2 emissions factor for 2017, this gives an emission of 5,102 kg CO2 just to make up for inherent losses resulting from inefficiencies in the motor/pump system. In addition to the increased emissions, compensating for the power loss at the hydraulic pump will, of course, also have an impact on costs: 1,000 hours @ $0.16/kWh = $1,520.

Due to their particular design, axial piston pumps generate considerable noise. The pulsating displacement of the hydraulic fluid, and the related alternating and widely fluctuating internal pump forces, result in housing vibrations that ultimately transmit to the entire machine. This causes a high noise level in the application.

Although sound insulation can be added as a secondary measure, that is always associated with extra work, the need for a larger installation space, and additional costs. In industrial

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DESIGN NOTES

High pulsations typical in axial-piston pumps result in problematic noise levels in electricdrive applications.

settings this is sometimes unavoidable, but it is almost unthinkable in the mobile-hydraulics sector due to the limited space availability.

When hydraulic pumps are used with diesel engines as originally intended, the problems of physical pulsation are barely noticeable. This changes fundamentally in applications with quiet electric motors, where the characteristic loudness becomes prominent in an extremely disagreeable way and is completely rejected by end users. Instead, they demand the lowest possible noise emission over a wide range of speeds and pressures.

A related concern is how the pump performs at low speeds.

That is because at high pressures, to prevent high wear due to mixed friction, variable-speed pumps must not fall below a certain minimum speed. This is particularly evident when positioning heavy loads, where only a low flow rate at high pressure will guarantee precise movements.

The large, non-compensated forces in bent-axis motors need to be absorbed by extra-large ball or roller bearings. This increases space requirements and makes integration more difficult.

In this case, speed is an important criterion for establishing lubricating films. However, due to the minimum speed limit (not less than 1,000 rpm), the pump delivers too much oil and the excess has to be discharged via a bypass. At high pressure, this results in large losses. These losses also have to be made up for by the battery: some of its capacity is simply being converted into useless heat. Last but not least, the high pressure of 350 bar that is required in mobile machines cannot be attained with simple external gear pumps.

The situation is similarly critical when the pump operates as a motor. When energy efficiency is one of the most important issues, the overall efficiency of the hydraulic drive unit does not score highly due to its inadequate energy recovery. When recovering potential energy (for example, a raised weight) and transferring it to an energy storage device, the losses are simply too high — which ultimately means that too little energy returns to the battery.

Another negative feature that make the use of hydraulic drives more challenging is the starting behavior of hydraulic motors, especially those based on a swashplate design: the motor is initially subject to loads and static friction before it suddenly starts to move. This process presents application difficulties, and it has a damaging effect when, for example, a hoist winch is being used to jog-position an awkward load. In addition, operation at low speeds is subjected to superimposed torque pulsations. This, in turn, can lead to oscillations in susceptible machines and thus make secondary measures necessary.

Last but not least, the substantial installation space that is needed is a drawback: large, non-compensated forces in bent-axis motors can only be absorbed by extra-large ball or roller bearings. This increases the space required in the machine, so integration is less straightforward.

All in all, there is an urgent need to improve hydraulic pumps and motors in terms of their efficiency, noise generation, installation envelope and variable-speed capabilities. The demands placed on mobile machinery — which are already high — will only increase in the future.

FPW

Bucher Hydraulics | bucherhydraulics.com www.fluidpowerworld.com

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| iStockphoto.com

DISTRIBUTOR UPDATE

How should manufacturers and distributors deal with problem employees?

A

Paul J. Heney • VP, Editorial Director At the recent NAHAD Annual Meeting & Convention in Las Vegas, Pamela Krivda presented one of the more interesting sessions

— dealing with difficult HR decisions. Many smaller component distributors and manufacturers don’t have the luxury of a large human resource department. What’s more, sometimes they don’t fully understand the legal implications of what they do in situations where employees aren’t performing up to standards.

She implored the audience to keep written records of every time an employee is given a poor review, spoken to about a work incident or anything else that shows they are not meeting expectations. But one of her most compelling arguments was to do something unexpected with poor performers: suspend them with pay.

Krivda said that she doesn’t use it as her first option; this would be after a verbal warning and then a written warning. Then she’d sit down with the employee and first review their prior history — she noted that this is also a way for you to clean up any holes in your documentation.

“If a few things weren’t documented, you can get them down now. So, you review the previous history with the employee … and you write everything down. So even if there was a verbal counseling, if you can make the employee sign for it, you write it down in here,” she said.

Krivda said that the employee is generally relatively happy that although they’re getting suspended, it is with pay, so they’re not overly concerned about what you write on the incident sheet, as far as past notice. Then, you go over the latest incident — say, being rude to a customer. Krivda would explain why the customer is important and why

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rudeness is never allowable in this sort of situation.

“If you’ve got the complaint from a customer, if the customer comes to you, ask them a lot of questions about it — because they’ll be willing to tell you chapter and verse about it. And that makes them feel like they’re not just taking up your time with nothing to complain to,” she said.

“Then you’re going tell the employee, ‘Here’s what we’re going to do. I want to know what you really think about your job here. Do you want this job or not? Now, if you want the job, you have to have it under the same terms and conditions as everybody else. You don’t get anything special. You have to take it under these same terms and conditions. And the terms and conditions are, you have to be polite and have a can-do attitude toward our customers.’”

Krivda said that the employee should then sign a form acknowledging that they want their job as a

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counter salesman for ABC Distribution. That the employee acknowledges and accepts his/her responsibility. Their job description should also be attached to it — if you don’t have one, now is the time to write one up.

“Somewhere in your rules, regulations, your handbook, whatever it is, you need to have a rule that says that employees must demonstrate a can-do or constructive attitude. Or, if you prefer, a collaborative attitude,” Krivda said. She loves this term because, she noted, who gets to decide whether or not it’s collaborative? The company does.

“Then you are able to say, ‘Your responsibilities on your job description include demonstrating a constructive attitude or a collaborative attitude, which

basically means do what we told you to do.’ That they understand that they have a job under the same circumstances as everybody else, same terms and conditions of employment. They understand and acknowledge that their performance has been unacceptable. They pledge to improve. No time limits on that, immediate and sustained. And they understand that failure will result in termination. Then they sign it,” she said.

“So, the beauty of it is, this doesn’t ask them for a darn thing that every employee in your organization does not have to do,” Krivda said. “Everybody has to abide by this same set of rules and circumstances.

It’s just that you don’t have to beat most employees over the head with it — most

employees just do it. Now, we have their signature and they have been told, ‘I want you to go home for a couple of days and I want you think over if you want the job or not. If you want the job it’s here, but of course you have to change your attitude. If you don’t want the job, just tell me. We’ll either figure out something or give you a little bit of time to find another job or just release you with no hard feelings.’”

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FUNDAMENTALS

Edited by Paul J. Heney • VP, Editorial Director

Ensure that your leak tag system is working Leakage is usually a significant add-on to the cost of operating any compressed air system. Almost every factory employee knows there are air leaks, and often can identify where the big ones are — but the follow-through on this knowledge is often a problem. This is where a good system of leakage detection and repair comes in handy.

During a recent visit to an industrial plant, an auditor heard from the plant manager about their excellent leak tag system — well, at least he thought it was excellent and fool-proof. All employees had the option of identifying leakage using an innovative inhouse leak tag system. Whenever a leak was identified, the employee could grab a leak tag from a tag bin and fill it out, identifying the location and severity, and hang it on the leak. A perforated part of the tag would then be ripped off the main tag and put in the maintenance department’s mailbox for repair.

This sounded like a great system until the auditor started looking, or rather listening more closely. Leaks were everywhere in this plant and no tags were to be found. A quick check of the compressor during non-production time showed the plant compressor was 60% loaded, even while the plant production machines were idle.

The auditor asked about seeing what the plant’s innovative tags looked like, but it seemed as if nobody knew where they were. Finally, they were located under the maintenance manager’s desk. It seemed like the tags were a good idea at the time, but the tag and repair system was not really a system, because it lacked follow-through. This sort of problem is not uncommon; the auditor regularly sees numerous leak tags flapping in the breeze from major leaks in sites he visits, sometimes years after the leaks were identified.

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A leak tag system needs to be followed through until repairs are completed.

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Some tips about leakage repair systems: • A good leakage repair system starts with employee awareness; the line workers need to be educated about how much leaks cost and what they can do about them.

• Often times, leakage detection and repair has to be gamified — that is, the employees sometimes require a little more motivation than the nice feeling about finding a leak to take action. Some plants make leakage detection a contest that workgroups can participate in to get recognition or reward.

• Leakage can be more easily detected with good ultrasonic tools.

These need not cost thousands of dollars, as there are some very affordable leak detectors available for purchase these days.

• A good system of tagging is important. Be sure when the leak is found it can be identified, described and located again when the repair is made. Or best, repaired immediately.

Diagnostic test equipment & data logging

• Ensuring follow-up is a must, finding leakage is often fun, but repair more difficult. Make sure that when the leak is identified, the repairs are scheduled in a timely manner. Typically, someone needs to be accountable for leakage levels; if your plant does not have someone, make sure this changes.

• The leakage repair efforts need to be part of normal mainte- nance. Make sure your maintenance program has a way to identify the general leakage level (such as a main flow meter) and has a system of tracking the level frequently so changes can be detected. Set target levels and keep at the repair process until the desired level is achieved. Make sure your system triggers action should the level rise over a certain threshold.

• If you have so many leaks you don’t know where to turn, get help, and attack with a special focused effort and the beginning of the process. And keep plugging until the job is done!

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ENERGY EFFICIENCY

Ron Marshall • Contributing Editor

Q&A: Compressor cooling issues

Q

Question: In a manufacturing facility, and especially with a VFD (which I understand likes cleaner air), how important is it to vent the intake and exhaust of the compressor to outside? I can’t see air up on the roof being much cooler than inside the plant in the hot summer and in the winter; you would mostly have to draw in plant air anyway due to the temperature.

Answer: It depends on the environment, but the most important thing is venting the hot air away from the compressor (not necessarily outdoors). Often, with no ducting to separate hot and cold air, or leaky ducting, the hot air discharged by the compressor will go right back into the intake, in a short circuit, causing the compressor to overheat. It is important that the ventilation duct not represent a restriction to flow, so must be well-sized and not subject to negative pressures due to other plant air exchangers. The best-case scenario is to vent the heat outdoors in summer and to cooler areas of the plant in winter.

Care needs to be taken with ventilation air inlet ducting — it can’t fall below freezing at any point, including when the compressor is off, or freeze-up can occur.

The compressor air to air cooler is a place where water condenses, so freezing can wreck the cooler and shut down (or prevent the start) of the compressor.

In dirty environments, finding a clean supply of cooling air is wise … but be aware that the VFD cooling intake is often separate from the main cooling air intake. In the case of dirty environments, some manufacturers have the option of remotely installing the VFD in a clean electrical room.

You have a point about rooftop air: it is often hot, but likely cleaner. But location of the intake source is sometimes important. One industrial plant placed the intake near their evaporative water-cooling system. The chemicals from the water mist caused contaminant problems in the compressor lubricant.

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Exhaust duct leakage on this compressor overheated the compressor room, leading to operating problems which overloaded the air dryer.

Best practices for systems in locations with summer/winter conditions is to have both intake and outlet connected to outdoors with mixing damper between the ducts to condition the cold air in winter, keeping it at a minimum temperature of about 50° F. A secondary automatic damper would direct heat to the plant in winter and outdoors in summer.

In tropical environments that are never below freezing, the compressors are usually placed outdoors in a rain protected location … but again, care must be taken to ensure the hot air discharge is not ingested by the compressor intake. This air should not be directed at a neighboring compressor or air dryer.

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MAINTENANCE

Practice good hydraulic system maintenance Steve Skinner • Industry Expert and Author Martin Cuthbert • Managing Director, Webtec

When it comes to hydraulic system maintenance, it is vital that the people involved in recording data, taking samples, using test equipment, etc., are properly trained in the jobs they have to perform and the equipment they have to use. No matter how comprehensive the maintenance procedures are, there will inevitably be occasions when maintenance personnel have to use their initiative, so it is important that they are properly equipped to do so.

Figure 1. Pressure test point

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Examples of good maintenance practice include the following: • Pressure test points. Fit pressure test points into the system where pressure readings are likely to be required (such as when setting pressure-relief or pressurereducing valves). Gauges permanently connected into the system may be subject to pressure peaks and ripple, and so tend to have a short life. They can be protected by ‘push to read’ or ‘twist to read’ valves, which normally isolate them from the system, or they can be removed completely and only connected when required via simple quick-release test points (see Figure 1).

• Access points. Include access points for taking fluid samples from the system, normally from the pressure line or from the reservoir. Sampling from the reservoir should ideally be via a pipe, taking fluid from the center of the reservoir, away from where water or contamination is likely to settle.

• Flow meters. Flow meters are sometimes permanently connected into systems but more often need to be connected temporarily for test purposes. This process can be made simpler by including quick-release couplings and/or three-way valves to divert flow through the meter when required (Figure 2). Care should be taken, however, to ensure that the test equipment and associated fittings do not create undue restriction (e.g., in the case drain line of pumps and motors).

• Adding new fluid. As stated previously, new fluid to be added to a reservoir will normally require cleaning, so provision should be made to incorporate a filter on the reservoir filling connection. If this is not practical, a filling point should be included so that it is not possible to simply pour fluid into the tank. If filling of the tank has to be carried out by pumping the fluid in (e.g., via a quick-release coupling or side connection), it is more likely to be done correctly via a fluid-transfer cart and filter.

• Label reservoirs. Color code or clearly label each system reservoir with the correct fluid to be used for filling and topping up. www.fluidpowerworld.com

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• Mark normal fluid levels. Mark the normal maximum and minimum fluid levels on the reservoir sight glass.

• Shut-off valves. Where shut-off valves are likely to cause damage if set incorrectly, for example on pump inlet or drain lines, they should be monitored via limit or proximity switches that are interlocked to ensure pumps cannot be started unless the valves are fully open.

• Drain valves. Consider using automatic drain valves on accumulators to drain the pressurized fluid whenever the machine is switched off. Manual valves should also be included (as a backup), together with an isolated pressure gauge to verify that the accumulators have been discharged.

• Components requiring regular attention. Ensure components requiring regular attention (filters, test points, gauges, etc.) are easily accessible, and that spillage trays are placed where fluid is likely to be spilled during maintenance activities (e.g., changing filter elements).

• Flush valves. Consider adding flushing valves around actuators (Figure 3). This will make the flushing process simpler when the system is first installed and will also be useful when actuator connections involve long pipe runs. In long pipe runs the volume of fluid in the pipe may often be greater than the displacement of a cylinder, so the fluid will just shuttle backwards and forwards along the pipe (i.e., it will never get back to the system cooler, filter or reservoir). A bypass valve around the cylinder can be opened periodically during maintenance periods to flush new oil into that part of the system.

• Make the correct way the easiest way. Adopt the philosophy that the easier it is to do something the more likely it is that it will be done. Also, the correct way of doing something should be made the easiest way of doing it, so that mistakes are less likely to happen.

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QUICK-RELEASE COUPLINGS

FLOW METER SHUT-OFF VALVE NORMALLY OPEN, CLOSE TO MEASURE CASE DRAIN FLOW

Figure 2. Monitoring pump drain line flow

A COMPLETE RANGE OF SENSORS:

RELIABILIT Y IN MOBILE HYDRAULIC CONTROLS!

Handle the unexpected with skilled troubleshooting No matter which maintenance methodology is used and how rigorous the process, there will inevitably be occasions when something unexpected occurs to cause a malfunction in a system or of a machine.

This is when troubleshooting skills become necessary, to locate the fault as quickly and accurately as possible. So, whereas maintenance deals with the expected, troubleshooting involves handling the unexpected.

Like maintenance procedures, troubleshooting on hydraulic systems should only be carried out by well-trained, experienced people with a good knowledge of both the machine and the hydraulic system itself. Troubleshooting activities may often involve running a machine in a

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MAINTENANCE

different way from its normal operation.

For example, the machine may have to be operated in manual rather than automatic mode, interlocks or guards may have to be temporarily removed, or directional valve manual overrides may be used instead of normal solenoid operation. During such activities the possibility of dangerous situations arising is much greater than in normal operation, hence the need for welltrained, experienced personnel who are aware of the risks involved and know how to take appropriate measures to minimize them.

Hydraulic specialists also need to have a good working knowledge of electronic control and communication systems, which are increasingly used in today’s machinery.

While the integration of electronics in mechanical and hydraulic components

has added an extra layer of complexity, the diagnostic capabilities of modern electronics have the potential to simplify troubleshooting activities.

This text is an excerpt from An Introduction to Practical Hydraulic System Maintenance: A Fluid Power Technician’s Guide, published by Webtec Products Ltd. This new book is available from Amazon.com FPW

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Managing rod-seal

friction friction

in hydraulic applications Advances in rod seal design, materials and test methods help improve the efficiency and reliability of hydraulic systems.

Chuck White • Director of Business Development, Hallite

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Friction is one of the most common and underestimated causes of rod seal leakage in a hydraulic system. However, measuring and addressing it can be a challenge because it requires skillful balance.

Too much friction will cause excessive seal wear, reduced seal life, and diminished hydraulic system efficiency, while too little or insufficient friction will result in excessive leakage. Left unchecked, both situations will lead to hydraulic system failure.

In today’s demanding operating environments, hydraulic cylinders work harder, faster, and for longer cycles than ever before. This has triggered an increased need for the most effective means to address friction-related rod seal inefficiencies in a hydraulic system. We will review some important developments that enable OEMs to overcome rod seal friction challenges. And because the U-cup is the Endurance tests by Hallite and MSOE help determine how seals perform in real-world conditions.

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SURFACE FINISH RECOMMENDATIONS - PTFE MATERIALS METRIC SURFACE ROUGHNESS

INCH

Rmr*

µmRa

µmRz

µmRt

µinRa

µinRz

µinRt

Dynamic Sealing Face Ød1

0.05 - 0.2

1.6 max

2 max

2-8

63 max

157 max

Static Sealing Face Ød1

1.6 max

6.3 max

10 max

63 max

250 max

394 max

Static Housing Faces L1

3.2 max

10 max

16 max

125 max

394 max

630 max

60% - 90%

*Rmr is measured at a depth of 25% of the Rz value based upon a reference level (zero line) at 5% material/bearing area.

SURFACE FINISH RECOMMENDATIONS - TPU & TPE MATERIALS METRIC

INCH

Rmr*

SURFACE ROUGHNESS

µmRa

µmRz

µmRt

µinRa

µinRz

µinRt

Dynamic Sealing Face Ød1

0.1 - 0.4

1.6 max

4 max

4-16

63 max

157 max

Static Sealing Face Ød1

1.6 max

6.3 max

10 max

63 max

250 max

394 max

Static Housing Faces L1

3.2 max

10 max

16 max

125 max

394 max

630 max

45% - 70%

*Rmr is measured at a depth of 25% of the Rz value based upon a reference level (zero line) at 5% material/bearing area.

Hallite’s tests have resulted in recommendations based on seal material and surface roughness. most common type of rod seal profile used by the fluid power industry, it will be our focus.

Friction is one of the most common and underestimated causes of rod seal leakage in a hydraulic system.

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Design considerations There are four major rod seal design factors that have a significant impact on friction — preload, groove fill, geometry and materials.

Preload is the spring force exerted on the sealing surface by the seal to prevent leakage. It defines the amount of squeeze a seal has in the assembly. Excessive preload provides better sealing with the downside of too much friction and wear. This eventually destroys the seal. When seals are subjected to pressure, they respond by creating more load on the sealing lips to contain fluids at increased pressure. Pressure causes a seal to deform resulting in additional contact of the sealing lips to the rod, so in low- to mediumpressure environments of 1,000 to 3,000 psi, gradual deformation occurs. However, in a high-pressure environment of 10,000 psi, deformation will cause full seal-to-rod contact and higher friction.

Most U-cup seals available today are considered dynamic, meaning they respond

to various pressures and adjust preload to maximize seal life. It is critically important to understand and properly calculate the amount of preload needed at certain pressures when designing rod seals for specific applications. Also, give proper attention to preload boundary lubrication — the light film of oil essential to prevent seals from wearing out due to friction and heat.

Groove fill, a measure of seal size in relation to groove volume, ensures proper seal seating and orientation in the application. Insufficient groove fill leads to seal rocking and improper seal position which causes leakage. Groove overfill leads to excessive seal wear, extrusion, and increased potential for leakage. Extrusion gap is the space left between the rod and the mating hardware. When a seal is subjected to high pressure, materials will tend to push through this gap (or extrude) and contribute to seal failure. A back-up ring is often used to help prevent extrusion in high-pressure applications. Attention in this regard is extremely important because

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improper extrusion gap is a key contributor to premature rod seal failure.

Geometry depends on the application.

There are a variety of symmetrical and asymmetrical rod seal U-cup geometries available. Factors to consider when selecting the right option include friction (or stick-slip) during operation, pressure range, acceptable leakage, and the type of rod wiper. An advantage of the symmetrical geometry is that it can be used interchangeably as a rod or piston seal, but it offers less stability in the groove than the asymmetrical seal when under load, creating a hinging effect. The symmetrical seal also presents more friction. An energizer can be used to create preload.

The asymmetrical geometry must be designed as either a rod or piston seal.

Its profile allows more fluid flow into the pressure groove than the symmetrical seal, making it more responsive with improved stability in the groove under load. The twin lip asymmetrical design provides additional stability and sealing. This option tends to present less friction.

Single and twin lip asymmetrical U-cup rod seal geometries offer a range

Static Sealing Surface - Groove

Static Lip Pressure Groove Dynamic Lip Dynamic Sealing Lip

Dynamic Sealing Surface - Rod

Secondary Dynamic Sealing Lip

Most U-cups are dynamic seals that respond to pressure changes and adjust preload to maximize life. of characteristics and advantages. The single lip U-cup rod seal is a low-friction seal with limited sealing capabilities when used without a wiper, so a wiper is recommended to assist with protecting the cylinder from harmful contaminants.

In terms of pressure, the single lip U-cup rod seal performs better than its twin lip counterpart, but it is not ideal for highpressure applications. Pressure spiking will cause the single lip U-cup seal to split down the middle of the pressure groove.

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Static Sealing Lip

For example, in a backhoe operation with pressure spikes upwards to 10,000 psi, the single lip U-cup is not appropriate because it is limited to a maximum rating of 6,000 psi.

The twin lip U-cup rod seal is a high-pressure seal rated to 10,000 psi.

It employs a primary and secondary sealing lip, offering improved sealability when compared to the single lip design.

It presents more friction than the single lip U-cup rod seal but offers better

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Difference in Rod Seal Friction - Geometry 40

36.2

35

31.4

30 Pounds Force

25 20 11.9

15 10

6.2

5.9

7.8

7.8

7.8

5 0

0

400

U-Cup Asymmetrical Twin Lipped

RHAM-MKT QRAM PRINT Ad #1 2018-11-21 v1-0.pdf

1200

PSI

7

U-Cup Symmetrical Loaded

21/11/18

performance under pressure. This is because stress is diverted to the secondary lip instead of the pressure groove, enabling the seal to better withstand pressure spikes. A shock-absorbing energizer with a back-up ring prevents extrusion.

Materials Materials play an important role in managing rod seal friction. The most commonly-used materials in U-cup rod seal design are elastomers (NBR, HNBR, FKM), Polytetrafluoroethylene (PTFE), polyurethane (TPU), and polyester (TPE). Softer materials tend to stick to dynamic surfaces and offer better sealability, while harder materials offer less friction but also less sealing.

3000

Seal geometry can play a major role in the level of friction in an application, particularly at higher pressures.

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The material’s interaction with fluid, or fluid compatibility is also important, especially as the industry focuses on the use of more environmentally-friendly oils.

Abrasion and compression set resistance should also be taken into consideration when designing rod seals. Remember that no single material is appropriate for every situation, so understanding the application is essential to material selection.

Fluid viscosity and surface finish Fluid viscosity and surface finish are two additional and very important factors that impact U-cup rod seal friction. Using improper viscosity fluids can starve the seal of essential lubrication, resulting in excessive wear. This was the case with a customer that reported a noisy cylinder accompanied with jittering of the rod on extend and retract. The customer was using low-temperature ISO 15 oil for an ambient temperature application. After the fluid was changed to an ISO 32 oil type, the problem was addressed; however, the life of the rod seal was greatly reduced while the ISO 15 oil was in use. This required a cylinder rebuild before expected end of life.

Another customer requested testing to show start up performance of rod seals at extreme cold temperatures. The test employed a customer-recommended ISO

15 Artic Hydraulic Fluid with a pour rating of -70° F with favorable results, but the oil congealed at -60° F resulting in very little boundary lubrication. Although the seals performed well at low temperatures, extended operation without a rise in oil temperature meant loss of seal performance over time. These are just two examples highlighting the role and impact of fluid viscosity on rod seal friction.

Surface finish is a measure of the lay, surface roughness, and waviness of a surface. The surface roughness of a cylinder rod or other machined part is based on measurements of peaks and valleys in a plane normal to the surface. There are several common expressions of surface conditions used by machinists. Ra, the arithmetical mean roughness, is the mean of absolute values of deviations from the mean line of the roughness profile. Rmr is the material component of the profile, the fraction of a line that cuts through material at a defined height above the mean, stated as a percentage. Rt is the total height of the roughness profile, the difference in height between the highest peak and deepest valley within the measured length.

And Rz is the mean roughness depth, the mean value of five maximum peak-tovalley measurements within five samplings lengths.

Surface mean roughness

Ra

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When measuring surface finish, Ra is the arithmetical mean roughness, the deviation of absolute values from the mean line of the roughness profile over the evaluation length. www.fluidpowerworld.com

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MSOE Rod Seal Endurance Test - Run #3 16

14

This long-term test gives an example of how seal geometry, material, preload and groove fill can affect cylinder leakage.

Leakage (ml)

12

10

8

6

4

2

0

50,000

100,000

150,000

Sample 1

200,000

Sample 2

Measured using Ra, Rz, Rt and Rmr, surface finish is critical when attempting to minimize rod seal friction and wear. It must conform to recommendations as defined for the seal profile and material being used.

Rt and Ra are the most common surface finish measurement types.

Understanding rod seal leakage It’s a fact. All seals leak. So exactly how much leakage is acceptable, and how is it measured? Unfortunately, a standard measurement for leakage does not exist.

Tolerance for rod seal leakage in each cylinder application is based solely upon the operator’s sensitivity within the environment in question. Generally, the quantity of leakage is assessed visually. For example, the amount of tolerable rod seal leakage in a hydraulic cylinder used within an agricultural production environment will differ greatly from what is allowable in a food and beverage processing environment.

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250,000 Cycles

300,000

Sample 3

350,000

400,000

450,000

Sample 4

To better determine which rod seal design offers optimum performance for a specific application, Hallite partnered with the Milwaukee School of Engineering (MSOE) to develop a rod seal endurance rig that tests 16 different rod seals simultaneously.

Testing is conducted under a variety of operating conditions using a range of fluids. Performance characteristics such as stroke speed and length, pressure and temperature, and pressure differential (extend and retract) are included in the test.

A major component of the test rig is physical leakage measurement (measured in ml) which is taken every 50,000 cycles.

Leakage between the rod seal and wiper and the outboard of the wiper is evaluated, and data collected enables calculation and evaluation of leakage across the tested seals. This approach also provides a visual record of how the seals react to specific surface finish changes.

Assessing and managing rod seal friction can be challenging, but it is not impossible. Sealing systems should be designed with the primary factors that impact friction in mind: 1.

2.

3.

4.

Preload boundary lubrication Groove fill Geometry Material

Because no hydraulic cylinder application is leak-free, determine how much leakage is acceptable, and then plan operations that function within a defined set of parameters.

FPW

Hallite | hallite.com/us

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M O B I L E

H Y D R A U L I C S

We’ve come a long way, baby:

the evolution of construction equipment

Josh Cosford • Contributing Editor

| Courtesy of John Deere

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On a road near my home, there exists a hand-laid stone fence, perhaps 4 ft high and a hundred times as long.

Crafted from locally-sourced rocks some century ago, I drive its length in awe as I imagine the physical and time resources used in its construction. The machinery to excavate, haul and lay heavy material was uncommon in the 1800’s, so I can’t reason it was constructed using anything but many strong hands.

The construction industry is as old as farming, and as societal needs grew, so too did the requirement for improvements in construction. The industrial revolution grew our capacity to construct buildings and infrastructure exponentially. Light and moderate construction techniques built our homes and offices, while heavy and intense construction made

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A vintage steam excavator, used in construction of railway lines. | istockphoto.com

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M O B I L E

H Y D R A U L I C S

the factories and the roadways to get there.

The hand-laid stone fence was obviously a light construction project, but it’s the heavy and intense construction so well suited to hydraulic motivation that has been important to civilization.

The 1954 Hydraulikbagger, was a compact machine ideal for light and moderate construction projects. | Courtesy of ASCE Library

Mobile construction equipment took form because of the inherent advantages of hydraulics — power density, controllability and reliability.

Modern construction gathers steam Steam power is a form of fluid power energy transfer, but instead of pressurized air or hydraulic fluid, heat energy is added to water until it turns to its gaseous form. This transformation creates pressure as gas volume increases, which was captured in actuators to power large machinery. This technology gathered steam, as it were, in the early 19th century, but records show as early as 1796 a steam-powered dredge was used to clear the beds of waterways in England.

In 1835, William Otis, cousin to American industrialist Elisha Otis of elevator fame, applied steam energy to create a single-bucket land excavator. Accepted as the first selfpowered, land-based machine used for heavy construction, it revolutionized the building of railway lines. This patented machine was able to move 300 yd3 per day, where two men and a wheelbarrow would drag this task out to a fortnight.

Some fifty years later, Sir W. G. Armstrong built the first excavator using hydraulics, where it was used in the construction of docks. It was steam powered, but also employed cables with only hydraulic actuation on one function. A semi-interesting aside: Armstrong’s company eventually merged with Vickers Limited, but disappointingly after much research, I could find no link to the Vickers of hydraulic fame.

Regardless, Armstrong’s machine didn’t work very well and left the door open for others.

The first machine to use only steam-powered hydraulic actuators without the aid of wheels and cables was the Kilgore 2-1/2 Yard Steam Railway Shovel. This machine was productive, but like the Armstrong machine, it was limited to rail line construction.

Creating a modern standard

It would take nearly another century before excavators looked and operated as they do 48

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today. For most of this span, excavators would remain cable-operated or some type of steam, mechanical, cable and hydraulic hybrid. Demag (now Komatsu) created the first 360°, all hydraulic, track-driven excavator as we know it today. The 1954 Hydraulikbagger was powered by a 42-hp, 3-cylinder diesel and capable of 2.5 mph while carrying about a half yard of material. It was compact, efficient, agile and productive, especially for light and moderate construction projects.

So effective was the B504 that its construction features are now standard for the industry. Once excavators were gifted fully-hydraulic operation, construction equipment was capable of utility and productivity not previously possible.

Decades earlier, the Ford Model T’s domination would pave the way (that’s right, I went there) for the development of interstate highways. The B504 was timed perfectly because the development of Eisenhower’s Interstate Highway System started shortly after. I’m not claiming the events were related in any way, but their timing ensured the construction industry in America would expand as never before.

Mobile construction equipment took form because of the inherent advantages of hydraulics; power density,

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The 21050K crawler dozer, launched by John Deere in 2015, was a completely new model, as its biggest and most powerful dozer yet. | Courtesy of John Deere

controllability and reliability. Step one for hydraulic machinery was getting it all to work reliably and efficiently, but because construction is a competitive, low-margin industry, advancements came fast and hard.

Productivity was chased, which needed the puzzle pieces of power, control and reliability to fall into place.

Early machinery was moderate pressure open loop, consisting of mostly gear and vane pumps running 1,000-2,500 psi. Even in the 1960s when hydraulic excavators were dominating their cable-operated counterparts, the technology advance was slow. OEMs saw the benefits hydraulics provided, so they applied the technology to loaders, scrapers and dozers, making them powerful and effective. But in the 60s, machining technology wasn’t able to provide the close tolerances required to make high pressure pumps, valves and actuators.

Higher pressures, sophisticated controls

As applied knowledge advanced, manufacturers realized high pressure was the key to productivity – and by “high pressure,” I mean 3,000 psi. Piston pumps can produce high pressure with efficiency, but they had to master tighter clearances and differing coefficients of expansion. Early www.fluidpowerworld.com

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variable displacement piston pumps used a swashplate with lever operation to control flow, providing an efficient speed control alternative to metering valves, which wasted energy.

The 1970s could be considered the decade of hydraulic creativity. To increase control and productivity, engineers were inventing clever ways to control hydraulics.

The first hydrostatic drives were mastered and applied to loaders, enabling them to transition quickly and smoothly between forward and reverse motion. Caterpillar had the pressure compensated axial piston pump patented, and torque limiting was also developed in the decade of disco.

Torque limiting (also known as horsepower control) is a method to automatically limit flow inversely proportional to pressure. As pressure rises, flow drops, and when pressure drops, flow increases. This method gave the best of both worlds, allowing an excavator to behave as if its prime mover was twice the rated horsepower. The swing, boom, arm and bucket functions could all move rapidly with no load, but then the pump would cut flow as pressure rises, supplying the force needed for heavy work.

By the 1980s, cable operation was nearly extinct in the construction industry.

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So effective was hydraulics, that even the control functions were hydraulic pilot operated, which was an older technology.

The brakes, the steering and the machine functions could be worked from the cab using pilot valves. Try to explain to your teenager that a joystick used to have oil running through it, and the distance and vigor the joystick moved would push fluid at the spools of the directional control valves with the same effort.

Enter load sensing However, the proliferation of load sensing technology in the 1980s freed up horsepower, and in combination with improving machining tolerances, pressure (and therefore power density) rapidly increased. Load sensing allows the hydraulic pump to provide the exact flow and pressure required by the actuators,

adding only a little extra energy to create pressure drop. It wasn’t uncommon to now see standard 4,000 psi for the implement functions and more than 5,000 psi for the travel circuit. With load sensing, running 5,000 psi doesn’t cripple flow when you’re limited with input horsepower.

Although mobile construction equipment had the most advanced hydraulic systems in existence, they fell way short when it came to electronic control.

Even electrical control was not a trusted method of operating pumps or valves. The 1990s didn’t see a lot of advancement with construction equipment, especially in the way that hydraulics were controlled. Digital machine monitoring existed, but most of the technology was supplied for operator comfort — climate control, stereo systems and 12-V chargers.

The advent of electronic controls

The turn of the century saw machine OEMs strong-armed into progress. The looming Tier 4 emissions standards forced manufacturers to rethink the design and implementation of construction machinery.

Machine functions were increasingly controlled electronically, where hydraulic joysticks were replaced by proportional control, cabs were fitted with LCD digital displays, and machine maintenance intervals were monitored electronically. However, pressure hadn’t increased in three decades, remaining in the 5,000 psi range well into the late 2000s.

Electronics are now prolific in the construction industry. Just as with your car, your excavator has programmable performance modes. You can run in “eco” mode, or with the adjustment of a convenient dial, ramp it up the high-power

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SECURE Metal-To-Metal

| Courtesy of John Deere

mode. GPS navigation, automatic grade compensation, traction control and hybrid drive systems are working their way into modern construction machinery.

The crawler dozer, pictured, is a machine of surprising technological advancement. High-end models have individually controlled hydrostatic drives for left and right tracks, themselves each closed-loop electronically controlled.

The dozer’s path is maintained based on operator control, and the software accommodates regardless of load, turning angle or traction. They are available with software applications, real-time data logging and customizable machine responses. If one operator prefers feathertouch, high response from her controls, while another prefers a slower, attenuated control method, both can save their user profile preferences. The machine can’t be started until the operator inputs their login, at which point the profile is loaded.

The value of power density is not lost on dozer manufacturers. New machines are closing in on 7,000 psi, allowing higher torque from smaller, lighter machines and realizing improved fuel economy. Lighter machinery also makes transportation to and from worksites much easier and provides a side benefit of reduced ground compaction.

What does the future hold?

So, what does the future hold for construction equipment? It’s obvious that pressure will continue to rise, enabling smaller, lighter machines to achieve productivity previously enjoyed by only large, high-powered equipment. Advanced materials will permeate machinery, using both carbon fiber and 3D-printed metals to increase strength while reducing weight.

Digital control with increased saturation of cyber-physical systems will be commonplace. A construction sight workday will be planned from a computer control station, where all worked is carried out remotely with operator-less machinery.

As well, the continued electrification will see engines replaced with electric prime movers and battery packs. At some point, machines will be fully autonomous, where www.fluidpowerworld.com

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a digitally scanned topographical map of the territory is inputted, and the machine is told how to grade or excavate to match the desired output.

Industrial environments increasingly see electric actuators, eschewing fluid power altogether. However, electric actuators will never replace hydraulic actuators in construction machinery. I make this bold prediction because electric cylinders and motors can never be made so small yet so powerful as to replace hydraulics. A 100-hp, bent-axis piston motor can fit into a shoebox, and that’s at current industry pressure levels.

Where I see electric actuation expanding is with power delivery. Instead of central power units and distribution through hydraulic control networks, actuators will be self-contained integrated actuators. The servomotor and pump combination will be built into the hydraulic cylinder, which will include a small reservoir and manifold containing all hydraulic controls. These units will be modular, configurable and controlled via wireless networks, while still providing the high force that makes hydraulics king.

The modern mobile construction machine has come a long way from the steam-powered machines of the industrial revolution. Continued advancement will see machines become more productive, efficient and powerful, while the reduction of machine operators will see worksites become safer, especially as robots replace construction workers. But I doubt I’ll ever see another newly constructed stone fence at the hands of robots.

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Pneumatic actuator

control options Pneumatic actuators are essential workhorses for machine and equipment motion. Here are some pointers about different styles for control and monitoring.

Pat Phillips â&#x20AC;˘ Product Manager Fluid Power and Mechanical Product Division AutomationDirect

Pneumatic actuators are commonly used in countless types of equipment and machinery because they provide a simple, cost-effective and durable way to implement linear or other types or motion. They are compact yet powerful for the force delivered and are often the preferred solution over electric or hydraulic actuation, both of which can increase weight and complexity.

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More-complex machinery often requires position switches to interlock functions and provide alarming and indication capabilities. | courtesy of AutomationDirect

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Rotary Compact

NFPA Tie Rod

Guided Rod

Pneumatic actuators are available in a variety of configurations, and most incorporate cylinders in one way or another.

Round Body

ISO 15552 Gripper

On the other hand, selection can get complicated due to the wide variety of form factors, options and configurations. Perhaps the most popular configuration is the basic pneumatic cylinder, but even this style has a number of permutations.

Not only are there several physical styles, but there are many methods for control and monitoring. This article will review some pneumatic actuator basics and consider main concepts related to how they are controlled.

Pneumatic actuator basics Pneumatic actuators convert the energy of compressed air into linear motion. Common styles include NFPA tie-rod, ISO 15552, round body, guided-rod and compact versions. A majority of actuators incorporate a closed

manually by a machine operator.

Actuators can be fabricated from a wide variety of materials using different construction methods. The equipment geometry must be considered to select the appropriate mounting and connecting methods, and the actuator must be sized to ensure it can deliver the proper motive force.

When to enhance control Several conditions can affect pneumaticactuator performance. Inconsistent air pressure or variable payloads can drastically change the operating speed. Wearing parts and overdue maintenance, whether internal to the actuator or within the

Pneumatic actuators are commonly used in countless types of equipment and machinery because they provide a simple, cost-effective and durable way to implement linear or other types or motion. cylinder housing containing a movable piston connected to a rod. Air pressure supplied to or removed from the piston moves it and the associated rod. The shaft generates linear motion, and additional mechanisms may translate this motion into a rotary or gripping action.

Pneumatic valves control the flow of compressed air supplied or discharged from one or both sides of a cylinder. These valves may be actuated electrically, with external air sources or

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external linkages and mechanisms, will also impact the ability to operate as designed.

A human operator using manual controls can observe the equipment operation and make adjustment as required. However, many types of machinery have much more complex and automatic sequences and interactions, necessitating monitoring to ascertain correct operation.

Any time one action directly impacts

| courtesy of AutomationDIrect

a subsequent action, it is important to confirm that the position of the first step has been achieved before moving on to the second step. A position sensor performs this function and lets the automation system proceed to the second step the moment the first is completed. In this way, even if equipment performance and speed change over time, sequential functionality can be maintained.

Many users choose to monitor all pneumatic actions. Most cylinders operate to two positions, extended and retracted.

By installing position switches for each case, the control system can be configured to alarm if a cylinder has not reached the commanded position when expected. It is also possible to add more switches to indicate when actuators reach midway positions.

Another enhancement is for the system to evaluate the time it takes for an actuator to move to the commanded position. During equipment setup and tuning, the nominal actuation time of each motion can be determined. Using this information, the control system can be configured so that any actions taking longer than expected, even if they eventually complete, will trigger a warning. End users are thus notified of impending trouble before a complete failure occurs.

Choosing the right options Once the decision is made to monitor actuator position, a few more choices are required. Position can be sensed on the actuator itself or on the driven equipment,

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depending on requirements. In all cases, the sensor environmental protection ratings (NEMA or IP) must be suitable for the installation location.

Installing sensors on-board the actuator is a reliable and proven method that can be consistently applied throughout a machine, but this will not sense a failure within the mechanical linkages or mechanism. For this reason, designers may choose to install position switches on the driven equipment.

Many actuators and cylinders include slots or other accommodations to readily accept compatible position switches.

Common styles are T-slot, round, and dovetail. For applications without those features, some sensors are configured to work with mounting bands or other adapter brackets.

A positive sensing arrangement also calls for the internal piston to be magnetic.

Position switches can be mounted on the cylinder surface in one or more locations to indicate the presence of the piston, and therefore the mechanism.

Although older-style mechanical reed switches are available and somewhat less expensive, solid-state switches provide a more contemporary and reliable option because they have no moving parts to wear out. These may also include indicating LEDs to help personnel set up

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and observe operation, and some types are connectorized for quick installation and replacement.

There are two main solid-state sensing technologies. Giant magnetoresistive is suitable for most applications and is less expensive than anisotropic magnetoresistive.

However, anisotropic magnetoresistive technology exhibits a higher sensitivity and narrower sensing field, making it a better choice for cylinders with short strokes.

When it is more critical to positively identify the position of driven equipment, it may be better to use traditional limit switches external to the cylinder. These can be mechanical or the solid-state proximity type, and each may require additional metal targets or fittings to activate the switch.

Regardless of the position-switch location, it must have the proper electrical characteristics. It is possible to use 120 Vac for machine controls, but most designers have moved to 24 Vdc for user safety and convenience. Mechanical switches operate like relay contacts. Solid-state switches come in PNP (sourcing) and NPN (sinking) varieties, which must be selected to match controlsystem characteristics. When driving other loads such as relays or lights, engineers must evaluate the switching power and current rating.

It is most common to use normally-

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open (NO) switches that close when position is sensed. However, there are cases where normally-closed (NC) would be desired. Most switches are configured only one way or the other. From an electrical standpoint, it is always desirable to choose the logic to be failsafe such that if the wiring or switch fails, the equipment will stop in the safest way possible.

Cost considerations Sensing elements are a good value, especially when required for critical applications. Yet it must be noted that for the most basic cylinders, the cost to add position switches to both ends of travel may equal the cost of the cylinder itself.

Adding sensing elements creates a ripple effect of material and labor impacts.

The switch parts must be selected to match the exact physical sensing need and the electrical characteristics of the intended control system. Designers must include the sensors on mechanical and electrical wiring diagrams. During installation, electricians must install the field wiring and ensure it is carefully routed to accommodate any motion. At startup, each actuator must be operated through its range, and technicians must adjust the position switches accordingly.

To take full advantage of the benefits

Pneumatic actuator position switches take many forms. They may fit into defined mounting locations or clamp onto the actuator exterior. | courtesy of AutomationDIrect

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offered by limit switches, engineers must define the operational and alarming characteristics in some type of sequenceof-operation document. Controls may be hardwired to accomplish this which, in turn, may require additional interlocks and indications. More commonly, a PLC and possibly an HMI will be used for this purpose, so these will need to be programmed.

After equipment is initially commissioned, the complete machine functionality must be thoroughly tested to exercise all possible operating conditions.

This is performed to confirm basic operation and more-advanced timing conditions.

Actuator automation can significantly help operational and maintenance personnel down the road, especially if the system is configured with sufficient diagnostics to indicate the trouble. The flip side of this is that sensing elements introduce additional maintenance concerns — as they may fail or drift out of adjustment.

The bottom line is that pneumatic cylinder control and monitoring elements are a valuable addition but introduce

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certain costs which must be weighed against expected benefits.

Hybrid approach To help contain costs, many designers pursue a hybrid approach to specifying actuator controls, especially when developing systems or subsystems that will be produced in quantity. When a piece of equipment is first undergoing development, engineers may tend to over-specify the instrumentation and put sensors in all possible locations.

While the system is in prototype mode, this allows them full access to use the automation platform for tracking cycle times and other operational parameters.

This helps fine-tune operation, adjust timing and troubleshoot problems.

Once the machine is running as needed, however, designers can sharpen their pencils and evaluate exactly which position switches are required for operation and maintenance. During this valueengineering phase, unnecessary elements can be removed to lower costs while still providing the instrumentation needed for safe and reliable operation.

Pneumatic actuators are workhorses for many different types of machines.

Whether manually controlled or operated as part of an automated system, there are many reasons to monitor actuator position and integrate this information into the control scheme. Careful attention to required physical and electrical characteristics will help designers choose the best fit for any application.

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PRODUCT WORLD

Differential pressure gauge Ashcroft Ashcroft.com The 1140 series differential pressure gauges are a budget-friendly solution for applications that do not require all stainless-steel protection. These gauges have a glass-filled nylon front case that allows the window to be easily removed and cleaned. No additional hardware is required for either direct or panel mounting. Designed for either liquid or gas media, Ashcroft 1140, 1141, 1142 and 1143 DP gauges offer static pressure capacities of up to 6,000 psi and ranges

Hydraulic hand pump Doering Doering.com The DCHP163 series cartridge-style hydraulic hand pump offers twice the performance of comparable cartridge style hand pumps. It is perfect for primary, backup, emergency power, parking brakes for heavy equipment, and hydrostatic testing applications.

This double-acting, high-pressure manual pump is designed for use with many fluid types including water glycol. The DCHP163 features integrated check valves and fits in industry standard 16-3 cavities. It is rated for operating pressure of 6,500 psi (450 bar) and operating temperatures of –40° to 100° C (–40° to 212° F) for Nitrile (NBR, Buna N) seals and –26° to 204° C (–15° to 400° F) for Fluorocarbon seals. These hand pumps have displacements of 0.54 in.3 (8.87 cm3).

from as low as 0-10 in.H2Od up to 0-150 psid. Dials scaled in flow are also available.

Expanded standard hydraulic cylinders Liebherr Components liebherr.com New hydraulic cylinder series is designed for a pressure range of up to 260 bar (3,770 psi) Three distinct production series are available: • 260 bar series consists of 28 basic piston/ piston-rod diameter combinations. There are four available mounting types and two alternative oil connections for each of these basic variants. Single-chrome or double-chrome coating is possible.

• The 380 bar series is for use in mobile applications when long life is required in highly dynamic applications. The “eye-eye mounting” was specially designed for connection to construction machinery and helps ensure trouble-free operation.

•

ISO 6022-compliant series is designed for stationary applications. This range provides 24 basic piston/piston-rod rated diameter combinations while extending the dimensions defined in the standard. Six mounting types and four alternative oil connections are available for each of these basic variants. Users can select singlechrome or double-chrome coatings.

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

IoT-enabled shock absorber ITT Enidine enidine.com Sentinel 1 is ITT Enidine’s first-generation on-board monitoring system. It incorporates microelectronic solutions for reliable performance monitoring. It features event impact signal trigger capabilities protecting valuable equipment and ensuring seamless operations for various manufacturing applications including automatic storage and retrieval systems, warehousing, overhead crane and amusement rides.

Key features include: • Advanced Intelligence Theory: Capture, measure and transmit pressure, velocity and positional data to a PLC interface • Predictable Maintenance Technology: Allows users to monitor and manage simple (wear indicators) to complex (sensor technologies) • Flexibility to provide beneficial information within various in-use applications including monitoring cycle count, hours of operation and internal pressure of shock absorbers and remote notification of shock absorber information

Precision vacuum regulator ControlAir Inc. www.controlair.com Type 480V precision vacuum regulator is designed with a push type locking knob which allows for smooth output adjustment and the ability to lock in your setpoint to avoid unintentional adjustments. It senses output pressure deviations to within 1⁄2 in. water column pressure. Regulating range is from 0 to 30 in. Hg (-100 to -1.3 kPa). The unit is small in size and lightweight — less than 1 lb. The standard bracket and integral panel nut allow for versatile and easy installation options. A soft valve seat design provides tight shut off and eliminates leakage in steady state operation.

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PRODUCT WORLD

Fingerboard-latching system Festo festo.us Fingerboard-latching system utilizes the VTEM Motion Terminal’s intelligent pneumatic valves to control and monitor the exact locked or completely open position of each latch without the need of electronic sensors and wire harnesses on the Fingerboard. The VTEM Motion Terminal senses and controls the position of each latch from closed to 100% open by continuous monitoring of cylinder air pressure and flow.

Each Motion Terminal features internal sensors, pressure regulators, flow control, exhaust valves, and processing and communications capabilities. Measurements are graphically displayed via human machine interface (HMI) and information is available to supervisory control systems.

Each intelligent valve replaces two ordinary pneumatic valves for a 50% reduction in the number of components.

Extreme-pressure hose Parker Hannifin parker.com R50TC/R56TC ParLock multispiral hoses are available with four or six spiral steel-wire reinforcement, for dynamic applications with pressure ratings to 56.0 MPa (8,122 psi). Parker Tough Cover (TC) is used to mitigate the problem of fittings tearing off. Hose types with TC offer a high hose-to-hose as well as hose-to-object abrasion resistance. The hose product line exceeds ISO 3862 Type R15 specifications. They are available in sizes from -6 to -20 (hose ID from 0.25 to 1.25 in. or 9.5 to 31.8 mm) with working temperature range from -40° to 100° C (-40° to 212° F).

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

PA Series NFPA actuator BIMBA bimba.com The PA Series NFPA actuator’s lightweight aluminum construction and modern extruded design are only matched by its flexible mounting configurations and several standard features. PA Series actuators offer a consistent and reliable way to convert pneumatic energy into linear force and motion.

The PA Series is designed to meet the same requirements as typical NFPA actuators but includes features

such as die-cast aluminum endcaps, extruded aluminum housing, and polymer pistons.

Benefits: • Reduce complexity with standard universal mount and bolt-on NFPA selection • Flexibility with integral switch mounting grooves on three sides of profile tube • Modern appearance with smooth end caps contoured to profile tube for easy cleaning

Technical Features: • Operating pressure: 250 psig • Bore sizes: 1.50, 2.00, 2.50, 3.25, and 4.00 in.

• Strokes: 0.125 – 100 in.

• Auto-cushioning for a “fit-and-forget” solution

Magnetic position sensors provide continuous linear feedback Balluff balluff.com These magnetic position sensors combine IO-Link, analog voltage, and analog current in a single device to overcome the limitations of discrete pneumatic cylinder switches. The newly released sensors provide continuous linear feedback — detecting and measuring the position of pneumatic or hydraulic cylinder rods and actuators through non-ferrous housing walls, over the entire measurement range. And they do it all contact-free. Suitable for most industries, they are especially advantageous for Industry 4.0 as they improve ease of automation size change and allow for condition monitoring and predictive maintenance.

Key features: • Analog voltage, current output and IO-Link interface • Continuous monitoring of piston position in tight spaces • Suitable for Industry 4.0 • Available in 8 measurement ranges from 32 to 256 mm, in 32 mm increments

www.fluidpowerworld.com

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2019

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Programming includes keynote sessions, industry panels, hands-on technology demonstrations, and networking sessions.

The Fluid Power Technology Conference provides technical fluid power information to professionals who design, maintain, repair, and operate machinery and equipment powered by fluid power systems, both hydraulic and pneumatic.

Technical sessions and topics include: Solutions for hydraulic system design Considerations for component selection Productivity and efficiency for hydraulic and pneumatic systems Advanced controls Latest trends in fluid power

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COMPONENT FOCUS

Josh Cosford • Contributing Editor

How are inline check valves used?

As far as directional valves go, the check valve is the simplest in both concept and function. They are designed to allow flow in one direction while blocking flow in the opposing direction — that’s it. Some valves get more complicated, such as the pilot-operated check valve, but the one most commonly used as a supplemental component to a fluid power system is the inline check valve.

Inline check valve. | Parker Hannifin Corp.

An inline component is any useful object located in a circuit and coupled to adjacent fluid conduits, in the line of the fluid connection, as it were.

Inline components are convenient and versatile, often added to enhance an existing circuit or as an upgrade to an existing machine. The inline check valve is no different and has many uses.

Many functions of a fluid power circuit require a one-way flow path, and the inline check valve provides the best solution. For hydraulic applications, a check valve will consist of a steel body with a spring-loaded ball or poppet fixed in place with a retainer. Pneumatic applications have more freedom of construction because of their lower pressure rating, so the materials can be brass, aluminum or even some type of plastic or composite.

The most common tactic for an inline check valve is to prevent the backwards transmission of pressure, rather than flow, and it’s pressure that creates flow anyway. An example of this tactic is the check valve typically installed after a pump in a system which employs an accumulator. The check valve prevents stored energy from making its way back into the pump, an especially important task when there is stored energy in the accumulator and the pump is not even running. Energy stored in an accumulator can be dangerous or damaging and must be controlled for hydraulic systems to be safe and reliable.

In complex load-sensing applications, the pump or compensator used to read the load sense signal from downstream of all control valves needs only to sense the highest pressure of all functioning actuators.

The load sense check valve network opens a parallel path of hydraulic fluid from each actuator to the primary compensator, and the highest pressure channel overcomes its check valve and subsequently closes every other check valve in the network. Although not an individually plumbed component true to the “inline” nomenclature, they are installed in valve banks or manifolds and exist only to open or close an inline flow path.

Inline check valves can be added to existing hydraulic circuits to add functionality. For example, an inline needle valve may have been added to a compression-loaded cylinder application, but the machine operator felt the cycle time could be improved. A needle valve reduces flow in both directions, and this application really only required metering of flow under retraction, so the addition of an inline check valve plumbed around either side of the needle valve creates a true flow control. Fluid will now bypass the needle valve as it travels through the check valve unimpeded, providing full flow when extending. The check valve blocks free flow in retraction, forcing fluid across the needle valve and controls the downward motion of the cylinder.

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