Fluid Power World May 2017

Mobile hydraulics powers vacuum lifting p. 36

3 keys to successful ag hydraulics p. 42

Load-holding valves made simple p. 50

www.fluidpowerworld.com

May 2017

Electrohydraulic drives interface with the IoT, Industry 4.0 PAGE 28

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A cause for optimism?

It’s been the heart of trade show season the last few months, with the triennial IFPE, the annual Hannover Messe and Offshore Technology Conference keeping the fluid power manufacturing community—not to mention us in the media—quite busy. It is always great to get out and see the new technology firsthand, to put your hands on the metal and get a true feeling for the new products being unveiled.

It’s clear to see that the miniaturization and lower costs of sensors continue to affect the fluid power space in a positive way. Machine monitoring is really taking off, from individual components to entire systems. Everything can—and is—being monitored, from hose to bearings to pumps to cylinders to seals. As you can see in our coverage in this issue, things like the IoT and GPS assistance in agricultural applications are becoming commonplace, helping to make gains in efficiency, performance and maintenance. Anyone using this sort technology will attest that it will continue to grow in importance.

I also find a lot of value in simply talking to people at tradeshows about how their companies are doing and what the outlook is for them. I heard a lot of manufacturers say that 2017 is looking a bit more positive for them, and they have confidence moving forward into 2018. From an industry perspective, about the only market people aren’t excited about is mining (and even a few people said there were a very few tiny glints appearing even in that field). Construction is making gains and ag is doing well for many people. Energy, while somewhat of a mixed bag due to oil prices, is still an area that companies see investment going into. Exhibitors at the OTC were cautiously optimistic about the remainder of the year.

And there’s good news on the trade show front, too. The combined IFPE-CONEXPO/CON-AGG shows featured a record 2.8 million square feet, with 128,000 attendees descending on the Las Vegas Convention Center. Meanwhile, the Hannover Messe announced that it was changing its every-other-year focus on fluid power and motion control technology to an annual thing—so the fluid power-centered halls at the trade fair will be open every year, instead of only during odd-numbered years.

The change goes into effect in 2018.

FPW

Paul J. Heney

Available In BSPP

Editorial Director pheney@wtwhmedia.com

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

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

No turning back on IoT After spending a week at the recent Hannover Fair, one comes to the inescapable conclusion that most everyone with a stake in the future of fluid power is either embracing the concepts of IoT, or is at least watching as the changes unfold.

We’ve all heard the hype surrounding what’s called the fourth industrial revolution—the age of digitization— that melds information technology with “intelligent” components to ultimately get a better handle on everything from the operating efficiency of a production line to knowing when to swap out an air cylinder.

The focus has been on enterprise-level software for cloud computing and advanced analytics; now the emphasis is shifting to the factory-floor.

Scores of Hannover exhibitors offered IoT-ready components like “smart” pumps, valves, cylinders and filters. Aventics, for example, displayed an add-on manifold module that listens to a valve backplane in parallel with the control signals. They use the data to determine the status of components like a shock absorber on a linear drive. “We not only count cycles but measure the acceleration that tells whether the shock should last another 4 million cycles, or if it’s going to fail next week,” said Dieter Michalkowski. “We’re not waiting until breakdown, and we’re not doing it too soon and throwing away good parts.” Maintenance becomes much more predictable and that saves money, he added. “It’s all a part of Industry 4.0, and it will be standard in the future.”

Likewise, Festo’s Motion Terminal can now capture data from production processes and send it to the cloud. “We can track pressures, flows, everything that is measureable and countable, and we use the information to visualize condition monitoring,” said advanced-technology engineer Cynthia Klett. In turn, a dashboard tells the shop floor of problems like component failures and air leaks. “Today, each conditionmonitoring dashboard is quite unique to a customer’s application. In 10 years, it will be commonplace,” she said.

Moving forward, Klett cautioned that companies must 4

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define where information gets stored, such as in a local database or in a private or public cloud; and whether the OEM, user or a third party has access. Developers also need to think more about the underlying business model, she said. Beyond merely selling hardware, companies might offer predictive-maintenance capabilities, consulting, and related engineering services.

Along those lines, Parker Hannifin’s web-based IoT application will specify user-defined thresholds, monitor equipment, send alerts, and even order replacement parts and schedule repairs, said Michael Aanenson of Exosite, a Parker IoT partner. Beyond that, the system tracks machine operations over time, even down to individual components. That knowledge, in turn, can be used to optimize performance, upgrade designs, reduce power consumption, minimize waste and extend machine life.

“Customers are asking for these types of solutions because there are obvious benefits,” said Aanenson.

“Preventing downtime is a major issue, energy efficiency is another. The cost for adding these sensors and a gateway is minor compared to what most of these machines cost to own and operate. These systems usually pay for themselves quickly,” he added.

FPW

www.fluidpowerworldonline.com

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C ontents |

vol 4 no 3

|

fluidpowerworld.com

F E AT U R E S INDUSTRIAL HYDRAULICS Electrohydraulic drives interface with the IoT, Industry 4.0

28

Electrohydraulic drives are primarily used whenever a high power/weight ratio, compact size and/or large forces are required for individual applications.

PNEUMATICS Mobile hydraulics powers vacuum lifting

36

May 2017

Vacuum-lift attachments make construction equipment more productive.

36 D E PA R T M E N T S

MOBILE HYDRAULICS

Three key priorities for successful agricultural hydraulic design

42

02 Editorial 04 Korane’s Outlook 08 Association Watch

Although we’d all love to rely on the KISS Principle, hydraulic systems for the ag industry must be energy efficient, easy to operate a nd maintain, and of course reliable.

HYDRAULIC VALVES

Load holding valves made simple Load-holding, or counterbalance valves, are simple but critical devices to mobile machine stability and cost.

6

12 Design Notes 18 Research and Development 22 Safety

50

24 Fundamentals 26 Energy Efficiency

55 Products

60 Component Focus 64 Ad Index

A | S | B | P|E

A | S | B | P|E

American Society of Business Publication Editors

American Society of Business Publication Editors

Fostering B2B editorial excellence

ON THE COVER

28

Modern injection molding machines require a balance of electrohydraulic and electric drive technologies to ensure optimal performance and automation. | courtesy of Bosch Rexroth

FLUID POWER WORLD

5 • 2017

2017 Regional

Fostering B2B editorial excellence

2017 Regional

PR INT

DESIGN

Revenue of $3 million or under

Revenue of $3 million or under

Award Winner

Award Winner

| istockphoto.com

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MAY 2017 • vol 4 no 3 • www.fluidpowerworld.com

EDITORIAL

NEW MEDIA/WEB/BUSINESS DEVELOPMENT

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

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

Managing Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

Senior Web Developer Patrick Amigo 860.603.2984 pamigo@wtwhmedia.com @amigo_patrick

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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

Contributing Editor Josh Cosford @FluidPowerTips

Videographer Manager John Hansel jhansel@wtwhmedia.com @wtwh_jhansel

Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane

Videographer Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh

Contributing Editor Carl Dyke @carlindustry VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Traffic Manager Mary Heideloff mheideloff@wtwhmedia.com Production Associate Tracy Powers tpowers@wtwhmedia.com

Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com

Videographer Derek Little dlittle@wtwhmedia.com Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick Online Coordinator Jennifer Calhoon jcalhoon@wtwhmedia.com @wtwh_jennifer MARKETING Digital Marketing Director Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

SALES VP, Publisher Michael Ference 408.769.1188 mference@wtwhmedia.com Garrett Cona 213.219.5663 gcona@wtwhmedia.com @WTWH_gcona Mary Ann Cooke 781.710.4659 mcooke@wtwhmedia.com Michelle Flando 440.670.4772 mflando@wtwhmedia.com @mflando Neel Gleason 312.882.9867 ngleason@wtwhmedia.com @wtwh_ngleason Tom Lazar 408.701.7944 tlazar@wtwhmedia.com @wtwh_Tom

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WTWH Media, LLC 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103 Ph: 888.543.2447 • Fax: 888.543.2447

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

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

SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

SUBSCRIBER SERVICES: To order a subscription please visit our web site at www.fluidpowerworld.com FLUID POWER WORLD (ISSN 2375-3641) is published eight times a year: in February, April, May, June, August, September, November, December by WTWH Media, LLC; 6555 Carnegie Ave., Suite 300, Cleveland, Ohio 44103. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Fluid Power World, 6555 Carnegie Ave., Suite 300, Cleveland, OH 44103

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Edited by: Mike Santora • Associate Editor

ASSOCIATION WATCH

Registration open for the 2017 IEOC

T

The 2017 Industry & Economic Outlook Conference schedule will feature a full lineup of industry experts.

The 2017 Industry & Economic Outlook Conference schedule will feature a full lineup of industry experts. As always, registration is open to everyone in the fluid power supply chain— NFPA members and non-members alike. Early bird rates end July 14. Register at: news.nfpahub.com/registration-open-2017-ieoc/ Attendee favorites Alan Beaulieu of ITR Economics, John Walker of Oxford Economics, Eli Lustgarten of ESL Consultants, and Jim Meil of ACT Research will all return to the stage to share their outlook and of course, will be open for questions during the IEOC Speakers Forum. New this year will be Kevin Surace of Appvance, who will give a talk about the Future of Manufacturing. Additionally, speakers will talk specifically about different market segments in the breakout rooms.

As usual, the event kicks off with the IEOC Invitational Golf Tournament at Chevy Chase Golf Course. Young NFPA members are always welcome to join the Future Leaders Luncheon on Tuesday and all attendees can network and mingle during the Power of Association Networking Reception and Dinner Tuesday night.

8

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www.fluidpowerworld.com

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ASSOCIATION WATCH

Overall, in 2016 the U.S. fluid power industry sold $5.5 billion dollars in exported products and $7.0 billion dollars in imported products.

“Overall, in 2016 the U.S. fluid power industry sold $5.5 billion dollars in exported products and $7.0 billion dollars in imported products.”

10

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New – Stats Toolkit IEOC drawing – 50% off IEOC registration As an added incentive to take advantage of NFPA’s market information tools and services, members who have a registered Stats Toolkit account by June 16 will be entered into a drawing to receive a 50% discount on their 2017 IEOC registration. If the winner has already registered for the 2017 IEOC, a 50% refund of the registration fee paid will be applied.

Hotel information The 2017 IEOC is again at the Westin Chicago North Shore. NFPA has reserved a limited number of rooms at a discounted rate of $175 plus tax. This special rate is only available until July 24 or until the block is full. To reserve your room, call the Westin reservations line at (847) 777-6500. Be sure to request the “National Fluid Power Association” rate.

U.S. fluid power exports help close trade deficit Even during a tough 2016, U.S. fluid power exports helped close the gap in the trade deficit. While U.S. fluid power imports dropped 8.2%, which just happens to nearly match the 8.8% drop in U.S. total fluid power shipments in 2016, U.S. fluid power exports only fell 2.1% during that same period. This translated into a 25.6% tightening of our U.S. fluid power trade deficit.

Overall, in 2016 the U.S. fluid power industry sold $5.5 billion dollars in exported products and $7.0 billion dollars in imported products. Both exports and imports of fluid power products continue to grow every year, with imports outpacing exports since 1998, creating a trade deficit for the last 18 years.

Over the last five years, U.S. fluid power exports have grown 17.8% and U.S. fluid power imports have grown 18.3%.

www.fluidpowerworld.com

5/15/17 12:00 PM

ASSOCIATION WATCH

Fluid power industrial consortium advanced manufacturing seminar After a successful first seminar, the second FPIC halfday educational event has been scheduled for Friday, June 2, at Precision Plus Swiss Turned Components in Elkhorn, Wis.

The June 2 seminar will focus on Advanced and Additive Manufacturing.

FPIC seminars are an ideal way to learn about the technological advancements that will help meet the future needs of fluid power customers, expand fluid power into new customer markets, and attract the best and brightest young engineers to fluid power. To register, go to nfpa.com FPW

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FLUID POWER WORLD

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DESIGN NOTES

Ken Korane • Contributing Editor

Pneumatics embraces Cinema 4.0

Experiencing films with all the senses is what cinema audiences can expect in one of the world’s 18,000 MediaMation cinema seats.

With this concept, the whole body senses the movie, thanks to movements controlled by Festo’s servopneumatics and VTEM motion terminals. In essence, this provides a unique way of combining the digital world with pneumatics.

The system brings virtual reality to a new level. For example, as a chase involving sports cars unfolds on screen, the cinema seats tilt to the left in a hairpin bend—only to swing back to the right when the car straightens out.

Cinemagoers feel the unevenness of the road surface and, when the driver brakes, they not only hear the screeching of the tires but also surge forward.

The cinema audience becomes one with the film. In the MX4D Motion EFX seats produced by MediaMation, an interactive-technology company based in Torrance, Calif., the audience has the feeling that they are actors 12

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themselves. The seats incline, shimmy and lift. Effects, vibrations and movements are synchronized with gusts of wind, water splashes and scents piped in through the V2 EFX armrests of the cinema seats, while pressure points are incorporated in the backs of the seats.

The IoT and Industry 4.0 are now delivering “Cinema 4.0” as the Festo Motion Terminal VTEM controls all kinds of motion and triggers all the effects. This versatile pneumatic control system integrates digital functions into piezoceramic servovalves. Preprogrammed function modules and motion apps eliminate the need for costly programming and setup, according to Festo. The proprietary motion apps “Proportional directional control valve” and “Proportional pressure regulation”

www.fluidpowerworld.com

5/15/17 12:16 PM

DESIGN NOTES

The Festo Motion Terminal VTEM controls motion and triggers effects on the MX4D Motion EFX seats produced

by Media Mation.

control flow rates and pressures to ensure fast and powerful yet gentle and precise motion sequences.

The motion profiles for the films are processed in a CPX-CEC controller directly on Festo’s Motion Terminal. Many hardware components previously required are now superfluous. Three VTEM valves control the three actuators of each cinema seat, while one valve is responsible for pressure regulation. Inexpensive standard VUVG valves are used for controlling effects such as gusts of wind.

“The Festo Motion Terminal makes everything much easier for us. Installation, commissioning, diagnostics and fault-finding can now be realized with far fewer components,” said Dan Jamele, CEO of MediaMation.

As a key contributor to Industry 4.0, VTEM allows many new functions to be integrated thanks to digitization and piezo technology. “We already have many different apps to choose from, such as proportional pressure regulation, presetting of travel time and selectable pressure level, depending on each individual film scene,” explained Takayoshi Kawakami, director of engineering at MediaMation. Thanks to fast and precise pneumatics and intuitive operation, the concept is well received in the age of “Cinema 4.0.”

FPW

Festo | festo.com

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DESIGN NOTES

Edited by: Mike Santora • Associate Editor

With cycle times of 30–45 seconds,

the CNC-controlled Foilpuller with

Gripper system for protective film removal

FIPA EOAT and vacuum technology

automates the film-removal process for metal sheets used in white good s.

FIPA recently created a custom EOAT solution for the removal of protective film from sheet metal with an automated process. Developed for Foilpuller GmbH, a stainless steel sheet metal processing company, the custom system combines high holding force vacuum cups with pressure regulating, air-saving compact ejectors for the Foilpuller system. With cycle times of 30–45 seconds, the CNC-controlled Foilpuller with FIPA EOAT and vacuum technology automates the film-removal process for metal sheets used in white goods, eliminating manual labor and delivering up to 97% savings in overall operating costs over standard vacuum generators.

The Foilpuller automates the processing of sheet metal in standard sizes of 1 x 2.5 m using flat vacuum cups and compact ejectors to apply suction to single pieces of sheet metal in a designated stack at the pick-up site. The vacuum cups prevent wobbling, while a vacuum shuttle delivers the sheet to a worktable where a cutting wheel lightly scores the protective film on the surface of the sheet.

Through precisely controlled cutting, the wheel only makes incisions where film needs to be removed to allow for mounting fittings, hinges, cutouts, and welding 14

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DESIGN NOTES

work, leaving the rest of the protective film intact. A scraper then removes the scored film to reveal a residue-free surface before FIPA’s gripper system places the sheet in a second designated stack for further processing.

The SM-F Series flat vacuum cups used in the Foilpuller have a flexible sealing lip for non-slip contact with sheet metal, and are suitable for almost all standard metal surfaces, including flat or textured stainless steel, varnished steel metal, coated plates, and printed film. The series’ reinforcement ribs provide slip resistance, absorb the high lateral forces from tipping metal sheets, and prevent deep-drawing effects that could warp thin metal sheets. Made of silicone-free NBR materials with a hardness of 60° Shore A, the vacuum cups also have a vulcanized aluminum connection thread designed to minimize leaking and ensure a tight fit, even during dynamic gripping cycles.

The EMA Series compact ejectors combine a pressure regulating, energysaving function with an electronic air-saving

“The Foilpuller automates the processing of sheet metal in standard sizes of 1 x 2.5 m using flat vacuum cups and compact ejectors to apply suction to single pieces of sheet metal in a designated stack at the pick-up site.” function to achieve outstanding operational efficiency for the Foilpuller. Designed for maximum energy savings without limiting performance, the ejectors supply a Venturi nozzle with compressed air to generate a vacuum, allowing the attached vacuum cup to quickly grip the workpiece. A vacuum switch continually monitors the vacuum level to control air savings and triggers the

“item gripped” signal at the first vacuum threshold limit (V1, 65%), allowing the scheduled item transfer to take place. When the vacuum reaches the second threshold limit (V2, 75%), the ejector interrupts the compressed air supply to the Venturi nozzle, reducing energy consumption to zero. The vacuum is sustained by a closed, non-return valve and continues to reliably grip the workpiece without any additional energy expenditure until naturally occurring leakage eventually lowers the vacuum threshold back to 65%, at which point the air-saving control cycle briefly generates a new vacuum until the 75% threshold is again achieved.

Once the item transfer is completed, the ejector’s blow-off valve generates a manually adjustable air jet to quickly release the metal sheet.

FPW

FIPA | fipa.com

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DESIGN NOTES

Edited by: Mary C. Gannon • Managing Editor

A pump is the heart of a hydraulic system. When the pump fails, the entire system is down until the pump is operational again. This poses a serious threat to any operation relying on hydraulic systems for productivity. Recently, a hydraulic valve manufacturer was losing 25 pumps a year on their centralized hydraulic system at a cost of $2,440 each. That’s only the pump cost—when you account for maintenance resources, lost oil and lost production, each failure costs approximately $25,320.

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Phone: 414-769-6400

Flow & directional control valves, pumps and motors.

Custom versions available

Fax: 414-769-6591

email: sales-us@webtec.com

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and time. Ensuring proper filtration

Flow condition monitoring

Test stand instrumentation

FLUID POWER WORLD

hydraulic system, pump failure can be devastating in terms of cost

to these critical components.

Diagnostic test equipment & data logging

16

Because it is the heart of a

helps to reduce the risk of damage

20,000 particles per ml > 4µ[c] 10,000 particles per ml > 6µ[c] 2,500 particles per ml > 14µ[c]

Toll Free: 800-932-8378

| Shutterstock.com

Filter change proves how costly dirt can be to your hydraulic pump

website: www.webtec.com

04/06/2014 16:51

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DESIGN NOTES

To reduce these failures, the manufacturer set an ISO code limit of 17/15/13 and turned to Hy-Pro Filtration for help. While surveying the system, HyPro noticed and addressed three factors contributing to these problems.

2 The tanks lacked breathers.

Hydraulic tanks should be sealed from the environment but there must be a way to allow air exchange to occur between the tank and environment as fluid enters and evacuates the tank.

Breathers were added to the tanks to allow this exchange to occur in a controlled manner by removing contamination from the air entering the reservoir before it reaches the fluid.

4µ

6µ

3 A Brand-X 12-µ filter element installed in the offline filtration system was upgraded to a 6-µ Hy-Pro DFE Rated G8 Dualglass element as more efficient filtration would be necessary to drop the ISO code below the 17/15/13 limit.

Fluid analysis samples were taken over the following 140 days to verify the condition of the fluid. The final sample returned an ISO Fluid Cleanliness Code of 12/11/7, even better than the manufacturer had planned for. That translates to a maximum of: • • •

4-Sep

28-Aug

21-Aug

14-Aug

31-Jul

7-Aug

24-Jul

17-Jul

10-Jul

3-Jul

26-Jun

19-Jun

12-Jun

5-Jun

29-May

22-May

15-May

8-May

1 The hydraulic tanks were open to the environment. This allows the dirt and dust in the environment to find its way into the fluid. These tanks were sealed to prevent further contamination ingression from the environment.

1-May

20,000 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 0

24-Apr

Particulate Contamination per Milliliter > Xµ

14µ

Simple changes like the three mentioned above almost completely eliminated pump failures due to fluid contamination, saving approximately $633,000 annually, with a 99.8% reduction in particulate contamination within the fluid.

FPW

Hy-Pro Filtration | hyprofiltration.com

40 particles per ml > 4µ[c] 20 particles per ml > 6µ[c] 1 particle per ml > 14µ[c]

to one Switching from a 12-µ filter element system rated for 6 µ from Hy-Pro increased amicleanliness, reducing particulate cont ately nation by 99.8% and saving approxim $633,000 annually in downtime.

www.fluidpowerworld.com

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RESEARCH & DEVELOPMENT

Mary Gannon • Managing Editor

3D-printed excavator wows the crowd at IFPE

Kicking off the Tech Experience at IFPE and CONEXPO-CON/AGG, the unveiling of the 3D-printed excavator—dubbed Project AME—was a fitting start to the “Imagine What’s Next” theme of the massive shows.

Oak Ridge National Laboratory (ORNL), in collaboration with CCEFP university student designers from the University of Illinois, the University of Minnesota, and Georgia Tech, as well as AEM and the NFPA, worked to create novel designs for the cab, stick and heat exchanger that were all printed at the Department of Energy’s Manufacturing Demonstration Facility located at Oak Ridge National Laboratory.

The idea for the 3D-printed excavator came during a visit to ORNL, which had recently printed a car for the IMTS show, said Mike Gust, Industry Relations Director for the CCEFP.

Just like other manufacturing methods, those used in the excavator differ widely, said Gust. The cab, which was printed in just half a day, is printed of aircraftgrade composites with carbon reinforcements, which is much lighter. This idea 18

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could allow for future customization of cabs designed specifically to the operator.

Printed with a robotic welder from Wolf Robotics, a Lincoln Electric Co., the 7-ft long, 400-lb stick was printed in just five days. The metal printer uses a laser-hot wire process for steel and titanium materials. Gust said it took slightly more than 1,000 passes to manufacture the entire boom. This boom did allow for the elimination of some hose and tubing by printing internal passageways.

“The boom or stick was—for first-time ever that we know of—something that large was printed out of steel,” said Gust.

The 13-lb powder-bed aluminum heat exchanger was printed using a Concept Laser X-line 1000 powder bed machine, which melts the aluminum as it is printing,

www.fluidpowerworld.com

5/15/17 12:41 PM

The 3D-printed heat exchangers feature a design impossible in traditional manufacturing. | courtesy of Oak Ridge National Laboratory, US Dept of Energy

creating a pressure-tight design up to 1,000 psi, said Gust.

The radiator features are simply not possible with conventional manufacturing. Hydraulic oil is cooled as it passes through tubes with special internal features to enhance cooling. Air flows over the tubes, which are shaped to reduce the required fan power. The aluminum oil cooler is printed or laser-fused layer by layer by the Concept Laser printer.

According to University of Minnesota student Brandon Hathaway, “We’re making a ready-to-use drop-in replacement device that can be added to the heat exchanger with very little added operation.”

“With these heat exchangers, you need a lot of sub-features.

On the outside where the air flows through, you need to get a lot of surface area, so you have to add these fins. Ours are at an angle because the printing process doesn’t allow horizontal or vertical ones you’d have in a traditional design,” Hathaway continued.

The tubes running across the fins have a lenticular shape, which is streamlined to help with the airflow. And little fins are staggered on the inside of the tubes. With traditional manufacturing, you couldn’t have both these designs manufactured together. “With 3D printing you have the possibility to incorporate those features together, so that’s one of the big benefits, is that you can take these unique features that are usually separate and put them into a combined device.”

Hathaway said this prototype allows the device to operate and efficiency improvements will come as they refine the device. Currently, it’s comparable to an existing heat exchanger.

Student researchers had some input from Daikin and Adams Thermal, which allowed them to test their device side-by-side with a traditional exchanger at its test facility.

The key to all three components and manufacturing types is to at least show they are comparable to current methods of manufacture, and hopefully, to make them stronger, lighter and eventually, more efficient and functional.

“It should be strong enough, so that it’s a functional part. Every one of these is designed to be functional, which is kind of a new wave of 3D printing,” Gust said. “The steel could be a game changer to custom-make what you need.”

As for real-world applications with manufacturers, Gust said the first thing would probably be tooling and fixturing.

Outstanding customer service High quality products www.aignepusa.com

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FPW

Project AME | web.ornl.gov/sci/manufacturing/projectame 5 • 2017

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Dynamic Machine Control.

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RUN DATES: May

SAFETY

J. Eric Freimuth • Hydraulic Training Associates

How do you safely design and use hydraulic cylinders?

Many of the failures in a hydraulic system show similar symptoms: a gradual or sudden loss of high pressure, resulting in the loss of power or speed in the cylinders. In fact, the cylinder may stall under a light load or may not move at all. Often the loss of power is accompanied by an increase in pump noise, especially as the system tries to build up pressure. Any major component, including the pump, the relief valve, directional control valve, or the cylinder, could be at fault.

In a sophisticated system, other components could be to blame, but this could require the service of an experienced technician.

By following an organized step-bystep testing procedure in an orderly fashion, the problem can be traced to a general area, and then if necessary, each component in that area can be tested or replaced.

Knowing a cylinder’s load rating comes down to all of its parts including seals and guide bands. This design from System Seals provides more accurate piston and rod guidance inside the cylinder under varying load conditions.

In this article though, we want to discuss the safety tips concerning cylinder design and use. What are some of the suggested things we should be looking for when selecting the right cylinder for the job? Answering these questions before installation is a start to safe and optimal cylinder design.

1 Is the cylinder rated for the work to be done? Using the F = P x A formula (Force = Pressure x Area) will ensure that the cylinder is sized properly to do the work at the required system pressure.

2 Is the cylinder designed to handle the load? With so many manufacturers today, choosing a cylinder that will hold up to the load requirements is important. Be sure to evaluate the seals and guide bands being used for bearing loads. Agricultural equipment typically uses ag-type cylinders that feature cast end covers bolted together with all thread and nuts onto a honed tube.

They also typically use O-rings for seals. These cylinders generally operate around 1,500 to 2,000 psi and are

Knowing which applications are best for tie-rod versus welded cylinders is critical in system design, as industrial applications rely more on tie-rod designs. | courtesy of Yates Industries 22

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SAFETY

designed to be either quickly resealed or thrown

away. Using this type of cylinder in a construction

application would prove to be dangerous and

self-defeating as it would be short lived for the work

to be done and may not hold up under the load requirements.

3 Tie-rod or welded? When is it appropriate to use a tie-rod cylinder or a welded cylinder? The typical response is that manufacturers of stationary equipment generally rely on tie-rod cylinders, as they can be configured to fit most unique applications and have many applicable valving blocks, making them simpler to configure to machinery. This reduces other possibly needed valves to accomplish work desired and helps to reduce costs. Rated to NFPA standards, tie-rod cylinders are easily inter-changeable with other manufacturers. Welded cylinders are most common in mobile equipment where weight and size of application work needs can be considered. These heavier duty designs are usually rated to 5,000 psi or higher.

Featuring a barrel that is bolted or welded directly onto the end caps, these designs do not require tie-rods, so thus are stronger and more resilient in harsher environments.

A COMPLETE RANGE OF SENSORS:

RELIABILIT Y IN MOBILE HYDRAULIC CONTROLS!

Welded cylinders, like this one from Yates Industries, are better suited for mobile machinery.

Above all else, it is important to be sure to use a cylinder that is rated for the job. Choosing a cylinder because of cost rather than design can be a mistake in many ways. Seals, wear bands, shaft seals, and porting all play an important part of selection.

FPW

Hydraulic Training Associates | htahydraulics.com

Gefran, a leading global designer and manufacturer of sensors for position, pressure, temperature, and force measurement, now offers a complete range of devices for earthmoving and lift equipment.

Gefran sensors use leading edge technology (Hall effect, MEMS, and magnetostrictive) to achieve the demanding requirements in operator and vehicle stabilization, rotation, reach, and inclination.

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FUNDAMENTALS

Edited by: Mary C. Gannon • Managing Editor

What hydraulic hose assembly works best for my design?

At some point during the design and build of new equipment, the question arises of which hydraulic hoses to choose. The market offers numerous options in a wide range of price points. With seemingly endless hose and fittings options, how do you select the best product for your application? Eric Durrant, senior global product manager, Hydraulics Business, Eaton, offers these tips to ensure hydraulic hose lives up to its recommended life cycles.

Specifying the right hose In general, there are five key steps to find the right hose for your machine: 1 Determine the media the hose will be conveying Not all hoses are built to convey all media. Will the hose be moving oil? What type of oil? The media moving through the hose may interact with the material that makes up the inner tube of the hose. Considering the media from the outset will help you avoid any potential negative interactions.

When selecting hydraulic hose, you must consider how the environment it operates in will affect its life. Considering the cover and effects of abrasion is critical to ensuring the hose lasts its recommended life cycle. Using hose protection devices like sleeves, wraps, etc. can prevent damaging abrasion. | courtesy of Essentra Corp.

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2 Determine the pressure, size and any industry specifications required Will the machine need to meet European standards (EN), International Standards Organization (ISO) requirements, or Society of Automotive Engineering (SAE) guide lines? Many industry specifications have similarities, but if there are specific requirements your machine needs to meet, it’s important to be aware of that early.

The pressure of the system and available space for a hose will of course impact your selection as well.

3 Determine the minimum and maximum operating temperatures Just as not all hoses are built to convey all media, not all hoses are built to withstand the same temperatures—hot or cold. A hose designed to last in hot conditions may not be designed to do the same in freezing conditions. Knowing the operating temperature of the machine will help eliminate potential hoses at the outset.

www.fluidpowerworld.com

5/15/17 2:31 PM

FUNDAMENTALS 4 Use the above information to determine the necessary

hose reinforcement

This is a critical step—choosing a standard or premium amount of reinforcement. The media, pressure, size, specifications, and temperature all feed into the choice of how much reinforce- ment your hose needs, as reinforcement will affect operating pressure, impulse life and bend radius of your hose. Too much, and you end up over-buying and can end up with a stronger hose that doesn’t bend as easily, forcing you to use more hose and space to make the product work. Too little, and your hose will not last as long as expected and may present safety risks to the end user.

5 Select a hose cover for additional security The final step is selecting a hose cover. The hose selection itself may limit your cover choices—selecting a standard hose with standard reinforcement will generally present you with a standard cover option. If you need a premium cover, you may need to consider upgrading to premium tube or reinforcement options.

The four most common hose buying mistakes When faced with overwhelming choices and a short timeline to get a machine built, it’s no surprise that mistakes can be made when specifying and buying hoses. Now that we’ve discussed how to properly choose a hose, let’s take a look at what not to do during hose selection.

1 Don’t by on price alone. One of the most common mistakes we see is when customers consider only the price of the hose when making a selection. Hose pricing can vary rather dramatically, which can add to the confusion and lead customers to either select the cheapest option, or choose a hose with a middle-of-the-road price without realizing what they are getting. A standard product will likely be the cheapest option, but would it be worth it to buy a premium product if it provided two times the lifespan? What if it provided five times the life span compared to the standard hose?

Suddenly, it’s not all about price.

2 Abrasion considerations. Another mistake is to buy a hose without considering the most common causes of hose failure. The first is abrasion. Look at your machine design—is your hose at an elevated risk for abrasion? If so, look at options for adding abrasion resistance to help the hose last longer.

3 Take care not to over- or underestimate covers. Covers can be another potential mistake for many buyers. Covers typically come in levels—good, better, best—and there’s a lot of variation between and within the levels. Can you reduce costs by buying a standard hose and pairing it with a premium cover? Maybe, but the combination will not match the lifespan of the premium hose. If your appli- cation needs the protection of a cover, it might be worth it to spring for the premium product, which may not need as much additional protection.

4 Don’t risk losing warranty guarantees. Finally, not

considering the warranty can be a big mistake on the buyer’s

part. It’s not uncommon to see hoses mixed and matched with

fittings from a variety of manufacturers. This is sometimes cost

driven, but frequently, it’s a timing issue. A customer needs to

replace a hose or fitting as quickly as possible—if the right hose

or fitting isn’t immediately available, they might choose something

that will work in the moment just to get the machine back up and

running. This can cause leakage, leading to downtime and mainte-

nance costs. Depending on the manufacturer, a warranty might be

available on the assembly, but is typically valid only if the hose and

fittings in the assembly are both from the same manufacturer.

Ultimately, selecting the right hose can be a struggle, but knowing what you need to consider can help cut through the immense number of options. By selecting the right hose from the outset, original equipment manufacturers can help customers optimize their investments and lower the cost of ownership. Avoiding maintenance and warranty issues also helps improve the bottom line of the OEM, while maximizing the number of usable hours on the machine.

www.fluidpowerworld.com

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ENERGY EFFICIENCY

Ron Marshall • For the Compressed Air Challenge

Air dryer control problems

A food processor purchased a surplus air compressor and dryer at auction for their processing facility. The compressor was much larger than required, but the plant manager had hopes for future expansion.

Because the air pipes in the plant run in unheated areas, a surplus heatless desiccant dryer was purchased as well.

The dryer has an older style dew point control installed that turns off the dryer regenerating purge—consuming 25% of the compressor’s capacity when it is flowing. This typically saves significant power because of the light loading.

It turns out tht the planned expansion of the plant never happened. Therefore, the average compressed air flow is much lower than the capacity of the compressor, an average of about 7%. A large storage receiver was installed to allow the compressor to turn off between cycles and save power.

An auditor did a plant assessment a few years after the installation and found the compressed air loading was much higher than expected.

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He found that, over the years, oil contamination had fouled the dryer desiccant because of less-than-optimum filter maintenance.

This made it difficult to reach the –40° dew point that triggers the control to save purge. The oil had also fouled the dew point sensor on the dryer control, which caused the dryer purge to run constantly. Overall the auditor calculated that due to the dryer control failure, about 78% of the compressed air produced by the oversized compressor and dryer was being consumed by dryer purge!

The customer is now considering a smaller compressor and more efficient dryer, likely funded partly by a substantial power utility incentive. Plant maintenance practices will also be reviewed.

Learn more about air dryers in our next Compressed Air Challenge seminar in your area. Visit www.compressedairchallenge.org for more information.

FPW

www.fluidpowerworld.com

5/15/17 2:38 PM

Mill Duty, Tie-Rod, and Welded Body Cylinders Custom designed and engineered with no limits.

Yates is a leading manufacturer of high performance cylinders, offering quick turn around times, quality support and the convenience of three locations. As a third generation company, we understand custom.

Yates Industries, Inc.

Yates Cylinders Alabama

Yates Cylinders Georgia

23050 Industrial Dr. E. St. Clair Shores, MI 48080 Phone: 586.778.7680 Fax: 586.778.6565 sales@yatesind.com

55 Refreshment Place Decatur, AL 35601 Phone: 256.351.8081 Fax: 256.351.8571 decatur@yatesind.com

7750 The Bluffs Austell, GA 30168 Phone: 678.355.2240 Fax: 678.355.2241 salesga@yatesind.com

Yates 4-17_FPW.indd 27

www.yatesind.com/harsh

5/15/17 11:06 AM

Electrohydraulic drives

interface with the IoT, Industry 4.0

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I N D U S T R I A L

Benno Birke Senior Vice President – Technical, Industrial Hydraulics Albert Köckemann Development Manager, Industrial Electronics Bosch Rexroth Lohr am Main, Germany

H Y D R A U L I C S

Electrohydraulic drives are primarily used whenever a high power/weight ratio, compact size and/or large forces are required for individual applications. These drives are often used together with electric drive technology in machines. However, in terms of automation, unlike electric drives, today’s electrohydraulic drives are still largely connected via analog interfaces and centralized closed control loops.

To compensate for the inherent differences of hydraulic drive technology and, at the same time, significantly enhance its performance and diagnostics capability, Bosch Rexroth has developed a consistent automation platform that can be configured for both centralized and decentralized systems.

This article first gives an overview over what’s already available and how it relates to the automation world. Second, we’ll delve into decentralized drives in greater detail, explain their benefits, and present some notable applications.

Technical landscape Current developments and target goals can be characterized by the following starting points: • Valves and pumps: Today, the majority of valves and control pumps are controlled via analog interfaces (±10 V, 4 to 20 mA). For the modern automation level, suitable digital interfaces are a must.

• Axis control loops: Control loops are mainly managed centrally in higher-level automation systems. In the future, control algorithms tailored specifically to hydraulic require- ments and with an adequate computing capacity will have to be available.

• Real-time-capable bus systems: In the field of automation technology, Ethernet-based bus systems are on the rise. The prevalence of a variety of control manufacturers in individual markets and regions results, unfortunately, in a very heteroge- neous situation regarding the bus systems that machine builders and users must support. Our systems can handle multiple communication (multi-Ethernet) protocols.

To fully integrate “classic” electrohydraulic drives and also take into account new “hybrid” systems, such as the servo-pump and self-contained axis, the target situation defines the newly developed, consistent automation system: • Electrohydraulic valves and servopumps can be controlled directly via the bus system.

• With regard to valves, a distinction must be made between an Integrated Field Bus (IFB) function and an Integrated Axis Control (IAC) function. In the IFB, an Ethernet-based bus system replaces analog interfaces. The integrated bus

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I N D U S T R I A L

H Y D R A U L I C S

capability allows additional data to be exchanged with the higher-level

control for configuring the valve or for transmitting internal state

variables. Open and closed-loop control tasks for the drive remain

within the higher-level control (centralized structure).

In the IAC, axis control loops (position, velocity, pressure and/or force control) operate in a decentralized arrangement. The higher-level control merely provides command values and status signals in real time.

• The “servo-pump“ system (Rexroth’s Sytronix product) uses the same

automation connections as in electric drive technology.

• The same is valid for the hybrid drive, which consists of an electric

servodrive with hydrostatic transmission (the so-called “self-contained

axis”). Axis-control functions in this hydraulic subsystem are

implemented as part of the converter firmware.

The latest hydraulic systems and controls make plastics processing more precise, economical and safe.

Integrated axis control is commonly used in injectionmolding machines for motion and force control.

Demands on the target system In developing future-looking Industry 4.0 type systems, requirements can be subdivided into the following three areas: Functional (essential) requirements:

• Implement all relevant Ethernet-based bus systems. Open interfaces

mean customers can use virtually all automation systems common on

the market.

• Tailor axis controller algorithms to suit the special requirements of

electrohydraulic drives.

• Valve and pump connections embrace integrated safety concepts,

where devices receive bus communications on one hand and

implement the required safety standard on the other. Examples

include press safety and the demands made on the closing axis of

plastics machines.

• Bus communication is not only used for transmitting command and

feedback values, but also for capturing additional information from

components and drives in terms of data, so the control introduces a

“Condition Monitoring Ready“ capability.

• Built-in tools such as software oscilloscope functions, essential for

commissioning, are available.

Desirable requirements and approaches:

• One consistent programming and commissioning tool for all drive

forms (electric and hydraulic drives)

• Identical bus connections for all drive forms (state machines)

• Identical parameter designations and scaling of machine data for all

types of drives

• Software-supported tools like “wizards” and automatic-optimization

algorithms simplify commissioning (in particular of hybrid drives).

Ethernet-based bus systems let individual drives communicate with higher-level controls.

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Thanks to PC-supported programming and Bosch Rexroth’s IndraWorks (IW) parameterization tool, which can be used equally for electric and hydraulic drives, engineers can consistently meet these requirements. Consequently, electric and hydraulic drive technologies are treated identically. Dialogs in IW tailored specifically to the individual devices take into account special characteristics of drives and simplify commissioning. www.fluidpowerworld.com

5/15/17 2:59 PM

NEW Instant Online Configurator.

The Rexroth Sytronix SVP 7010 is a variable-speed pump drive that offers high accuracy and dynamic performance with low energy consumption.

Commercial requirements:

• User acceptance requires a portfolio of components and drives which are

widely scalable with regard to performance and functionality, because

customers only pay for what is actually required for the application at hand.

• The extra cost resulting from the digitization of valve and pump electronics

must be justified in actual applications through the added value offered by

direct bus integration, reduced commissioning expenditure, lower cabling

effort and important additional capabilities such as decentralized control and

condition monitoring.

Now you can configure Fabco-Air products anywhere.

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

Even your smart phone!

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

It generates everything you need from one location.

Decentralized drive systems

To provide additional details, here’s a closer look at the components and subsystems in IAC drives. The components available for this can be classified into the following subsystems:

• Valves: Direct and pilot-operated proportional and high-response valves of

the 4WRPE family are currently available in sizes 6, 10, 16, 25, 27, and 35.

• Pumps: Servo-controlled pumps in Model Series A10 and A4 in sizes 28, 45, 71,

100, 140, 180, 250 and 355 are available today.

• Digital integrated electronics (termed On-Board Electronics or OBE) for these

valves and pumps are used in IFB and IAC variants, as described in more

detail below.

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

In terms of hardware, robust IP65 electronics is available in the IFB and IAC. Both are equipped with interfaces for up to four pressure sensors (either current or voltage signal range). In the IAC, interfaces for position measuring systems (SSI) and incremental interfaces (1 Vpp) are also available. For communications, an integrated multi-Ethernet interface permits connection to one of the following bus systems:

Additionally, the program includes an unprecedented DECONSTRUCTION feature.

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

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

Sercos, EtherCAT, POWERLINK, VARAN, PROFINET or EtherNet/IP.

In other words, every component “speaks” six languages. Hardware variations due to different bus systems can thus be avoided. This is also interesting for users needing to run different central controls because of their customers’ demands. The selected bus system is activated via the software.

Safety is also an important consideration. Capabilities such as “Safe Halt,“ “Safe Direction“ and “Central Position Monitoring“ run independently of the bus system via two certified digital inputs and two associated digital output signals. With regard to the valves, they provide safe shutdown of the output stages for the solenoid. This approach permits safety functions without having to design the entire bus system, master included, as a safe system.

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Try it out now at

www.FABCO-AIR.com 31

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

5/15/17 3:01 PM

I N D U S T R I A L

H Y D R A U L I C S

Software functions of the OBE for valve-controlled drives (comparable functions are available for control pumps) include various bus systems, as described above. Other considerations are:

• Valve controller: While the dynamic behavior of the valve can only be modified by the manufacturer, the user can adjust the valve characteristic (curve).

• Closed-loop flow control: By means of up to four integrated pressure sensors built in a sandwich plate directly below the valve, an electronic “pressure compensator function” (load independent flow) can be implemented. This is particularly useful for applications where the use of a position-measuring system is out of the question due to cost or technical reasons (for example, in the core-pull function in plastics machinery).

• Closed-loop pressure control: Apart from pure press control functions (pressure and differential pressure), alternating control and force-limitation modes can be activated.

• Position controller: All of the algorithms required for hydraulic drive technology are stored in the controller. This also includes processes for state feedback and continuous path control.

Other considerations include diagnostics and commissioning aids. Apart from analysis tools such as a software oscilloscope and error log, the system provides wizards for the precalculation of control parameters, as well as automatic optimization tools for axis controllers in continuous path-control modes. Future software versions will offer condition-monitoring functions.

However, the set-up already monitors valve functions. In addition, the IAC also offers axis monitoring functions (such as maximum velocities, forces and dynamic following errors).

Finally, the system has an integrated PLC. It lets the customer program functions such as adjusting the controller to suit individual applications, special motion profiles or applicationspecific reactions to errors. Here, the customer can flexibly integrate its know-how and protect it accordingly.

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Check this out!

Stand-alone hybrid linear axes combine an electrical drive and hydraulic cylinder.

They reduce installation space and engineering time and are IoT compatible.

Application examples

This drive structure suggests itself particularly for applications in which: • Various machine axes can operate independently of one another, or • How the motion of one axis depends on that of another only has to be accounted for when generating command values (such as, for example, with interpolating axes).

A further criterion using IAC can be when controlling a large number of axes. The decentralized control approach relieves the central control of most tasks and, in addition, cabling efforts can be drastically reduced.

For example, IAC is commonly used in injection-molding machines for motion and force control. Optimized digital closed-loop control of the injection

also reduces cycle times while improving the machine’s energy efficiency.

Differential force control permits the application of only the required forces, helping protect the mold without compromising speed. And as noted previously, hydraulic drives with onboard electronics can improve safety on machines such as these. One obvious reason is to protect workers during clamping actions. But also, if a part does not cleanly release and remains in the mold, the electrohydraulic control system senses a malfunction, stops movement and prevents damage to the machine.

Another application example involves automating axes in a sawmill. In this case, the need for a large number of self-contained axes and sizeable physical distances between them were decisive for choosing a decentralized

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Thanks to PC-supported programming and Bosch Rexroth’s IndraWorks (IW) parameterization tool, which can be used equally for electric and hydraulic drives, engineers can consistently meet these requirements. process ensures tight precision, say over pressure, speed and force when closing and clamping the mold. That’s because the transition from velocity to pressure control of clamping—with high accuracy— is essential to maintaining dimensional stability of the injected part as well as the mechanical integrity of the machine. It

drive structure. EtherNet/IP was used as the bus system to communicate as needed with higher-level controls. The system, which has run in a three-shift operation for more than a year under harsh operating conditions, shows the robustness and reliability of the electrohydraulic system.

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The Sytronix DFE supplies pressure and flow on demand.

A variable-speed electric drive controls an electrohydraulically driven axial-piston pump.

Finally, consider a highly complex rotary-indexing machine. The demands on the drive axes and the entire automation system are extremely exacting with up to 48 interpolating electrohydraulic axes plus electric servodrives. Requirements for continuous path and positioning accuracies are on the order of a few microns.

The CNC technology used for the axes must handle up to 28 NC channels. Here, the IACs operate in conjunction with an MTX control and a Sercos bus system. The result is a 20% increase in productivity compared with previous versions of the machine. At the same time, lower cabling and commissioning costs as well as optimized CNC performance reduced overall system costs. The machines work troublefree around the clock.

The efficiency of electrohydraulic drives and not least their full and “easy” ability to integrate into automation systems are, apart from the cost, essential competitive criteria that speak in favor of this drive technology. The concepts presented here are characterized by consistency in terms of automation. The key aspects are:

• The integration of open bus interfaces into the hydraulic components • The integration of hydraulic “know- how” into the drive firmware • Identical behavior to that of electric servodrives when it comes to automation • One consistent commissioning and diagnostic tool for all drive types, including valve-controlled, pump- controlled and hybrid systems consisting of an electric servodrive with a downstream hydrostatic transmission.

Whether central or decentralized axis control is the better choice depends on the specific application. Regardless, such concepts make hydraulic drive technology “Industry 4.0” ready, while maintaining its competitiveness as physically compact, robust and capable of high speeds and large forces.

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Mobile hydraulics

powers vacuum lifting Vacuum-lift attachments make construction equipment more productive.

Ken Korane • Contributing Editor

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Construction equipment has long been used to move material like large pipes and concrete slabs, typically with ropes, chains or slings tied to the bucket or stick. Lately, however, operators of these machines are turning to vacuum-lifting technology as a faster and safer alternative. According to officials at Vacuworx, Tulsa, Okla., vacuum-based devices can improve worksite productivity and, more importantly, keep workers out of harm’s way.

Benefits of vacuum

Vacuum-lifting systems work much like simple pick-and-place vacuum cups seen in industrial packaging settings, but on a much larger scale. And they offer numerous benefits over conventional handling operations, explained Bill Solomon, president of Vacuworx. First, vacuum eliminates the need for unsafe and time-consuming lifting mechanisms such as hooks, slings or chains. With no cables and chains to

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The SS 2 unit brings vacuum-lifting capabilities to skid-steer loaders. It runs off the host machine’s auxiliary hydraulic system with a minimum 10 gpm flow and maximum pressure of 3,000 psi.

The all-aluminum product weighs 98 lb and, thanks to quick-connect couplers, readily attaches to any skid steer. The SS 2 handles steel plate, saw-cut concrete, granite and marble slabs, landscape pavers and other materials weighing up to 2,716 lb. | courtesy of Vacuworx

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The PS 1 portable vacuum lifting system, powered by rechargeable batteries, has an 8-hr run time. The unit weighs only 25 lb with pads measuring 8 x 12 in. to 16 x 16 in., and can lift up to 1,654 lb. It’s suited for use on small equipment like mini electric excavators. | courtesy of Vacuworx

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hook and unhook, there is less downtime between lifts and faster load and unload cycles.

Second, vacuum ensures a powerful positive engagement of the load, where slings and chains can shift or loosen, endangering employees. And it reduces or eliminates the need for tag-line operators on the ground to hold and guide the load.

Consider the overall economics, said Solomon. A length of chain is obviously less expensive than a sophisticated vacuum handler, but in terms of dollars and cents, it becomes a speed and safety issue, he noted.

“If you’re using chains, imagine you have a machine carrying a 20,000-lb load, and a guy with a tag line on each end trying to guide it and keep it from spinning or wobbling. And the operator of the machine has to watch out for the workers while trying to move and place the load,” he said. Operators can only move the load as fast as the people on the ground, and everything stops if they’re in the way, he continued. “Worse, if the chain breaks and that piece of 20,000 pound material starts to go, the guys holding onto the tag lines are along for the ride.”

Vacuum lifting essentially removes personnel from the work zone. “Now, the operator has full control, not only of lifting, but of placing and manipulating the product. He puts that material where it needs to be and goes back for the next piece in less than a minute,” said Solomon. Conventional processes can take upwards of 15 minutes per cycle, he added.

Also, there is no need for employees to climb on trailers or into trenches to attach and detach the connections, and it also eliminates the need for costly cribbing or spacers for pipe or plate. That plays into the economics and safety of the application as well.

Vacuum-lifting systems can increase productivity, while the need for fewer ground personnel reduces the risk of accidents and lowers payroll and insurance costs. ROI is often in 4 to 6 months or less, said Solomon.

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Versatile lifters The AMC Series hydraulically powered, vacuumlifting system mounts on machines ranging from compact equipment to larger excavators and truck-mounted articulating cranes. The models have a compact overall footprint and are particularly suited for contractors and rental companies who often must work in congested urban streets and tight spaces. They operate using the hydraulic power from the host machine without significantly reducing the equipment’s overall lifting capacity.

The AMC 6 has a

13,200-lb lift capacity and comes standard with a pin adapter for excavator mounting. The AMC 4 features a hydraulic quick-change adapter for truck-crane applications and has a lift capacity of 8,800 lb. Both models can accommodate single or double vacuum-pad arrangements, and they can grip steel, plastic and concrete pipe, as well as trench plate and concrete slabs.

How hydraulic vacuum lifting works

Vacuworx systems are comprised of four principal components: a vacuum pump, reservoir, sealing pad, and alarms. Hydraulics on the host machine drives the vacuum pump to operate the system. (Optional versions run off electric motors; and a selfcontained unit has an 8-hp diesel engine as the motive force.)

In a standard system, the machine’s auxiliary hydraulics powers a hydraulic motor. The motor, in turn, connects through a gearbox to drive a vacuum pump. The pump maintains a near-constant vacuum in the pressure reservoir, which is sized based on application requirements. A suitably sized vacuum reservoir also maintains holding power in the event of a hose break or power failure.

In a typical medium-size set-up, hydraulic flow is about 10 gpm with a maximum pressure of 3,000 psi. Vacuum level is around 20 to 22 in.-Hg, depending on the lifter and load. When activated, the

system pulls a vacuum between one or more pads and the object to be moved, providing a powerful suction and a positive seal—and the needed lifting force. The vacuum seal holds with minimal leakage until the operator activates the release.

Vacuum pads are sized to handle pipe, flat material or special shapes. The pad seal itself is built up from multiple standard elastomeric sections, which

The CM 3 compact modular product adapts to many applications and host machines. With a rugged allsteel construction, the device can accommodate single or double pad configurations and holds a variety of materials like concrete slabs, steel plates and pipe weighing up to 6,600 lb. | courtesy of Vacuworx

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Vacuworx calls Tough Seal. The material is formulated to withstand rugged jobsite conditions like abrasion, exposure to oil and water, sunlight and UV radiation. It’s also suited for extreme temperatures, from –40° to 215°F. Rips and tears can be field repaired and worn seals are readily replaceable.

Vacuworx vacuum lifters can adapt to a variety of jobs just by switching out the pad. Standard curved pads fit pipe dimensions from 4 to 48 in. and can be customized for other sizes. Flat pads can be configured to specific dimensions depending on the application. Specialty pads are also available.

Finally, warning lights and audible alarms alert the operator to low vacuum levels or system faults. The system operates via an electronic wireless remote control transmitter with matched receiver.

Multiple lifters can work side-by-side without interference.

Varied applications

Standard models lift a variety of materials. These include concrete and ductile iron pipe; steel pipe, including products

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Heavy-duty RC lifters are designed to handle material like large pipe and, as shown below, large concrete sections. | courtesy of Vacuworx

wrapped in tape or with coatings like FBE (fusion-bonded epoxy) and coal-tar enamel; and plastic pipe such PVC and fiberglass.

Other materials suitable for vacuum handling are concrete road barriers, saw-cut concrete, sidewalk sections, landscape pavers, pre-cast concrete slabs and culverts, and steel plate and piling. Lifting systems can also be customized for many applications and lift capacities.

Lifters can attach to hydraulic excavators and backhoes (with or without coupler systems), wheel or track-type loaders, cranes, pipe layers, skid steers, forklifts and knuckle booms. They can also be mounted for a variety of in-plant applications.

A couple trends are helping shape demand. One is for morecompact and lighter lifters. That’s because less weight hanging off the end of the host machines equates to a greater load capacity, noted Solomon. Another is the number of recently introduced products designed for small machines such as skid steers, loader backhoes, and boom trucks with cranes, he said.

Today’s vacuum-lifting products span a wide range of sizes and lift capabilities. For instance, portable lifting systems powered by rechargeable batteries weigh only about 25 lb but can lift nearly a ton. At the other end of the spectrum, Vacuworx RC Series lifters handle materials weighing up to 55,000 lb. The self-contained units can be powered by diesel engines, or the models can operate off the machine hydraulics and eliminate fuel costs, emissions and noise.

They’ve been used to move pipe sections 42 in. in diameter and 80 ft long, and are capable of gripping pipe up to 120 in. in diameter. The limiting factor is usually the capacity of the host machine.

FPW

Vacuworx | vacuworx.com

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It’s not a web page, it’s an industry information site.

So much happens between issues of Fluid Power World that even another issue would not be enough to keep up. That’s why it makes sense to visit fluidpowerworld.com and stay on Twitter, Google+, Facebook and LinkedIn. It’s updated regularly with relevant technical information and other significant news to the hydraulics and pneumatics community.

fluidpowerworld.com pneumatictips.com • mobilehydraulictips.com • sealingandcontaminationtips.com • hoseassemblytips.com

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Three key priorities for successful agricultural hydraulic design Although we’d all love to rely on the KISS Principle, hydraulic systems for the ag industry must be energy efficient, easy to operate and maintain, and of course reliable.

Carl Dyke • CD Industrial Group, Inc.

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Designers of hydraulic systems for agricul-

tural machines face some difficult challenges. This is especially true for high horsepower tractors with not only steering and brake functions, but where a great variety of hydraulic implements will be connected and towed. With the operating parameters of a farmer’s collection of cross-branded, specialty implements unknown to a tractor designer, the hydraulic system may be either inefficient due to over-sizing and over-design—or it might fail to perform adequately if under-designed.

Self-propelled row crop harvesters, as well as fruit and vegetable harvesters now approach the size of many pulling tractors with engines larger than 500 hp. Some forage corn harvesters have engines with more than 1,000 hp. For some of these machines, the only reason to start the engine is to power hydraulic pumps. Others split the mechanical functions between a direct drive gearbox and a hydraulic system. System design must balance the challenge of evenly distributing hydraulic flow to all of the subcircuits, while retaining the capability of bringing all of the hydraulic power to bear on motor functions for quick travel between growing areas.

The common challenge across the entire spectrum of agricultural machinery is to create a hydraulic system that is energy efficient, easy to operate and maintain, and of course reliable. Partial automation is an absolute minimum necessity for large-scale machines where the operator’s attention can be drawn in so many directions.

First up: energy efficiency Assuming that hydraulic motor torque requirements and displacements have been calculated and that cylinders have been sized to produce the required lifting forces

If you were in charge of engineering this hypothetical crop harvester, where would you place the filter? Behind the wheel gives a cleaner look, but out in the open makes the filter accessible for routine maintenance. Small design decisions like this one can have large consequences! | courtesy of CD Industrial Group

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Use of a gear pump typically means that system pressure is at maximum (relief valve setting) when using only a portion of total available flow to control cylinder speed.

(within a normal range of hydraulic pressures), the choice of pump size and style will be the next major decision. For a small scale farm, a utility type of machine may incorporate a fixed displacement gear pump with an open center valve bank for the sake of simplicity and low cost. Even though the pump may be pressure-unloaded with flow directed back to tank when no hydraulic function is in use, higherthan-needed fuel consumption still occurs due to the full flow rate.

When only part of the total flow available from the pump is needed for a cylinder—deliberately extended at slow speed by judicious use of the valve lever—the excess flow is forced over a spring-loaded pressure relief valve. The partially shifted valve spool closes the pump unload path to tank, and places a partially open valve in the flow path as a major restriction and pressure load. The pump is forced to work at full flow and at maximum pressure, even if the cylinder is only lifting a light load. In other words, the flow requirement for cylinder speed may only be a fraction of the total flow available, yet the pump can only pump at the full rate. In addition, the cylinder may only need to lift a light load (requiring minimal pressure), yet the system overall will be at maximum pressure due to the restriction of the partially 44

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opened directional valve. Fuel consumption is highest when pumping at full flow and full pressure, but this may be acceptable for a simple tractor with manual steering, and where hydraulic cylinder motion is occasional while working with the machine.

For large, production-scale machinery with continuously running hydraulic functions such as planting or harvesting circuits, and with the need for forceful steering actions at any time, the variable displacement piston pump remains the standard choice.

A pressure-compensated and load-sensing

piston pump avoids the inefficiencies of a simple gear pump. It provides a flow rate that automatically matches cylinder and hydraulic motor flow demand, across multiple parallel circuit paths, and also sets the maximum system pressure only slightly higher than what is currently needed for the highest operating load.

Pressure feedback is delivered to the load sense compensator on the pump from the highest pressure circuit within the system. This feedback adjusts the pump on the fly. With the maximum pump displacement sized just slightly larger than the anticipated maximum flow, fuel efficiency is delivered by a pump that can continuously adjust pressure and flow as needed.

The load sensing feature also offers greater flow accuracy within the system overall. Minor changes in engine speed do not show up as flow variances because the load sense compensator can adjust the pump automatically. If the hydraulic system is operating motors on timed production functions on a harvester, then this flow accuracy has a direct impact on production and quality.

The pressure compensator is a control mechanism on the pump that reacts when a preset maximum pressure level is reached. Instead of using a system relief

Cutaway of a typical load sensing (flow compensating) hydraulic system.

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valve as the primary means of pressure limiting, the compensator reduces the pump displacement and keeps it near zero until the excessive pressure condition (e.g. an overload at cylinder or motor) dies down. When pressure drops down, the compensator allows the pump to increase displacement once again. The pressure compensator is similar to a standard relief valve in that it keeps the system pressure from rising above a safe level. But the pressure compensator does this by reducing the pump output, rather than inefficiently diverting extra flow back to tank. The pressure compensator provides a similar safety feature as a relief valve, but with the added bonus of energy savings.

The flow and directional control valve banks on most modern tractors and harvesters feature electronic control. With variable current solenoids, the valves are capable of proportional flow to set cylinders and motors in motion at the desired speed.

“The common challenge across the entire spectrum of agricultural machinery is to create a hydraulic system that is energy efficient, easy to operate and maintain, and of course reliable. Partial automation is an absolute minimum necessity for large-scale machines where the operator’s attention can be drawn in so many directions.”

The valves can hold a cylinder in a locked position (e.g. crop cutting height or plow depth), or allow a cylinder rod to move freely in and out so that an implement can float up and down with ground contours. For smaller, directly attached implements, this raise-andlower cylinder is found on the tractor’s three-point hitch. For larger towed implements with their own cylinders and hydraulic motors, pairs of quick couplers from tractor valves commonly referred to as “remotes” are found at the rear of the tractor to receive hydraulic hose connections.

A pressure compensator is typically found within each section of the valve bank. Most often this extra valve component is found on the inlet side of the main spool. The compensator senses the load pressure of the cylinder or motor in motion, and adjusts the pressure at the inlet of the main valve spool to ensure a steady pressure differential across the spool, thus maintaining a steady flow rate even when system pressure or cylinder load pressure 5 • 2017

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Schematic of typical load sensing (flow compensating) hydraulic system. Brake-shoe, brick stacks only for ease in understanding load pressures.

changes. This means that the operator does not have to quickly move a valve lever in reaction to a hydraulic function that is changing speed during motion. The pressure compensator eliminates the problem.

The valve bank contains a network of shuttle valves with tiny steel balls or poppets inside. These shuttle valves (aka ball resolvers) allow for the load pressure from only the highest loaded valve section to be transmitted to the load sense compensator on the pump, via a special signal hose. The use of the load sense compensator on the pump and the valve bank with shuttle valves as described completes a closed loop control scheme with the use of a fluidic pressure line to deliver feedback from the load to the pump.

Load-sensing systems are considered to be among the most fuel efficient for continuously running hydraulic systems. They can also be challenging systems to correctly adjust for tractors pulling implements of infinite design variation. There are lots of components involved, making system troubleshooting a complex process.

Recent innovations such as Parker Hannifin’s Split Pump Intelligent Flow Architecture use one piston pump for each major function on the machine, allowing for even greater energy sav-

While these look like basic connections to a source of flow, these remote valve connections bring a level of sophistication to simple hydraulic functions on towed implements. The valve bank lurking behind modern remote couplers can be capable of high levels of automation.

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ings. These types of systems, already proven for loaders and some excavators, will slowly make their way onto agricultural machines.

The pump flow rate and the proportional valve spools are electronically controlled.

This offers options around combining pumps for use with one implement cylinder during fast motion requirements, or for separate functions when operating several different cylinder motions at the same time. The internal parts of the valve bank are simpler and the use of a load-sense signal hose between pump compensator and the valve bank is eliminated in favor of faster electronic pump control.

Energy saving designs for hydraulic systems on large agricultural machines also translate to lower oil temperatures, which lower or even remove the need for large coolers and fans. A size reduction for fluid reservoirs is also possible for these systems.

Ease of operation Hydraulic functions on an agricultural machine are considered easy to operate when the operator does not have to make continuous corrections to cylinder positions (e.g. crop cutting height, steering) or adjust flow rates to hydraulic motors. Quality and

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production for plowing, planting or harvesting are the top priorities on large-scale machines. The operator’s brainpower is best used to monitor the big farming picture. With the high travel speeds and the wide crop rows possible on high horsepower machines, the operator still has lots to do. Operator-programmed controllers are extremely common. These controllers can be programmed to remember how much time it takes for hydraulic cylinders to unfold an implement. This “timed detent” feature can then be used later with the push of a button to accomplish the same operation.

The minor points of machine control and position correction should be automatic with an allowance for operator override. Automation and operational ease is the result of typical electronic controller and touch screen use with electrohydraulic valves. The possibilities for a machine that in the past was hard physical work to operate, continue to expand with steering guidance systems now moving well beyond the servo-operated steering wheel.

Unlike the world of construction machinery, where steering is often controlled by joystick on many models, the familiar steering wheel connected to an orbitrol valve (aka hand metering unit) is slow to disappear from agricultural machines. There are however, entirely automated steering controls and valves connected in parallel to the steering wheel on some machines.

Designers should now give standard consideration to the installation of linear position sensors inside the cylinders on the steering axle or in the cylinders used for articulated steering.

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Non-steering cylinders are also worth considering for the installation of linear position sensors, to enable more position memorized automation. Some newer sensors that are suitable for double rod steering cylinders can mount on the outside of the cylinder tube with only the magnet inside on the piston. The electronic control equipment on the machine may not yet be configured for fully automated, robotic steering, but many systems already offer a level of GPS-based guidance for the long straight runs across the field, allowing the operator to avoid fatigue.

Ease of maintenance and repair Ease of maintenance and repair is a valued feature that many farm operators look for.

While easy-to-access fill ports and easy-view sight glasses are welcomed, many speak with notable praise for the machine designer who makes adjustments and wrench work easy. With 45° elbow fittings, or wide radius tube elbows at the cylinder ports, the connections are easy to work on

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Modern sensors, such as this Hall effect, cylinder position sensor shown, offer new automation possibilities. | courtesy of Rota Engineering Ltd.

when damaged hoses have to be replaced.

Rows of closely spaced hoses and fittings clamped along the machine frame can work out sufficiently if the fittings are offset from each other to allow room for wrenches.

Mounting filters for easy removal and change-out is not always the most visually pleasing layout, but mechanics appreciate it. It also helps to make sure that maintenance tasks are not skipped.

Even something as basic as filter placement can have a big impact on maintenance; if filters are accessible and easy to remove/change out, this simple maintenance task is less likely to be overlooked.

Agricultural machinery continues to be a key product for the application of hydraulic systems. As innovative components and system designs that make for more efficient operation are being released from time to

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time, the use of automation is increasing very rapidly. This is especially true for largescale machines designed to help the farm operator with production yield, time usage and human input energy.

It is exciting to see innovations from other industries, such as mining and construction, crossing over into the agricultural world and making a difference in the average farmer’s day. As innovations in hydraulic system design continue to filter into agriculture, farmers will enjoy the rewards of even greater efficiency, easeof-operation, and hopefully, reductions in maintenance complexity.

FPW

CD Industrial Group carldyke.com LunchBoxSessions.com

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Load holding valves made simple

Load-holding, or counterbalance valves, are simple devices but critical to mobile machine stability and cost.

Todd McIntryre • Global Planning and Strategy Manager, SiCV • Eaton

Load-holding valves, which are also known as counterbalance valves, are a small but important part of any mobile machine. Though they are simple in design, their application can often times frustrate even the most skilled and experienced engineers. Having a basic understanding of load-holding valve operation and how to apply them can allow engineers to improve the stability and reduce cost in mobile equipment.

Why use load-holding valves?

A load-holding valve can provide these basic functions:

1 Load holding, which prevents the uninitiated movement of an actuator on a machine.

They are used when a machine requires the boom to remain in one position for extended periods of time.

For example, an individual using a cherry picker to per- form work on utility lines would be frustrated were the boom to drift downward. The poppet design of a load- holding valve limits the movement to almost zero.

This gives the worker confidence that they can complete their work without boom drift.

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2 Load control provides a counterbalance when lowering a load. It can prevent the actuators from running ahead causing uncontrolled movement or pump cavitation.

When lowering a load it is important that the operator maintains complete control of the actuator. For example, when lowering a pallet of bricks with a telescopic handler the load will accelerate with the assistance of gravity and potentially become unstable. A properly applied load-holding valve can prevent this from occurring.

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tractors with mechanical

H Y D R A U L I C

V A L V E S

Valve (2)

Pilot (3)

Cyl (1)

Figure 1. A direct-acting, load-holding valve allows the load pressure to work against the full area of the poppet.

3 Load safety prevents uncontrolled movement of an actuator in the event of a hose failure.

All hoses have a fixed life and are often the first component in a hydraulic circuit to fail. Without a valve positioned and set correctly, a boom or winch could free fall creating a very dangerous situation.

At their core, load-holding valves are an extremely important safety related device. By helping prevent dropped or uncontrolled loads—whether the load is logs, dirt or even a person—load-holding valves keep worksites safe.

Basic operation of load-holding valves

To easily understand how to apply loadholding valves, it is important to first understand how they work. A a very basic hydraulic example is when a directional valve is being used to raise and lower a load vertically.

A standard load-holding valve has been placed between the line running from the directional valve to the rod end of the cylinder. Although known by many different names, a standard load-holding valve can be described as a “pilot-assisted relief valve with a free flow check.”

As the operator raises the load, he or she will direct flow to the rod end of the

Direct poppet area cylinder. In this upward direction, you are working against gravity and the load will not want to run ahead. For this reason, the flow from the valve will pass through the free flow check portion of the loadholding valve and lift the load by retracting the cylinder.

Lowering the load will present greater challenges as the operator is now trying to move the load in the same direction as gravity in a controlled fashion. With the added acceleration of gravity, the load will have the tendency to run ahead of the control and pump.

Without the use of a load-holding valve, the operator may lose control of the load

Figure 2. Load pressure works against a smaller, annular area of the poppet in a differential area load holding valve.

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with mechanical drives.

H Y D R A U L I C or the boom may become unstable.

A load-holding valve provides the needed control by relieving flow from the rod end of the cylinder. When the operator intends to keep the load still and has the directional control in the closed position, the free flow check will prevent fluid from moving from the rod end of the cylinder to tank and hold the load in position.

As the operator lowers the load and directs flow to the bore end of the cylinder, pressure will be applied to the load control valve through the pilot line. The combined pressure from the pilot on the bore end of the cylinder and the load pressure from the rod end of the cylinder will open the load-holding valve, allowing flow from the cylinder to tank to lower the cylinder.

As the load begins to lower and accelerate, the pilot line pressure will decrease and begin to close the load-holding valve.

This prevents the load from running away.

With the valve closed, the pilot pressure increases and the load-holding valve will again open, allowing the load to lower in a controlled fashion.

Using a load-holding valve that can meter this flow in a controlled manner is absolutely critical in designing a stable and efficient load-holding system.

Load-holding valves for standard applications

Engineers can meet the requirements in a wide variety of load-holding applications using a standard load-holding valve. However, there are two very different design types of standard load-holding valves on the market.

They are known as direct acting, Figure 1, and differential area design, Figure 2.

With each of these designs, the valve has a single poppet to meter flow from the cylinder to the directional valve, and the load pressure works against this poppet. The

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V A L V E S

difference in the two designs, which is critical to boom stability, relates to the spring force required to reseat the valve.

Direct-acting valves, Figure 1, have a large poppet area working against the load pressure. Because of this large poppet area, greater spring force is required to reseat the poppet. This direct-acting design is common among the millions of types of relief valves applied every year in standard hydraulic circuits.

In contrast, a differential area loadholding valve applies backpressure to the poppet that offsets the load pressure and results in a smaller, annular effective area of the poppet. Therefore, less spring force is required to re-seat the poppet.

Spring force is important because it directly affects the stability of the valve. A higher spring rate is an advantage in many applications where unstable loads introduce varying induced pressures. The higher

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H Y D R A U L I C

V A L V E S

spring rate prevents the valve from reacting too quickly and over-opening, which causes boom bounce or audible instability.

Differential valves, with a lower spring rate, are prone to rapid opening. While this can be advantageous for some higher flow applications, the rapid opening can often lead to instability which results in boom bounce or high pitched squealing. The rapid opening also makes the valves more sensitive to changes in temperature, wear and general mechanically induced friction.

Load-holding valves for highly dynamic machines

For machines with high dynamic loads, such as on a concrete pumping truck with multiple booms, a machine designer would need to look beyond the standard valve. In the example of a concrete pumping truck, heavy concrete is being pushed through multiple booms, changing the loads signifi-

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Improving machine design with load-holding valves

operation it is paramount that they are assembled correctly and in the right place on the machine. They also have to be secure in their cavity to prevent loosening or unscrewing. Industry common cavities often have large bearing areas to transmit torque between the load-holding valve and manifold. By using a larger mating surface, the common cavities reduce assembly torque. Higher torque can result in manifold deformation which can generate contamination or reduce security of assembly.

There are a number of common opportunities where choosing the right load-holding valve can make a difference in a new machine. With the right valve, boom stability, productivity and safety can be improved, noise at start up and potential for contamination can reduced and designs can be simplified.

Given the importance of these valves in a system to ensure safety and security of

Eaton | eaton.com

cantly as portions of the booms are empty or full of dense concrete. Stabilizing these loads takes a more advanced valve.

The machine designer has a couple of choices when presented with extremely unstable conditions—either they restrict the flow or can use a two-stage load control valve where the initial restriction is removed once the movement is stable.

A restrictive valve operates by restricting the opening so the oil has to be driven across an orifice. This is inefficient in that it generates heat and makes it difficult to control the actuator speed.

The two-stage valve creates an initial restriction that is then removed as the valve stabilizes and the pilot pressure increases.

FPW

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PRODUCT WORLD

K2 axial piston pump

FFKM compounds

Danfoss powersolutions.danfoss.com

COG cog.de

The series 45 pump portfolio is being updated

This FFKM product family launches with

with the addition of the K2 frame axial-piston

four compounds: two universal materials,

pump. The smaller K2 frame, 25-45 cc,

a special FFKM compound for use in the

has been reduced in length by up

oil and gas industry and a compound for

to 20%, width by up to 10%, and

the food and pharmaceutical industry. The

weight by up to 30%.

two universal materials, COG Resist RS 75

The modular design of the K2

AL and COG Resist RS 80 AL demonstrate

axial-piston pump offers greater

resistance to chemicals and acids, and

flexibility in installation and lets

possess excellent mechanical properties.

the pump be easily integrated into

machine systems. K2 pumps offer a

at temperatures of up to 325°C, and

range of displacements, controls and

COG Resist RS 80 AL is heat resistant

configurations that have been designed to

up to 260°C. Both FFKM compounds

fit multiple off-highway applications in the agriculture,

demonstrate low gas permeability and

construction, road-building, material-handling, forestry, and

low levels of swelling. The COG Resist

turf-care industries.

RS 92 AED seal material was developed

COG Resist RS 75 AL is heat resistant

especially for applications where

Abrasion resistant spiral wire hoses Gates gates.com

resistance to explosive decompression is required, and has been tested to NORSOK standard M-710 and NACE TM 0297.

The XtraTuff cover offers 25 times more abrasion resistance than the standard hydraulic hose cover as per ISO 6945 standard. While fully maintaining the MegaSys hose performance and flexibility, the new cover provides wear performance in hose-to-hose and hose-to-metal contact applications.

Available in sizes -6, -8, -10, -12, -16, and -20, the EFG4K-XTF and EFG5K-XTF spiral wire

hoses exceed all performance requirements for SAE 100R12 and 100R13 respectively. They also meet Flame Resistance Acceptance Designation “MSHA 2G” for use in demanding mining environments.

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PRODUCT WORLD

Total Air Preparation (TAP) units and Ethernet/IP modules

Low-speed, hightorque motors expansion

Automation Direct automationdirect.com

Muncie munciepower.com/mh The MH Series low-speed, high-torque motor is available in 16 displacement sizes. Its roller gerotor design reduces sliding friction between the rotor and stator. The roller gerotor design provides smooth performance, high efficiency and durability for low-speed operation.

It has a high-pressure shaft,

increasing life and performance. The motor’s spool valve design gives smooth operation over a wide speed and torque range. In addition, the MH Series has a three-pressure zone design that provides lower case pressure and extended shaft seal life.

AutomationDirect’s line of NITRA pneumatics now includes Total Air Prep (TAP) units and NITRA Ethernet/IP protocol compact modular valve (CMV series) modules.

Both TAP units contain an automatic drain air filter with clogged filter indicator,

relieving regulator, lockable shut-off valve, pressure gauge and air dump. Electric models also have an adjustable electric soft start/shut-off valve and an adjustable pressure switch with indicator LEDs. TAP units also have a 0 to 120 psi pressure range and are IP65 rated and CE approved.

Two versions of the multi-functional filter-regulator assembly offer a common

small footprint regardless of piping requirements. Units ship with ½-in. NPT inlet/ outlet ports. Optional NPT or BSPP port inserts in sizes 1⁄4 thru 1-in. are available (sold separately). Any combinations of port sizes are available all in one small footprint.

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

Smart I/O-Link connectivity added to valve portfolio Parker parker.com These new I/O-Link modules can be quickly integrated with existing valve ranges. Ethernet based protocol independent and vendor neutral, this new module offers plug-andplay valve compatibility for customers currently using Industrial Ethernet, meaning they can benefit from similar performance and reduced system complexity at a lower cost. This communication technology lets devices be easily integrated in the same way as all commonly used Fieldbus and automation systems—users do not need to be trained in a new protocol. In addition, the network configuration can be stored or written into the code and downloaded to the device with no programming required.

Redundant absolute rotary encoder SIKO siko-global.com The WV58MR rotary encoder is based on robust magnetic scanning technology. The measurement range of 4,096 revolutions (12-bit Multiturn) is broken into 16,384 steps (14-bit). SIKO uses a newlydeveloped gear to allow the Multiturn to capture information. In contrast to battery-powered or self-contained Multiturn technologies, it continues to deliver position values for years to come. The two galvanically separated sensor units of the rotary encoder record positions entirely autonomously. Absolute position and speed are continuously provided to the controls through the interface.

Three different versions of interface are available. In addition to a version with two separate CANopen interfaces, customers can also choose from a version with bus-in bus-out and two node IDs, and one that reliably transmits via CANopen Safety. This provides full flexibility, allowing them to adjust the encoder to their applications.

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PRODUCT WORLD

Compressed air delivery through modular interfaces HARTING HARTING.com The Han Pneumatic Module Metal is a new compressed air module that meets the increased demands on interfaces for flexible production processes. It employs robust, durable high mating cycle contacts made of metal that can be plugged and unplugged at least 10,000 times, optionally with or without hot-swap valve.

The new interface is distinguished by push-in fittings that operate on the push-pull

principle and its ability to be used use at high operating pressures of up to 10 bar (previously 8 bar). This translates into a significant increase in the types pneumatic hoses that can be used while also extending the possible applications for the entire low-pressure area.

Custom hydraulic solution design service Webtec webtec.com This custom hydraulic solutions service is based on much lower volumes of typically 100 to 5,000 pieces per year, depending on cost and complexity. This provides benefits for design engineers at OEMs, who may not be able to use a standard product. Now they have access to a myriad of bespoke solutions.

Based on a service that comprises research, development, test and

manufacturing, custom hydraulic solutions can include many different components. For instance, special combination monoblock valves for flow, pressure and directional control can be designed that help to reduce the size of the system envelope and piping, and cut assembly costs. Alternatively, any OEMs looking to reduce energy consumption and prevent overheating will benefit from custom-designed, highefficiency flow control valves to suit exact requirements.

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

Direct drive Bosch Rexroth boschrexroth.com The Hägglunds CBM motor delivers enough power for a range of applications. Compared to its predecessor (Hägglunds Marathon), the Hägglunds CBM offers 50% more torque at 6,000 Nm/bar, and is 50% smaller and lighter. This makes it the most powerful direct drive in the world. The motor is based on the tried-and-tested Hägglunds CB platform and has a specific torque of 6,000 Nm/bar. The Hägglunds CBM motor features keyways which make attaching the motor to the drive shaft easier, thereby simplifying installation of the entire system. Alternatively, shrink disk adapters are also available. For users of the previous Hägglunds Marathon motors, Rexroth provides optimization sets for subsequent upgrades.

Enhanced compact cylinder line

New vane pump

Bimba bimba.com

Eaton eaton.com/hydraulics

Blue and Improved Flat-1 products have

The new VSQ (Vane-Speed-Quiet) pump series is designed to

been redesigned to offer enhancements

provide operators with a minimum speed range of 0-50 rpm to

applying the most recent advances in design

decrease energy usage and improve efficiency in dynamic industrial

technology.

applications like injection molding or metal forming.

The VSQ vane pumps combine the features

The Blue and Improved Flat-1 line has

of vane pumps with 0 RMP low-speed capable

19 new product enhancements such as

architecture to support efficiency and energy

permanent grease lubrication, an improved

savings up to 70%. High operating pressures

bumper design and hard chrome-plated

of up to 290 bar reduce pump sizes and the

piston rods with an option for stainless steel.

small size helps minimize installation costs.

The Blue and Improved Flat-1 continues the

The Eaton VSQ vane pump forms a

Blue and Improved program initiated a few

compact unit in combination with

years ago with the release of the Blue and

flange and E-motor.

Improved Original Line.

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COMPONENT FOCUS

Josh Cosford • Contributing Editor

Why should you care about manifolds?

Without manifolds, systems could look like this—a jumbled mess of connectors, fittings, adaptors, tubes and hoses.

Rats and the damn dirty nests they live in—that’s why you should care about manifolds. Nobody likes a rat’s nest. Well, perhaps little baby rats care about a rat’s nest. And mommy rats. Mommy rats adore rat’s nests.

Okay, so probably all rats like a good rat’s nests. Any why not? They’re warm and snug, and make for a great afternoon siesta. But you and I? We want nothing to do with a rat’s nest.

In fluid power, a rat’s nest is a shamble of connectors, fittings, adaptors, tubes and hoses. It’s when your pneumatic circuit looks like your wadded white iPhone headphones when you put them in your pocket for a third of a second. It’s like when your hydraulic plumbing looks like L.A.’s Four Level interchange. We’ve all seen those jury-rigged systems where they’re trying to split off ports, connect ORB to metric or join multiple return lines together. It’s not pretty, folks.

In simplest terms, a manifold is a component from which you attach other things. That’s probably too simple an explanation, because it also describes a wall, a Lego block and a telephone pole. A slightly less elementary explanation is that it cleans up plumbing—and this is why you should care.

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A manifold can be used to split a primary source of fluid off into secondary circuits, or conversely, be used to join together exhausted fluids. A manifold can also be used as a plumbing standard for which to attach valves. In some cases, a manifold can be used to replace fluid connections in an entire circuit. I’ll elaborate on these three primary uses, all of which are pragmatic options for engineers, technicians or millwrights to exploit.

For plumbing purposes, a manifold is excellent for cleaning up a rat’s nest. There are many reasons that a rat’s nest exists. It could be poorly thought out installation of a new system, where the technician was given a circuit to plumb, but no other resources but a shelf of

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UNLESS OTHERWISE SPECIFIED

SIGNATURES

DATE

00 O 2.

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9 mm ALL INFORMATION DISCLOSED BY THIS DOCUMENT IS CONSIDERED CONFIDENTIAL AND PROPRIETARY BY ACE CONTROLS, INC. & DESIGN, MANUFACTURE, USE, REPRODUCTION & SALE RIGHTS ARE RESERVED BY ACE CONTROLS.

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UNLESS OTHERWISE SPECIFIED

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| courtesy of Daman Products Co.

MATERIAL:

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800-521-3320 www.acecontrols.com

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be used in both pneumatic and medium pressure hydraulic applications. Although aluminum isn’t typical for use in highpressure hydraulic applications, you can beef up the side wall thickness to allow 3,000 psi operation, especially with better alloys, such as 6061. Aluminum is the top choice for integrated circuits, which I’ll describe later.

Ductile iron is a cast alloy with graphite, and is less brittle than cast iron. It machines well, and is strong enough to handle 5,000 psi or more in manifold applications. It is quite heavy, so is sometimes used sparingly, especially for mobile applications sensitive to unnecessary mass. For high-pressure industrial applications, it’s the standard because mass of stationary machinery is usually a non-factor.

The header is typically used after a pump to split off plumbing lines into subcircuits. You might see it after a pressurecompensated pump, where multiple lines are distributed to individual closed center valves at locations across the machine. A header is far superior in form and function to a similar setup using fittings alone. Not only does it look cleaner, it reduces the opportunities for leaks, both at machine start-up and after periods of maintenance.

Even more important than a pressure header, in my opinion, is a tank line header.

It seems there is much more thought put into the plumbing of pressure lines than tank lines, and I imagine more than one machine heard the words, “Okay, now what do we do?” If you do one thing to clean up your plumbing, please use one or more tank line manifolds. Once your tank lines are a mess, it gives all future technicians working on the machine no motivation to keep the plumbing clean, and it goes downhill from there.

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The second common use for manifolds is as subplates for valves. There are a few common valve standards, the most common being the industrial CETOP/ISO/ NFPA valves, which are commonly referred to by their sizing of D03, D05, et al. These valves are usually solenoid operated, with anywhere from four to seven ports in the bottom, where they are interfaced with the machined manifold. They attach the valves to the manifold with cap screws.

If the manifold is designed to contain just one, it’s called a subplate. It will be machined with the previously mentioned drillings to interface with the valve, but those drillings will terminate with port cavities for pressure, tank and work lines.

Most often, the subplates will contain just those four ports, plus through holes for mounting the manifold to a rigid surface.

Subplates are absolutely required for all ISO valves, because if the valve has work ports already, it is a different standard entirely.

Sometimes the valve manifolds are manufactured to accept multiple valves, combining the benefits of a subplate and header. The manifold contains all the pressure, tank and work ports to create a complete hydraulic circuit, and is a tidy method to plumb up a hydraulic circuit, especially since the manifold often contains its own cavity for a relief valve. Using the versatility of ISO valves, this means a manifold can have all the pressure, flow and directional valves attached to itself, creating a complete hydraulic circuit.

However, there is one downside to the stacks of valves piled atop a manifold; the opportunity for leaks. Generally, a valve stack doesn’t leak until years of heat cycles lead to brittle O-rings, but it does happen. To sidestep this issue, we can take advantage of the third common manifold use, which is the integrated circuit.

The integrated circuit uses a single block of machined metal, and no matter the complexity of the circuit or number of valves, the only place for external leakage is the connection ports. Cartridge valves are spools or poppets built from a single axially aligned cartridge, with O-rings separating

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each cavity. The valves are threaded and screwed into the block, which itself is a series of passages and cross drillings— these can get quite complex.

Because of the myriad cartridge valves available, such as from Sun Hydraulics or HydraForce, a hydraulic circuit can be as complex and specific enough as you can dream up. I’ve personally designed circuits with more than seventy valves, including load sense check valves, compensators, directional valves, proportional flow controls, and so forth. However, the same block with seventy valves still only had a dozen ports, so you can imagine how much this cleans up plumbing. Plumbing seventy separate valves would warrant intervention from FEMA.

Sometimes, the performance of cartridge valves can be limited, as their

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COMPONENT FOCUS

compact nature makes the integrated circuit often flow very little. As flow increases in a system, the cartridge valve options decrease, especially greater than 40 gpm or so. Going much higher in flow above this range requires logic elements in the form of large poppet valves operated by pilot valves. All the same trick valves can be used in controlling these valves, but it adds complexity and size quickly.

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Extremely high flow systems use slip-in cartridge valves, and in fact, they’re the only way it makes sense to flow ridiculous volumes of fluid; we’re talking hundreds of gallons per minute. I’ve seen hydraulic manifolds as big as a Smart car, being fed by four pumps and containing over a hundred valves, including ISO valves mounted directly to the block. If you think a rat’s nest looks bad for a 10 gpm system, imagine trying to plumb 700 gpm worth of hoses, tubes and fittings in close proximity.

If you’re a designer and you want your machine to be taken seriously, especially by those in the industry, you must absolutely use manifolds wherever possible. Their ability to clean up a hydraulic or pneumatic circuit cannot be overestimated. Even if you care less about future maintenance, you should care about appearance. You’re not a rat, after all.

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