Fluid Power World November 2016

Keep your mobile machine running efficiently p.36

Comparing the real costs of vacuum generators p.44

Is hydraulic efficiency a myth? p.54

FLUID POWER

November 2016

www.fluidpowerworld.com

How does

extreme heat affect hydraulic hose?

PAGE 60

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Engineering education: The science vs. technology split

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Although it’s been more than two decades since I received my engineering degree, it took me this long to fully understand engineering education. My breakthrough came last month when Dan Burklo, Dean of Math, Science, and Engineering Technologies, Northwest State Community College, spoke at a manufacturing workforce conference in Columbus, Ohio, that I attended.

Burklo explained that there are really two distinct areas that everyone from parents to high school teachers need to understand: Engineering science and engineering technology. Engineering science, which is what I took back in my college days, is what most people think of—a typical engineering studies program, rooted in the theoretical side. Engineering technology is less conceptual, and more focused on applying the science and implementing it.

As Burklo told the audience, a high school teacher who sees a child brilliant in math might persuade her to go into engineering science, while encouraging the child who loves to tinker and tear things apart to go into engineering technology.

We hear a lot about a skills gap in the workforce, and this might be ground zero.

A hiring manager from one major Ohio manufacturer described how they can find all the engineers they want, but they struggle to find engineering technology graduates. The engineers, he said, can’t go down to the manufacturing floor on their first day and fix a faulty robotic arm—but the engineering technology kids can.

Part of the problem is that parents think that manufacturing is still the dirty, thankless enterprise that it was many years ago. But today, Burklo pointed out, it’s a clean and rewarding career, with a lot of opportunities.

“There’s a very low portion of graduates in the engineering technology area.

What that means is you have an opportunity for some of the highest-paying and most rewarding careers. It isn’t actually just about pay. These are nice jobs; they’re not dirty jobs. Jobs that you feel good about going to ... you get to use your brain.

You get to think a lot. You get to get your hands dirty if you want to.”

One key is figuring out how to sell engineering technology to kids. Maybe the question shouldn’t necessarily be, “Are you really good at math?” but instead focus on “Do you like exploring? Do you like searching for new information? Do you like doing puzzles? Do you like discovering new ways to understand things better?”

Figuring out which students would be a better fit in engineering science versus engineering technology is critical, now more than ever, as we figure out how to stay competitive in manufacturing.

FPW

Paul J. Heney Editorial Director pheney@wtwhmedia.com

On Twitter @DW_Editor P: 770-497-9292 F: 770-497-9391 murrinc.com

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11 • 2016

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FLUID POWER WORLD

11 • 2016

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vol 3 no 8

November 2016

C ontents |

|

fluidpowerworld.com

F E AT U R E S MOBILE HYDRAULICS

How can you keep your mobile machine running effiently?

36

Learning how to properly maintain your hydraulic system with precision will help support a high-performance, well-functioning machine.

PNEUMATICS Comparing the real costs of vacuum generators

44

Industries including packaging, electronics, automotive, glass and plastics are discovering the advantages of this low-cost option for vacuum systems.

INDUSTRIAL HYDRAULICS

Is hydraulic efficiency a myth?

Although many detractors sneer at the idea of efficient hydraulics, right-sizing components, proper system design and modern technology can go a long way to achieving system efficiency.

HOSE AND TUBING How does extreme heat affect hydraulic hose?

Aging, softening or hardening caused by excessive heat can destroy a hydraulic hose’s inner tube, cover and reinforcement.

6

FLUID POWER WORLD

Contents_FPW 11-16_Vs3 MG.indd 6

44 D E PA R T M E N T S

54

02 Editorial 08 Korane’s Outlook

11

11 Association Watch 16 Energy Efficiency 18 Design Notes

60

26 Fundamentals 28 Research and Development

18

33 Distributor Update 34 Safety 76 Product World 80 Ad Index

60

Vision for the future 69 FLUID POWER

A | S |B |P|E

A | S |B |P|E

A | S |B |P|E

American Society of Business Publication Editors

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Fostering B2B editorial excellence

ON THE COVER

Special high-temp hydraulic hose can beat extreme heat.

Image: istockphoto.com

5 • 2016

2016 Regional

Fostering B2B editorial excellence

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

In recent years, operating pressure and power density in many newer hydraulic systems have increased significantly.

Not too long ago, pressures in circuits topped out at around 3,000 psi. Now, systems running at 5,000 to 7,000 psi or more aren’t uncommon. On one hand, that can mean better performance, smaller and lighter components and, possibly, sizeable cost savings. On the other, it can also increase the susceptibility to wear and premature failures in hydraulic systems.

New-generation pumps and motors are designed to handle higher loads and offer long life. However, one can’t always say the same for the fluids they use. That’s because the type and quality of oil has a significant impact on the wear characteristics of hydraulic components and, with it, the reliability and longevity of fluid-power systems.

Unfortunately, as hydraulic components and systems have rapidly evolved to meet more-rigorous operating conditions, the standards for rating fluids have not kept pace. According to engineers at Bosch Rexroth, the problem is that while pressures, temperatures and oil-circulation rates have risen sharply, the minimum requirements of relevant standards like ISO 15380 and ISO 12922 do not reflect the elevated loads and stresses that today’s hydraulic fluids face.

One result is that a high-pressure circuit may run troublefree with one fluid but quickly fail with another—even though both fluids meet the same standard.

Until now, machine manufacturers could only rely on arduous and expensive trial-and-error tests to find suitable fluids that meet their application requirements. To address that, Bosch Rexroth recently developed a new evaluation method for rating hydraulic fluids that realistically reflects higher performance demands.

In the test, described in Rexroth data sheet RDE 90235, technicians assess the behavior of fluids and their interactions with components like axial-piston pumps and motors in hydrostatic drives, under real-life conditions.

8

FLUID POWER WORLD

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11 • 2016

Photo courtesy of Shell Oil

Eliminating a weak-link in hydraulic performance

The Bosch Rexroth test goes far beyond current DIN and ISO requirements, explained a spokesman for German fluids manufacturer Liqui Moly. “Conventional tests work with 350 bar; the new standard up to 500 bar,” he said. And the Rexroth rating has an oil stress factor 13 times more severe than seen in the Eaton 35VQ25 pump test, which is widely recognized as a typical mainstream hydraulic-fluid qualification, according to engineers at Shell Oil.

Rating criteria are based on component weight and dimensional changes, material compatibility issues, and the degree of fluid breakdown during the tests. From this, technicians report conclusions on the long-term running behavior of the components based on how well the test fluid stands up. Currently worldwide, only products from four oil and lubricant manufacturers: Fuchs, Liqui Moly, Shell and SRS, meet all the requirements and make the list.

The upshot, according to the suppliers, is that these approved high-performance fluids offer a host of benefits for machine builders and users. Not only can equipment run with higher loads and temperatures, components see less wear and last longer, reservoirs and lines can be smaller, and fluid change intervals are longer—all which leads to less downtime and lower costs, versus machines running on conventional hydraulic oils. Look for more companies to get on the approval list soon, or for OEMs to reconsider their fluids suppliers.

FPW

www.fluidpowerworldonline.com

11/16/16 2:24 PM

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Edited by: Mike Santora • Associate Editor

ASSOCIATION WATCH

NFPA and the DOE’s Co-Optima program

The Department of Energy’s CoOptimization of Fuels & Engines Initiative aims to transform transportation fuels and vehicles to maximize performance and energy efficiency, and minimize environmental impact.

Image courtesy of Ron Cogswell.

Earlier this fall, CCEFP researchers presented technology to the DOE’s “Co-Optimization of Fuels & Engines Initiative” or Co-Optima for short. Organizers of this program aim to transform transportation fuels and vehicles to maximize performance and energy efficiency, minimize environmental impact, and accelerate widespread adoption of combustion strategies. They’re looking to figure out which combination of fuels, engines and drivetrains result in the highest overall efficiency.

CCEFP co-deputy director Professor Zongxuan Sun introduced them to the CCEFP’s Free Piston Engine/Pump, a new engine design that is easily optimized for almost any kind of fuel, and which directly converts internal combustion to hydraulic power. It’s an opportunity not just to achieve the objectives of the Co-Optima program (saving energy and saving fuel), it’s an opportunity to significantly grow the fluid power market, by focusing on vehicles such as mobile machinery and large trucks.

The Co-Optima organizers saw the potential and said they would include language in their next call for funded projects that would allow further exploration of this promising technology. It was a significant win for the CCEFP—validating that the industry-generated ideas that it pursues can represent real market opportunities.

FPW

NFPA www.nfpa.com

www.fluidpowerworld.com

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11 • 2016

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Paul J. Heney • Editorial Director

ASSOCIATION WATCH

Can fluid power play a role in wearable exoskeletons?

The Indego powered lower limb exoskeleton from Parker Hannifin enables people with spinal cord injuries to walk and participate in over-ground gait training.

Popular movies have long imagined robotic assist type machinery, from the Power Loader exoskeleton that Ripley wore in Aliens to the military weaponry showcased in Starship Troopers and Avatar—not to mention basically the entire premise of the Iron Man movies. But, as so often happens, the real world is catching up to the imaginations of so many science fiction writers.

At last month’s Fluid Power Innovation and Research Conference, held at the Hyatt Regency Minneapolis, Professor Thomas G. Sugar of Arizona State University discussed the trends in wearable robots, and what opportunities these devices may hold for fluid power technology.

The key to these devices, Sugar argued, is that more and more humans are simply dying of decay—we’re getting older as medicine has improved. And even for those with disease—say, cancer, heart disease, or diabetes—it’s often harder to walk, to get up and down, to lift objects.

“People are getting older and they still want to walk, they still want to be agile,” Sugar said, noting that sitting is believed to contribute to diabetes, cardiovascular disease, and greater risks of other types of mortality. “We need to walk, so that’s why wearable systems [are needed]. We need to walk.”

Sugar said that the foundation of technologies for wearables is here now.

“We’ve got batteries, microprocessors.

You’ll always need better actuators, but there are systems out there. Wearable robots are key for the health market, assisted market, manufacturers, military, and recreation.”

Whether working on exoskeletons, orthoses, or prostheses, he said that

designers need to build devices that seamlessly interact with the user; you cannot force them into some type of motion. The person has to be able to walk and have the robot “follow” them— you can’t disrupt the gait cycles or normal movement. People want to be able to move comfortably. And the massive exoskeletons that many people envision aren’t the reality in the near future, smaller units–ideally 10 lb or less in weight— are ideal. Sugar said that in testing, people who wore larger devices, in the 16-lb range, felt like they were walking through a swimming pool or that it was like a piece of exercise equipment.

Sugar’s team has created a hip exoskeleton, with 10% metabolic augmentation. He said that it’s actually 10% easier to run with the device than no device at all. They had people running fast, too—12.8 miles per hour. They have been focusing on phase angles to assist with delivering power to the user, looking at the velocity and position of the limbs.

Sugar detailed some of the numerous aspects to wearables that are currently in development, including: • Devices that power the hips and knees, forcing people to follow a pattern of walking • Prosthetics that can test for stiffness in an individual user and tune for it

www.fluidpowerworld.com

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Sugar stressed that battery life and component durability are key concerns.

“The army said that they wanted a soldier to walk an eight-hour march, so that’s about 5,000 to 8,000 steps. With a 5-A, 24-V lithium ion battery, we do eight hours of marching. You can only do that if you store energy properly,” he said. “We typically use about a 1-lb battery, that gives you about three hours of life, of just continuous walking, and the idea is that you swap out. That’s not the problem. The bigger problem is [in the private sector], Medicare will only pay for one ankle every five years, so you need a device that can do about ten gigs, motor and bearings need to do about 10 gig cycles—so life cycle is the biggest concern.”

14

FLUID POWER WORLD

11 • 2016

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• Devices specifically for amputees (large number of amputees from military veterans and diabetics) • Rehabilitation exoskeletons attached to treadmills to allow people to walk • Devices that allow stroke victims to practice repetitive tasks and build up those neural pathways • Gravity-compensation devices that are used with muscular dystrophy patients • Wearables that allow the elderly to successfully get up out of chairs • Pneumatic muscle systems for a variety of assistive uses • Hydraulic systems for picking up huge weights, suitable for warehousing uses • Devices that tie into work tools and reduce the load on the user, such as a rake that is used to lay down asphalt • Hand-assist devices that allow the user to better grip objects • So-called chairless chairs, which allow the user to squat—they then lock in place, so the user can work in an otherwise uncomfortable position • Recreational devices, which assist in skiing—using pneumatic or hydraulic damming devices for the knees, and • Assist devices to let recreational runners run faster

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Both hydraulics and pneumatics can find niches in wearable devices in the coming years, and Sugar stressed that the industry should consider looking more at soft robotics, where pneumatics is obviously a critical player.

“There’s a big push into this, to get away from big, clunky devices,” he said.

And for hydraulics, where it may be more well-suited to handling loads?

“There still is this need for people to load and unload things. I met the CEO of Walmart at a conference two weeks ago, and he said, ‘Well, we have all these robots at the distribution centers, its perfect—and distribution centers are lights-out robotics, and that’s definitely where we’re going.

But I’ve got 11,000 stores, and on average, two trucks go to each store each night, so we have got to unload 22,000 trucks every night—there’s still a need for humans there.’”

FPW

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ENERGY EFFICIENCY

Ron Marshall • For the Compressed Air Challenge

Compressed air fail: Draining profits

A food products company suffered a failure of one of its compressors—this caused production outages due to low pressure. As a result, it was forced to rent a portable compressor and place it outside, in order to return the production schedule to normal. This portable compressor consumed about $10,000 per month in combined rental and fuel costs.

Around the same time, a compressed air auditor did a system assessment of the facility. The auditor discovered that the plant powerhouse had timer drains, which were blowing excessively. A manual drain had been opened at the portable compressor; it was draining more than 50 cfm constantly, even though the portable compressor was very lightly loaded.

A check with the customer discovered that the timer drains were all set for long draining times due to moisture problems experienced during a hot summer period. The blowdown time was further increased when the portable was installed, as it seemed the moisture problems had gotten worse. At the same time, the airless drain in the refrigerated dryer failed and was replaced with an open drain—blasting full pressure through a 3⁄8-in. hose!

16

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11 • 2016

A leakage test determined that if all of the drains were set to normal and/ or replaced with airless drains, the flow demand would be reduced significantly.

Furthermore, a leakage test was done and it found that if some of the leaks in the plant were repaired, the air loading would decrease enough so the portable compressor could be turned off.

This plant was draining its profits away, and personnel didn’t even know it. Further repairs returned things to normal, with one less compressor.

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

FPW

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DESIGN NOTES

Moving modules for Brazilian oil Edited by: Mike Santora Associate Editor

TUPI BV is a consortium composed of Petrobras Netherlands BV, the British Gas Group and Galp Energia S.A. Together, the consortium is working on the ongoing development of the Lula Alto field, located in the Santos Basin, Brazil. When they needed a load-out of the first set of four modules bound for the FPSO (Floating Production, Storage and Offloading) P66 vessel, they turned to Mammoet, the world’s largest service provider specializing in engineered heavy lifting and transport.

Preparing the load-out of one of the four modules using Mam-

Working towards a tight deadline with the P66 nearing completion, the consortium was looking for a partner to install the last four modules.

The modules range in weight from slightly over 1,000 to 1,425 metric tons. They were built by BJCHI in Sattahip, Thailand and shipped by module carrier to Brazil for integration onto the hull of the FPSO.

The load-out was the result of close cooperation between BJCHI and Mammoet Thailand. BJCHI provides manufacturing and installation services for its customers’ industrial plants. Building and delivering FPSO modules is a move into new territory for BJCHI, which is venturing into the oil and gas market for the first time.

The Mammoet team had to manage the total logistics operation including chartering the module carrier MV Mega Trust to ship the modules to Brazil, complete naval engineering, weighing the modules and a load-out at the fabrication yard using

moet’s SPMTs.

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Load-out of the 1st module onto the module carrier MV Mega Trust using Mammoet’s SPMTs.

60 axle lines of Self Propelled Modular Transporters. SPMTs are hydraulically operated trailers with high lifting capacity. The wheels can be rotated 360° and due to the modular nature of the trailers, the lifting capacity can be increased by adding more trailers to the configuration. The basic principle of an SPMT is the fact that loads are transported above the wheels of the trailer and that their small circumference allows for a low loading height. Each of these wheels is mounted on an oscillating axle. Each axle is mounted on a hydraulic “suspension,” obtaining: • The regular load distribution between the axles, whatever the road super elevation may be, over which the convoy is travelling. This load distribution is obtained by the inter- communication of the hydraulic cylinders, giving a constant pressure, whatever the suspension height may be.

• The sustentation of the load is obtained hydraulically, following the support in three points on the ground. Scheuerle, a German manufacturer of heavy transport vehicles, engineered and fabricated the hydraulics for the SPMT.

Reinder de Haan, Commercial Manager Logistics Sales Mammoet: “The key success of this project is the close working relationship between Mammoet and our clients.”

Seongjin Lee, project manager at BJC: “This project was challenging from every aspect. Nothing was on our side in terms of the short project period, rare materials and long lead times.

However, with good support from all BJCHI’s sub-contractors, vendors and employees, as a team we finally made the load-out.”

FPW

Mammoet mammoet.com

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DESIGN NOTES

Edited by: Mike Santora • Associate Editor

Better performance density for filters The primary objective for developing ARGO-HYTOS’ EXAPOR MAX 2 filter element was greater machine availability, longer service intervals, lower-cost spare parts, and lower operating costs for machine operators in the area of mobile and industrial hydraulics.

To improve the performance density of the filters, ARGO-HYTOS engineers took a closer look at the conditions in the fold channel. Here, they found the factors responsible for pressure loss in the folded material. The result was a web technology for creating a hybrid fabric that ensures a consistent and optimal opening of the fold channels. Pressure loss in the fold is reduced by as much as 50%. These results were confirmed in numerous trials.

When configuring hydraulic systems, a smaller filter size can be used depending on the application. Pressure loss reduction means bypass valves open less often and for shorter periods. Consequently, fewer particles get through the bypass to the pure oil side.

The structure of the three-layer filter material consists of various fine glass and polyester fibers. This new type of material matrix in the pre-filter and ultra-fine filter materials of the EXAPOR MAX 2 filter elements may improve clogging capacity by as much as 60% in filter fineness 5 µm(c).

The unusually low differential pressure and the high clogging capacity of the EXAPOR MAX 2 filter elements enable long service intervals and better cold start characteristics.

In hydraulic pitch adjustment systems, for example, filter elements are subject to strong flexural fatigue stress induced

by volume flow and pressure fluctuations.

Due to the flow rate fluctuations, differential pressure changes occur on the filter element, which results in the flexural fatigue stresses.

The fabric that has been developed and patented for the EXAPOR MAX 2 filter consists of a mix of stainless steel and polyester fibers. The stainless steel threads arranged longitudinally ensure dissipation of electrostatic charges, preventing damage to the filter material and the compromising of oil purity. The polyester fibers arranged transverse to the metal threads ensure optimal flexural fatigue strength and avoidance of fatigue failure.

The plastic sheathing shrink-fit on the filter bellows improves technical aspects and enhances the visual impression of the filter elements. The plastic sheathing is customerspecific and individually imprinted. All EXAPOR MAX 2 filter elements are fitted with this feature which clearly increases the recognition value of the filter elements. This is just one of the many copy protection measures designed to protect the products and the customers.

Benefits include: • Increased operational reliability: The risk of sudden machine failure and down- time, especially of wind-energy plants, can

EXAPOR MAX 2 filter elements create higher dirt holding capacity to extend the filter element changeover. This increases the operating reliability and service life reserve for wind power plants with time-based maintenance intervals.

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11/16/16 3:24 PM

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DESIGN NOTES

be significantly reduced. Maintenance intervals can be extended, resulting in significant cost and time savings.

• Filter element changeover period can be extended because of the higher dirt holding capacity. This increases the operating reliability and service life reserve with time- based maintenance intervals.

• Improved oil cleanliness extends the wear service life of components and of the hydraulic and lubricating oils.

• Significant reduction in pressure loss combined with improved dirt holding capacity results in a higher performance density that enables the use of smaller filters, depending on the application.

Simulation graphic of the pressure relationships in the fold of a filter element (sectional view). The perimeter of the fold is shown in black and the support fabric is shown in white.

• In the fight against product counterfeit designs, ARGO-HYTOS developed increased copy protection thanks to customized geometries of EXAPOR MAX 2 filter elements.

FPW

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DESIGN NOTES

Edited by: Mike Santora • Associate Editor

Custom gripper system for removing hot parts When ZEIBINA Kunststoff-Technik GmbH sought to upgrade its manual demolding process for automotive lighting reflectors, it went to FIPA to correct the problem. Previously, to ensure part removal free of marks or paint-wetting impairment substances (PWIS), employees had to handle hot (120°C) plastic parts themselves. FIPA’s new custom gripper automated this process and also reduced cycle times to 33 seconds, considerably increasing factory throughput.

The engineers at FIPA’s primary manufacturing facility designed the custom gripper system to include components from the company’s modular construction kit. This kit includes: sprue grippers combining high closing force for secure gripping with a soft, heat-resistant HBNR elastomer coating; finger grippers that prevent lateral slipping; and sensor-enabled grippers that monitor the handling sequence.

The custom gripper system is made of components from FIPA’s modular construction kit. The kit includes sprue grippers combining high closing force for secure gripping with a soft, heatresistant HBNR elastomer coating, finger grippers to prevent lateral slipping, and sensor-enabled grippers that monitor the handling sequence.

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DESIGN NOTES

“After the lighting reflector blanks are removed from the injection molding machine, they’re transported to another system that coats the plastic parts with vaporized aluminum and other metals to ensure high surface stability. But for this process to be a success, the parts must be pristine, which proved too challenging for off-the-shelf solutions,” said Dirk Zeibig, managing director at ZEIBINA.

“Due to the shape of ZEIBINA’s injection-molded parts and the force required to remove them from the mold, it was clear that a standard vacuum cup solution would not suffice. So, after a close and open exchange with the ZEIBINA team, our engineers used several components from our modular gripper kit to customize an automated handling system to their lighting reflector manufacturing process,” said Rainer Mehrer, President of FIPA.

FIPA components used to assemble the custom gripper system for ZEIBINA’s injection-molded reflector process include:

• GR04.103 sprue grippers which feature a high-strength, anodized aluminum body and actuator jaws with both gap-free closing capabilities for small sprues and a 10mm clamping diameter to

accommodate larger parts;

• GR04.103-4 interchangeable sprue gripper jaws coated with extremely soft hydrogenated nitrile butadiene rubber (HNBR), which enable the mark-free gripping of delicate components.

• LT10 compact reflective sensors, which enable the long-range optical monitoring of workpieces. They can accommodate any mounting position and feature a small footprint, adjustable sensitivity, an LED display, and lightweight body; and a variety of clamping elements, extrusions, and profiles.

FPW

FIPA fipa.com

• GR04.101A single-acting sprue grippers with direct part detection and large area sensor activation capabilities, regardless of sprue position.

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FPW_DESIGN NOTES 11-16_Vs3 MG.indd 25

• GR04.045 35° angle stroke gripper fingers with single-action, spring return design.

Discuss This and other engineering topics at www.engineeringexchange.com

11 • 2016

FLUID POWER WORLD

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11/18/16 10:32 AM

FUNDAMENTALS

Josh Cosford • Contributing Editor

What is electronic control in fluid power?

Hydraulic valves operate most commonly in one of three ways; mechanical/manual control, pilot control or electric control.

Mechanical control involves something physical pushing on the valve, such as with a roller or cam, which itself shifts the spool or poppet.

Manual control was long the king of valve control, especially with mobile hydraulics; they’re inexpensive and easy to use. Pilot control is more complex, and requires a pilot valve to shift it, so it’s usually limited to high flow or high-pressure valves.

Proportional valves offer more sophisticated, and yet still inexpensive, options in hydraulic system control.

Pictured here is a range of proportional flow, directional and pressure control valves from HydraForce.

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Electronic control of hydraulic valves has been gaining popularity for decades, and with the recent down market (but not down content) move of electronic control systems and devices, their use has accelerated. Just like with consumer electronics, the cost to manufacture high-powered electronic components has dropped as well. So why should this matter to you?

First of all, your attachment to the mechanical lever should have ended the same time you got over your blankie. Some people just can’t get over the loss of a manual backup to their hydraulic valves, but they’re needed no more than a lever is to back up the finger swipe control on your grandson’s iPhone. Not only are electronics dirt cheap, they’re also extremely reliable. I never pay the extra coin for the extended warranty at the electronics store, because let’s face it, I haven’t had a device break down since I pulled the channel knob off my tube TV

Another example of electronic control can be seen in this new valve design from Eaton, the CMA Advanced Mobile Valve, which provides access to real-time operating data for precise control while optimizing performance. trying to tune in Knight Rider.

I’ll admit, you can get a lever valve for less than a hundred bucks, and that’s darned cheap. However, you can get a solenoid valve and a toggle switch for just as cheap. Granted, a lever valve can be metered to accurately control flow rate, and a solenoid valve is just on and off. However, just like other electronics, electro-proportional control of solenoid valves has become inexpensive as well.

An inexpensive proportional valve can be had from HydraForce, Sun et al for not much more than your lever valve.

www.fluidpowerworld.com

11/16/16 4:02 PM

FUNDAMENTALS

These “prop valves” are simply valves with metering notches on the spool, and coils that can vary their magnetic field based on the current provided them. Something must take your input signal and convert it to something usable by the prop valve, which is where valve controllers come in.

They take the 4-20 mA, 0-10 V or other signal and convert it to the Pulse Width Modulated input the valve can use. These controllers used to be quite expensive, but have been reduced drastically like the rest of the world of electronics. A combination of valve and controller can be had for a few hundred dollars, which although more than a lever valve, still provides variable flow control.

There is a caveat to inexpensive electro-proportional valve and controller systems, of course; their performance falls in line with their price. These valves just aren’t made for high performance systems, and that’s okay, because they suit their purpose. Their coil strength is often low, with high hysteresis, poor frequency response and non-linear performance.

They are susceptible to performance variances due to changes in inlet pressure and actual pressure drop. Higher-end valves are superior in most of these qualities, and have further benefits like on-board electronics or spool position feedback.

But if you’re replacing a lever valve, you’re probably not picky.

I like a lever valve just as much as the next guy, but they should only be used where an electrical signal does not exist, like a logsplitter or 1965 Ford tractor. And let’s face it, even your old tractor could run two 6 V batteries in series to control any 12 V solenoid valve. Nobody is going to ignore your mistrust of the internet and force you to sign up to online banking (which you should), but perhaps it’s time to get on board with electric control of hydraulics.

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RESEARCH & DEVELOPMENT

Ken Korane • Contributing Editor

A nanoscale view of hydraulic fluids There’s a growing realization that the type and formulation of hydraulic fluids can have a significant effect on machine efficiency, performance and overall life. But to date, fluid manufacturers have, for the most part, relied on traditional laboratory methods to develop new fluid chemistries.

Now, in the project “Simulation, Rheology and Efficiency of Polymer Enhanced Fluids,” sponsored by the Center for Compact and Efficient Fluid Power, researchers will examine fluid behavior on the molecular scale.

The research team led by Ashlie Martini, Professor of Mechanical Engineering at the University of California, Merced and Paul Michael, Research Chemist at the Milwaukee School of Engineering, looks to gain a better understanding of interactions on the atomic level. What they learn may ultimately lead to more-efficient hydraulic fluids.

“The high-level project goal is to find connections between the fundamental behavior of polymer-enhanced fluids and the performance of fluid-power systems,” said Martini. “Specifically, we’re trying to connect hydraulic efficiency to fluid rheology and then rheology to fluid molecular structure.”

A key tool in the research is molecular dynamics simulation, which can provide basic insights into material behavior and has not previously been applied to fluid-power applications.

Molecular dynamics simulation is a nanoscale modeling method, explained Martini.

Empirical expressions describe the forces on atoms and molecules as they interact. The method starts with the initial configuration of 28

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Researchers will relate computer simulations of fluid behavior to rheometer tests of viscous performance. the material to be modeled—in this case the basestock and additive molecules of a hydraulic fluid—and then the simulation predicts how that configuration changes over time.

“The empirical models are not new, but applying them to fluid-power systems is,” she said. “Our contribution is twofold.

At the front end we model the molecules of interest—those of the fluid and the relevant additives.” Then the simulation runs and outputs the positions and forces on the atoms. “So we have to post-process the raw data to calculate fluid-power relevant

properties like viscosity,” said Martini. In the end, researchers will link simulations with rheometer measurements and dynamometer testing of polymer-containing fluids.

The three-part project began in July and the first aim is to experimentally bridge rheology and efficiency. “Our first goal is to relate viscous properties measured in a rheometer to hydraulic efficiency. It’s certainly known that higher viscosity means less leakage, but we want to make those ties more quantitative and direct,” explained Martini.

www.fluidpowerworld.com

11/16/16 4:15 PM

RESEARCH & DEVELOPMENT

Current work involves four ISO Grade 46 fluids with zinc (ZDDP) antiwear additives. Two are straightgrade fluids without polymer additives; and two are high-viscosity index multigrade fluids with two different polymethacrylate (PMA) additives. Rheometer tests confirmed that multigrade fluids have a higher viscosity at higher temperatures. Dynamometer testing of the fluids at Milwaukee School of Engineering showed that piston-pump flow losses were reduced by the higherviscosity fluids, as expected, said Martini. Differences in the shear stability of fluids were also observed. After 200 hours of testing, the multigrade oils decreased in viscosity by 5 to 13% but the straight-grade oils were unchanged. While tests are ongoing and more data are needed, she said, the goal is to quantitatively correlate viscosity and shear stability to flow losses.

In the second part of the project, slated for this fall, molecular dynamics simulations of basestock with polymer additives will be used to model fluid properties, and rheological testing of viscous performance will validate those simulations.

The simulation studies involve fluids with polyisobutylene (PIB) polymer additives. There are several reasons for choosing PIBs, explained Martini, but most significantly, PIBs have simple and well-characterized molecular structures, so they’re amenable to molecular-dynamics modeling; they’re also smaller than PMAs and, thus, are more easily modeled; lastly, they can be purchased in relatively narrow molecular weight ranges, which makes them quite suitable for use in lab experiments.

The team is currently developing methods to study how concentration and polymer entanglement impact the viscosity of fluids with PIB additives. Molecular dynamics simulations will involve molecules of PAO 2 base fluid and PIB additives with different molecular weights and concentrations. “We want to explore how molecular weight and also entanglement of molecular chains affects viscous properties and rheology,” said Martini.

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FLUID POWER WORLD

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RESEARCH & DEVELOPMENT

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Researchers started by modeling the PIBs at two different molecular weights, combined them with models of the base fluid and adjusted system volume to ensure a 10% weight concentration. “In this way, we’ll be able to specifically isolate the effects of molecular weight and also the entanglement,” she said.

At the same time researchers will run rheology tests on actual PIB-containing fluids. Experiments using a cup-and-bob and parallel-plate rheometer will shear the fluid and generate a shear profile within the fluid.

The ratio of shear strain and shear stress is the viscosity. “Effectively, the simulation does exactly the same thing: applying a shear strain, calculating the shear stress and the resulting ratio of the two will be the viscosity,” noted Martini.

Thus, they’ll actually measure the viscous behavior of the fluids and compare it to the simulations to determine the effect of molecular weight for a given concentration and also, how the PIB molecules interact or entangle to affect viscosity at different shear rates. From there, they’ll move on to different concentrations to introduce one more variable to the system.

Next spring, the researchers will link molecular simulations with the initial dynamometer studies. “We’ll introduce dynamometer testing and hope to relate efficiency to the viscosity and molecular features, and connect all three pieces of that puzzle,” said Martini. “As you can see, what we’re trying to do is pretty bold. We’re trying to go all the way from molecules to hydraulic efficiency, that’s a pretty big aggressive target.”

But it will give a better understanding of the relationship between molecular structure and the behavior of fluids in machines that may someday significantly benefit the fluid-power community.

E E NT

Milwaukee School of Engineering msoe.edu Center for Compact and Efficient Fluid Power ccefp.org

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FLUID POWER WORLD

11 • 2016

11/16/16 4:17 PM

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DISTRIBUTOR UPDATE

Paul J. Heney • Editorial Director

Helping to solve the distribution riddle Anyone who’s been around the fluid power industry for a short while will realize how important distribution is—and how it’s been adapting. Distributors in other technology areas may be essentially commodity part sellers or stocking warehouses.

They may fight on price, with flashy online ads that wouldn’t look out of place on Times Square.

But in fluid power, distribution has grown with the industry over the years, with distributors working with OEMs to choose the right equipment, to design the necessary circuits, or even build entire subsystems for an end product. And repair and maintenance is a critical aspect of many fluid power distributors’ services today.

Our editorial team recognized that one thing our industry was lacking was a comprehensive way to find a distributor and compare them side-by-side. So, over the past year, we’ve been building out an online resource to do just that. Our Fluid Power World Distributor Search is now live at: http://mfg.fluidpowerworld.com Because distribution is, at its heart, a local business, you can define the geography, picking a state and city for your search. You can select multiple manufacturers, as well. So if you want to only see branch locations of distributors who carry Yates Industries and Eaton Hydraulics in the state of Texas, no problem.

We’re also in the process of adding additional questions to search and results options. Eventually, you’ll be able to specify any of the following if these criteria are important to you in a distributor: • • • • • • •

Service/repair capabilities Do they employ Certified Fluid Power Specialists?

Engineering design services offered Hose assembly Cylinder repair Field service Fluid power training classes

Data points like these are critical in fluid power distribution, because all distributors are unique—they vary in size, product lines and services offered, as well as branch locations. This is why we’re excited to unveil what I’ll call the Beta version of the Fluid Power Distributor Search. But we need your help, too. If you have suggestions for how we can improve the site, please let us know. And as companies are always being acquired, branches are moving physical locations and distribution agreements are modified, our data is constantly in flux. Please click the “New Distributor Submission” button on the site if you see anything that needs to be changed or updated.

FPW

http://mfg.fluidpowerworld.com

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SAFETY

Edited by: Paul J. Heney • Editorial Director

9 proper installation and handling tips for hose assemblies There are many areas of safety to be cognizant of when working with fluid power systems, and perhaps the most potential hazards can come from hoses and hose assemblies. Proper specification and installation of these fluid transmitting devices is of critical concern. In addition, all hose has a finite life and there are a number of factors which can reduce its life. Proper installation and handling of the hose assembly is one contributor to the life expectancy of the hose.

Whether you’re a fabricator, an installer or an end user, you need to be aware of the following safety areas.

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1 Media permeation Hoses should always be used in well- ventilated areas. Certain media will permeate through hoses that can displace breathable air in confined spaces. Consult the manufacturer if in doubt.

2 Fluid injections Fine streams of pressurized fluid can penetrate skin and enter a human body.

Fluid injection wounds may cause severe tissue damage and loss of limb. Consider the use of guards and shields to reduce

FLUID POWER WORLD

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Image courtesy of CD Industrial Group

the risk of fluid injections. Treat all leaks as though they are pressurized and hot or caustic enough to burn skin. If an injection occurs, immediately contact a doctor or medical facility. Do not delay or treat as a simple cut. Fluid injections are serious injuries and prompt medical treatment is essential. Be sure the doctor knows how to treat this type of injury.

3 Whipping hose If a pressurized hose or fitting comes apart, the loose hose end can flail or whip with great force, and fittings can be thrown off at high speed. If a risk of hose whipping exists, consider the use of guards and restraints.

4 Fire and explosions from fluids All hydraulic fluids, including many designated as “fire resistant,” are flammable and will burn when exposed to the proper conditions. Fluids under pressure that escape from system containment may develop a mist or fine spray that can explode upon contact with a source of ignition (e.g.; open flames, sparks, and hot manifolds).

These explosions can be very severe and could cause extensive property

damage, serious injury or death. Care should be taken to eliminate all possible ignition sources from contact with escaping fluids, fluid spray or mist, resulting from hydraulic system failures.

Select and route hoses to minimize the risk of combustion.

5 Fire and explosions from static-electric discharge Fluid passing through hose can generate static electricity, resulting in static-electric discharge. This may create sparks that can ignite system fluids or gases in the surrounding atmosphere. Use hose rated for static conductivity or a proper grounding device. Consult the manufacturer for proper hose and coupling selection.

6 Burns from conveyed fluids Fluid media conveyed in certain applications may reach temperatures that can burn human skin. If there is risk of burns from escaping fluid, consider guards and shields to prevent injury, particularly in areas normally occupied by operators.

7 Electrical shock Electrocution could occur when a hose assembly conducts electricity to a

www.fluidpowerworld.com

11/16/16 4:10 PM

•

•

•

•

•

SAFETY

person. Most hoses are conductive. Many have metal fittings. Even nonconductive hoses can be conduits for electricity if they carry conductive fluids. Certain applications require hose to be nonconductive to prevent electrical current flow. Other applications require the hose to be sufficiently conductive to drain off static electricity. Hose and fittings must be chosen with this in mind.

Consult the manufacturer with any questions. Metal hoses are conductive; always use proper grounding to minimize the risk of electrical discharge.

Caution: if routing hydraulic hose near an electrical source cannot be avoided, nonconductive hoses should be considered.

SAE J517-100R7 and 100R8 hoses with orange covers marked “nonconductive” are available for applications requiring nonconductive hose.

8 Pneumatic applications Consult the manufacturer for proper hose and coupling selection. The covers of hose assemblies that are to be used to convey air and other gaseous materials must be pin perforated. Exercise care not to perforate beyond the cover. These perforations allow gas that has permeated through the inner tube of the hose to escape into the atmosphere.

This prevents gases from accumulating and blistering the hose.

9 Hand-held operated tools Extreme care is necessary when connecting hand-held or portable powered tools to a power source with a hose assembly. Always use a strain reliever at both ends of the hose assembly to prevent excessive bending, kinking and stress at the coupling to hose interface. Never use the hose assembly

to carry, pull, lift or transport the tool or power unit. Exposed hose near the operator should be covered with a fluid deflection apparatus such as nylon sleeving, for protection against injection injuries should a hose rupture occur. Operators should be protected with proper safety equipment such as face masks, leather gloves and safety clothing as dictated by the job, fluid and tools being used. If the connecting hose assembly could be subjected to external forces that may inflict damage, use an appropriate guard.

This article was adapted from NAHAD’s Hose Safety Institute Handbook, which provides industry-leading performance standards for hose assembly specification, design, handling and management. For information or to purchase the handbook, please visit www.nahad.org, or contact Debbie Mitchell at dmitchell@nahad.org.

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How can you keep your mobile machine running efficiently?

Part 1 Learning how to properly maintain your hydraulic system with precision will help support a high-performance, well-functioning machine.

Carl Dyke • CD Industrial Group, Inc.

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Half of the battle in hydraulic system troubleshooting is knowing exactly what ‘normal’ is. It’s hard to diagnose a component or a section of a system without knowing normal parameters, such as:

• Speeds • Pressures • Valve response times • Sounds • Vibrations • Heat levels, etc.

The other half of the battle is preventing breakdowns from occurring in the first place. But again, ‘normal’ is the reference and the intended operational state.

Proper hydraulic system maintenance conducted at the right time should keep a mobile machine in normal or optimal condition. The value of careful observation of a machine in operation cannot be overstated. Learning exactly what to observe takes effort and dedication on the part of a maintainer.

What a machine owner ultimately desires is a hydraulic system that provides responsive, consistent, smooth, and forceful motions whenever the machine is put to work, for as many years as possible, and with the fewest surprise breakdowns. The business goals of maintenance on a mobile machine are typically stated as maximum capital life and optimal availability with very high levels of reliability.

For machines with a hydraulic system such as a loader, grader, vacuum truck, or a recycling truck, regular care is a must. For an excavator or a skid steer loader that is entirely operated by hydraulics, preventative maintenance work is truly job critical.

Many basic checks need to be carried out regularly to avoid being caught off guard. The operator can be trained to take care of all of the daily maintenance tasks such as fluid level checks and leak inspections.

The service shop should only need to duplicate these tasks after major teardown and repair work has been

Verify and adjust maximum system pressures (relief valve, pump compensator) at least annually.

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tervals go on for pages with no specific test parameters or details. Typically, only two check mark columns are present beside the PM list: ‘OK’ and ‘Needs Repair.’ Many hours can be spent in the maintenance bay confirming that major components of the hydraulic system are still bolted to the machine frame and not leaking. Again, these are tasks that the operator should be carrying out as a normal course of observation each and every day.

Slightly more complex maintenance tasks are often left undone, such as: • Pump performance testing • System pressure settings • Cylinder and motor wear condition monitoring • State of cleanliness inside the reservoir • Particle count in the fluid The reservoir is at the heart of a hydraulic system. Keep the breather clean, or switch to a high performance filter-breather for extremely dusty environments. Use a desiccant type of breather-filter for moist environments. Filling via a filter transfer pump instead of pail and funnel may allow for operation with pump inlet strainer.

carried out. Other tasks that require more skill and thoroughness are best left to the shop technician.

The types of checks and tests that establish the precisely correct operational state of the hydraulic system take time to perform—but they do offer payback. If carried out regularly and correctly, these procedures provide the maintenance department with data on any performance deviations. The data, in turn, provides clues as to what could be a major problem in the very early stages. This is where maintenance activity becomes truly valuable.

So many preventative maintenance (PM) work orders in fleet shops are merely checklists with ambiguous tasks such as “check accumulator for leaks and operation,” or “check the swing motor mounting bolts,” or “check all levers and pedals for proper operation.” In some shops, these task lists for hour-specific maintenance in-

Thermography cameras are now affordable for small fleets. Comparing the heat signatures of parallel cylinders and motors is just one way to keep an eye out for internal leaks.

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These contribute to the failures that affect business results. One PM task that has recently become quite popular is the sampling of lubricants and hydraulic fluids.

If the task simply says ‘Sample Fluid,’ with a space for a completion check mark, then hopefully the technician doing the sampling has had the training to know how best to collect a consistent and valid sample. This is like going to the doctor for a checkup and then being sent to the lab for a blood test.

You want a highly trained lab technician for a number of reasons, all tied to quality.

Hydraulic fluid sampling is very important work, and just like lab work, the quality of the results depends on the technician’s skill and consistency.

Hydraulic fluid sampling and lab testing done right, with the results properly analyzed, is a maintenance task that not only saves money on unnecessary filter element replacements, but can also signal when to finally drain and replace the fluid, and when to start investigating a potential pump problem. The fluid only needs to be changed when it has actually deteriorated.

A pump saved from failure or changed out before catastrophic system damage has obvious business benefits. These are all

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big money savers. However they require a customized and science-based approach to maintenance—as opposed to arbitrarily assigning tasks for a certain interval of running hours.

It is not uncommon for maintenance planners in large organizations to schedule the changeout of major components, such as a hydraulic pump, based on the number of running hours. In many of these cases, however, the hour interval is established by a reliability team that has carefully studied one particular model of machine, in the company’s unique operating environment for many years. The interval for the component changeout is often stretched beyond the original equipment manufacturer’s recommendation. In some cases the interval is shorter. The point is that a customized, scientific approach is applied in these cases for the sake of the desired business results.

At minimum, fundamental care and maintenance of the mobile hydraulic system should address the following major areas:

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1 Levels—Maintaining the level of fluid in the hydraulic reservoir is about much more than just making sure that there is enough liquid volume to supply all cylinders at full extension. The surplus volume also provides cooling, allows for a minor amount of air bubbles that may have entered the system to dissipate, and perhaps allows some solid particles (not yet trapped by a filter) to settle out in front of the tank baffle as the fluid returns from the work application circuits.

Failing to keep the reservoir at the correct level can invite condensation to accumulate on the exposed inner surfaces, and drip down into the hydraulic fluid. If the operating environment is humid or moist, a desiccant breather or a vacuum-breaker style of breather/fill cap will be helpful.

Be sure to check the normal fill level when all single rod cylinders are retracted and with the brake or steering accumulators bled back to tank.

Does your machine feature an electronic pilot control system? If so, you likely have some variable current valve solenoids on proportional pressure control valves. The operator’s control levers signal these valves either directly or through an electronic control module. These valves have very small components inside and move only a tiny fraction of an inch. Contaminants will foul electronic proportional valves quickly and leave the machine out of service. If you have been filling your main reservoir with a pail and funnel, now is the time to consider a new method. Pumping fluid into the reservoir via a filtration system has become standard practice for many fleets.

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2 Leaks and safety—If you see dripping or hydraulic fluid spraying from any hose, tube, fitting or component housing, do not touch any surfaces at or near that leak location. A fluid injection injury could be fatal or leave you disabled for life. Be sure to achieve a zero pressure state before any close inspection of a leaking component, or disassembly of any fluid line connection.

Internal leaks can also develop. The operator won’t be able to observe these directly. Unusual noises and temperatures are often the only clues.

3 Temperatures—Hydraulic oil temperature monitoring provides very useful clues to the state of a system.

If the reservoir is topped up, and if cooling fans and radiators appear to be functioning normally, then higher temperatures are often correlated with internal leaks.

At high pressures, a surprising amount of flow can pass through a fairly small orifice opening. Flow through this abnormal path will cause a heat build-up due to the friction of fluid molecules rubbing against the orifice surfaces.

The presence of an internal leak can sometimes be revealed by a slowdown in cylinder stroke or motor speed, though in systems with sufficiently oversized, variable displacement pumps, a slowdown may not occur. A component such as the pump itself, or a motor or cylinder that has lost its internal seal, may only register an unusually high temperature.

The pilot system is easily overlooked due to its small size. But keeping an eye on the pressure setting and filter of this critical system supports reliability goals.

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The operator should be trained to watch for the normal hydraulic fluid temperature as reported on the instruments in the cab. Any increase in temperatures should be reported without delay. A maintenance technician can then be dispatched to verify the cooling system performance, and to use his thermography camera to compare against each other and against carefully documented normal values, the heat signature of critical components such as pumps, swing motors or boom lift cylinders.

The operator can also be trained to periodically check the speeds of a hydraulic fan motor, using a non-contact photo tachometer, and to clean the hydraulic cooler/radiator.

4 Pressures—For most large machines, and even for some small- and medium-sized machines with electrical/electronic operator joysticks, the first layer of hydraulic control is the pilot control system. A pilot system may even be present on machines that feature very little electrical and electronic control.

These pilot systems are separate hydraulic circuits used to move large directional valve spools into position, or to shift a pump swash plate.

Maximum pilot pressures are often only one-quarter or one-fifth of the maximum pressures found in the main cylinder and motor circuits. Yet without periodic testing of these medium pressure systems, a worn pilot pump or maladjusted pilot circuit relief valve can result in many wasted hours of flow testing and diagnostics for slow functions in main circuits. Checking the health (pressures and the range of current supplied to the solenoids) of the pilot system several times per year provides an opportunity for fine-tuning.

It is important to test the main system relief valve pressure several times per year.

In some cases, the maximum system pressure is limited by a cutoff pressure control (compensator) on the main piston pump. In many cases, both a relief valve and pump compensator are present in the system, with the relief valve to be set higher than 42

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Verifying the standby (margin) pressure setting on machines with a load sense system can be time consuming on the first occasion, but helps ward off fuel consumption, hydraulic system overheating and slow function response.

the compensator. Again, without periodic checks—which do take some time to carry out—many hours can be wasted chasing a system overheating problem or a function slow down, or even a function stall.

Many mobile machines use the energy-saving hydraulic design known as load sensing. Standby pressure (sometimes, but not always the same value as margin pressure) means an additional, adjustable pressure control on the pump housing. A function such as swing or boom lift demonstrating a slow response to the operator’s lever movements can be caused by a low standby pressure. The standby pressure might typically be specified by the equipment manufacturer at 300 psi. What if the adjustment has changed due to vibration or due to heat softening of the control spring or other factors? It doesn’t take too long to check this pressure value every year and tune as needed. The factory maintenance manual usually lays out this procedure in careful detail.

At the beginning of this article, there was a reference to checking the accumulator. Not a lot can be learned from the outside. For most machines, it doesn’t take long to attach the gauge and valve from a precharge fill kit to verify the correct nitrogen gas pressure. It is better to bring the proper attention to the maintenance

of an accumulator on the PM sheet, with a task such as ‘Verify Accumulator Precharge Pressure at X psi, at an Ambient Temp’ only once or twice per year than to have an almost useless ‘Check Accumulator Operation’ task showing up for every 500 hours.

Stay tuned for our February issue of Fluid Power World, where we’ll talk further about system maintenance, with a closer look at the components used in mobile machinery, including actuators, pumps and motors, hoses, brakes and more.

FPW

CD Industrial Group Inc. carldyke.com LunchBoxSessions.com

Discuss This and other engineering topics at www.engineeringexchange.com

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Industries including packaging, electronics, automotive, glass and plastics are discovering the advantages of this low-cost option for vacuum systems.

Comparing the real costs of

vacuum generators

Vacuum generators come in an extensive array of types, sizes, designs and efficiencies to suit widely ranging applications. And while maximizing performance for a given task is important, anyone using a vacuum system should also take a close look at overall costs before specifying essential components.

Given that energy is a valuable and, at times, expensive resource, the cost of running a suitable vacuum system should play an important role in any design. For circuits based on vacuum ejectors, the amount of energy necessary to operate a pneumatic vacuum ejector with compressed air cannot be overlooked. Always remember one golden rule at all times: air is expensive.

With electric-motor-driven vacuum pumps, on the other hand, users can measure and assess energy costs much more easily based on prevailing electricity prices and electrical power consumption.

Let’s take a closer look at these two basic types of vacuum generators, and how they compare on the bottom line.

Mike Guelker

Product Manager-Pneumatic Actuators Festo Corp. • Hauppauge, N.Y.

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Vacuum ejectors

Vacuum ejectors basically generate vacuum using pneumatically driven nozzles without moving parts. They produce high vacuum at relatively low flow rates.

A classic ejector consists of a jet nozzle (also called a Laval or venturi nozzle) and, depending on the design, at least one receiver nozzle.

Compressed air enters the ejector and a narrowing of the jet nozzle accelerates the flowing air to up to five times the speed of sound. The ejector has a short gap between the jet-nozzle exit and the entry to the receiver nozzle. Here, expanded compressed air from the jet nozzle creates a suction effect at the gap which, in turn, creates a vacuum at the output vacuum port. www.fluidpowerworld.com

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Image: Festo Corp.

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Venturi nozzle

A single-stage ejector includes a jet nozzle and one receiver nozzle. Compressed air enters the ejector and a narrowing of the jet nozzle accelerates the flowing air. In the short gap between the nozzle exit and receiver entry, compressed air expands, generates suction and creates a vacuum at the output vacuum port.

Receiver nozzle Vacuum port

Among their benefits, vacuum ejectors are compact, lightweight, relatively inexpensive and they respond quickly, with fast start and stop times. They are wearresistant and essentially maintenance-free, although suppliers recommend operating them with dry and filtered compressed air.

And they can mount in any position and experience no heat build-up in operation.

Another advantage is that vacuum ejectors consume energy only as needed.

Compressed air to run the ejector is only required during suction and workpiece handling, and remains switched off during discharge and return when no vacuum is required.

Vacuum ejectors come in two basic versions, single and multi-stage. A single-stage ejector includes a jet nozzle and only one receiver nozzle. A multistage ejector also includes a jet nozzle.

However, in line with the first receiver nozzle are additional nozzle stages, each of which has a larger diameter in proportion to the falling air pressure.

Air drawn in from the first chamber, combined with compressed air from the jet nozzle, is thus used as a propulsion jet for the other chambers. In both versions, air exiting the receiver nozzle is generally discharged via a silencer or directly to the atmosphere.

Many ejectors also have a built-in energy-saving function that ensures compressed air is only consumed during vacuum generation. After attaining the necessary vacuum level, the ejector is switched off. Vacuum is maintained and monitored using valves and switches. A typical energy-saving function includes a 2/2-way valve, pressure switch and a nonreturn valve.

In general, multi-stage ejectors can generate pressures up to approximately 85% vacuum and have higher suction flow rates compared with single-stage ejectors.

Multi-stage ejectors have, on average, a much lower level of air consumption and

Nozzle A multi-stage ejector has several nozzle stages, each of which has a larger diameter in proportion to the falling air pressure. Air drawn in from the first chamber, combined with compressed air from the jet nozzle, is used as a propulsion jet for the other chambers.

Air exiting the receiver discharges via a silencer or directly to atmosphere.

Compressed air Suction port

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thus consume less energy than singlestage ejectors. However, their evacuation time is higher, which in some cases can reduce the energy-saving benefits over single-stage units.

On the downside, vacuum ejectors do not produce extremely high suction rates. Festo ejectors, for example, generate suction rates that are relatively limited at approximately 16 m3/hr. Beyond that, higher compressed air consumption per cubic meter of vacuum increases energy costs dramatically, although designs with energy-saving functions can compensate for this to a certain degree.

Vacuum pumps

Mechanical vacuum pumps generally fall into one of two different types: positivedisplacement and dynamic/kinetic.

Displacement vacuum pumps essentially operate as compressors with the intake below atmospheric pressure and the output at atmospheric pressure. They draw in a fairly constant volume of air, which is mechanically shut off, expanded, and then ejected. The main feature of vacuum pumps of this type is that they can achieve a high vacuum with low flow rates. Types include reciprocating piston, rotary vane, diaphragm and rotary screw. They are often suited for precision industrial applications.

With kinetic vacuum pumps, gas particles are forced to flow in the delivery direction by applying additional force during evacuation. Rotary blowers, for example, operate according to the impulse principle: a rotating impeller transfers kinetic energy by impacting air molecules. In operation, air is drawn in and compressed on the suction side by the impeller blades.

These vacuum pumps generate a relatively low vacuum, but at high flow rates (high suction capacity). They are usually suited for handling extremely porous materials, such as clamping cardboard boxes, and where large suction rates per unit of time are important.

Among the advantages, typical positivedisplacement industrial pumps generate up to about 98% vacuum—beyond the capability of ejectors. (Some specialized designs attain extremely high vacuum levels above 99%.)

And blowers can offer high suction rates well beyond 1,000 m3/hr.

However, electromechanical vacuum pumps are almost always in continuous operation with vacuum requirements regulated by valves. This means that electricity consumption and, consequently, energy costs can be quite high. They also have high initial costs and ongoing maintenance expenses.

Finally, compared to ejectors, they are larger, heavier, and tend to have more-restricted mounting orientations.

Here’s an overview of the features of different types of vacuum products.

Vacuum ejectors Single stage Multi-stage Compact & lightweight Medium size & weight Fast response time Fastest response time Lowest flow rate Medium flow rate Lowest initial cost Medium initial cost Maintenance free More sensitive to dirt

The Festo OVEM ejector-type generator has an integrated valve to control the vacuum.

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Vacuum pumps Largest & heaviest — Highest flow rate Highest initial cost Highest maintenance cost

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Comparing energy costs

In some cases, the preferred type of vacuum generator for an application is fairly obvious— such as a vacuum blower when the task requires low vacuum and high flow. But in many settings, the choice is not clear-cut. Here, it pays to compare the energy and operating costs of likely candidates.

As noted above, actual performance and efficiency of individual vacuum generators can vary widely by type and manufacturer.

Engineers can narrow the options by doing a bit of math. Here are some straightforward calculations to help compare the economics of vacuum generators of similar performance.

In this example, we compare annual energy costs for vacuum ejectors with and without an air-saving function, and for an electrically driven vacuum pump of similar performance.

Assume that: • Electricity price is $0.11/kWh. • To generate compressed air from atmospheric air, taking into account electricity price and all costs such as material, depreciation, and labor, plan on costs of approximately $0.022 per 1 m3 (35.3 ft3) volume at 7 bar (100 psi) supply pressure. These costs apply at pressure range up to about 10 bar. At higher pressures up to 20 bar, the cost for compressed air can easily double.

• Supply pressure for the ejectors is 6 bar.

• Energy used to compressed air (1 m3 at 7 bar) is 0.095 kWh/m3.

In addition, let’s assume the following criteria for purchase and maintenance costs.

• Initial cost of a vacuum pump is $786.

• Initial cost of an ejector is $371.

• Annual maintenance costs for the vacuum pump is $337.

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(Note that referencing the initial cost of an ejector in the example would apply to a vacuum generator like the Festo OVEM, which has an integrated control valve to turn the ejector and vacuum on/off. It also has a vacuum pressure sensor and may or may not have the “air-saving” feature. Festo also offers very compact, low-cost generators (VN family) 11 • 2016

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The VN ejector is a compact, lowcost generator controlled with an external valve.

Vacuum ejectors are compact, lightweight, relatively inexpensive, and they respond quickly, with fast start and stop times. They are wear-resistant and essentially maintenancefree.

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controlled with an external valve. The cost of a VN is approximately $35 (plus a control valve and, possibly, a sensor). Thus, costs will vary between stand-alone generators and generators with integrated valves/sensors.)

Consider a typical handling operation where the equipment runs 250 days/year and 16 hours/day. Each operating cycle takes 5 seconds and individual work steps include evacuation, workpiece pick-up, transport, vacuum discharge, unloading and return to the start position to begin the next cycle. The amount of time required for each step depends on the vacuum generator.

An ejector with an air-saving function consumes air (energy) only while picking up the workpiece, and this requires 0.5 seconds.

An ejector without an air-saving function consumes compressed air during pickup and transport of the workpiece. This requires 2 seconds.

The vacuum pump consumes energy for the entire operation cycle, as the pump does not normally switch off. Run time per cycle is 5 seconds.

Compare the energy costs for these vacuum generators as follows: • Calculate the number of products (units) per year from total running time (sec)/time per operation cycle (sec) = 250 x 16 x 3,600/5 = 2,880,000 units.

• Determine running time per year by the number of units × the run time for an ejector per unit. For an ejector without an air-saving function it is 2,880,000 units x 2 sec = 5,760,000 sec or 96,000 min. For an ejector with an air-saving function, run time is 1,440,000 sec or 24,000 min.

• Assume air consumption at p = 6 bar is 505 l/min. Calculate air consump- tion per year from running time per year/air consumption = 96,000 min/ 505 l/min = 48,480 m3 for the ejector without an air-saving function. With the air-saving function, it is 12,120 m3.

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From this information, calculate energy costs per year based on air consumption (without air saving) x price per cubic meter for compressed air = 48,480 m3 x $0.022/m3 = $1,066.56. Likewise, for the ejector with an energy saving function the annual cost is $266.64.

This shows that an ejector with an air-saving function can cut air consumption by 75% or, in this example, by more than 36,000 cubic meters of compressed air per year. That equates to a savings of $800 per year.

Vacuum pumps driven by electric motors require similar attention. Run time per year = operating hours per day x operating days per year = 16 x 250 = 4,000 hours. Assume a 1-hp electric motor consumes 0.55 kW/ hr. Energy consumption per year = running time per year x energy consumption per hour = 4,000 hr x 0.55 kW = 2,200 kWh. Energy costs per year = energy consumption per year x costs per kWh = 2,200 kWh x $0.11 = $242.

Finally, let’s compare overall costs for the vacuum ejectors and vacuum pump. Remember that a vacuum system includes investment, maintenance and energy

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costs. Investment costs are initial, one-off costs, while maintenance and energy are annual costs.

A typical vacuum pump has an investment cost of $786, annual maintenance cost of $337 (after 4,000 to 6,000 hours of operation) and energy costs of $242. In contrast, an ejector without an air-saving function has an investment cost of $371, energy cost of $1,066 but no maintenance costs.

Likewise, the ejector with an air-saving function has an up-front cost of $371, energy cost of $266 and, again, no maintenance costs.

A direct cost comparison shows that the vacuum pump has the lowest energy costs, closely followed by the ejector with an air-saving function.

The ejector without the air-saving function has considerably higher energy costs than the other vacuum systems. If we also take maintenance and investment costs into account, this reduces the advantage that the vacuum pump has over the other systems due to its low energy costs.

The example shows that in many applications, ejectors more than justify their existence. The high investment costs for vacuum pumps as well as annual maintenance costs associated with their continuous use and wearing parts confirm this conclusion. While ejectors may use more energy, their simple design keeps initial costs and maintenance costs to a minimum.

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Is hydraulic efficiency a myth?

Although many detractors sneer at the idea of efficient hydraulics, right-sizing components, proper system design and modern technology can go a long way to achieving system efficiency.

Josh Cosford • Contributing Editor

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“Hydraulic efficiency” is a term alluding similar sentiments to “exact estimate” or “scientific belief.” It’s not that hydraulic efficiency is an oxymoron, per se, but these aren’t traditionally two words that make sense shoulder to shoulder. If efficiency was your top benefit on the list of machine requirements, fluid power wouldn’t have been on your short list of options, at least in the past half-century or longer.

Efficiency is a word now more commonly familiar to us, thanks to the escalation of green values—especially those defining the way we use natural resources. No longer can we take a limitless and inexpensive source of energy for granted, nor can we abuse the dirty sources of inexpensive energy at the expense of our precious environment. We must take full advantage of our energy resources to achieve the work required for maintaining our standard of living, while reducing associated waste along the way.

What is efficiency?

I define efficiency as work-in minus work-out. Essentially, it’s the differential between the energy your process requires and the energy input required to achieve that process. Your process could be stamping, rolling, injecting, moving, pressing or any other mechanical function capable of being achieved in a rotational or linear motion. If you’re running a punch press, for example, the machine efficiency is defined as the current draw of the pump’s motor minus the combined force and velocity of the punch die.

Most machines are designed to convert energy from one form to another, which can sometimes occur multiple times. Because of the Laws of Thermodynamics, you cannot change energy from one form to another without creating waste energy, and this is a fact regardless of the energy transformation taking place. In the case of a hydraulic machine, you must convert electrical energy to mechanical energy within the electric motor, resulting in partial waste. Then you must convert mechanical energy into hydraulic energy within the pump, resulting in partial waste. Then you must convert hydraulic energy back into mechanical energy at your cylinder or hydraulic motor, resulting in partial waste.

The amount of energy wasted in the above example could be staggering, especially if you’re using an old machine with old components. Let’s say you have a 10-hp electric motor—and keep in mind electric motors are rated on power consumption, not power output. Your old motor might have an efficiency of 85%, meaning it will produce 8.5 hp at its shaft, the other 1.5 hp being wasted as pure heat.

• Piston pumps, such as this axial piston pump from Hengli America, are some of the most efficient hydraulic pump designs available.

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• The internal workings of the hydraulic gear pump.

In your old power unit, you have a worn and tired gear pump. When new, a gear pump is lucky to have 80% efficiency, so I’ll be generous to throw 75% at this example, since gear pumps become less efficient over their lifetimes. So this pump can convert only 6.4 of the motor’s 8.5-hp shaft output into usable hydraulic energy. The rest of the energy is, you guessed it, wasted as pure heat. We’ve now lost 36% of the electrical energy inputted, and we haven’t even done anything yet.

Just to be intentionally derisive, I’m going to choose a hydraulic motor as our actuator; a gerotor moHydraulic motor efficiency ratings tor to be exact. These moRadial piston motors 95% tors come at a modest price and perform at a modest levAxial piston motors 90% el. They were a clever design back in the day, but have Vane motors 85% high leakage to lubricate the myriad components, and Gear and orbital motors 80% they leak even more if you operate them outside their optimum torque and speed curve. Leakage, I should note, is a designed element of most hydraulic components, based on gaps and clearances with internal moving parts, which is required to lubricate that component. More moving parts or higher clearances means more leakage, and I should further note, any fluid lost to leakage carries with it pure heat equal to the pressure and flow of the leakage.

Now that I’ve blasted gerotor motors, I’ll back it up by saying they’re often incapable of reaching 80% 56

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Image courtesy of CD Industrial Group Inc.

efficiency. There are some versions of these “orbital” motors, like the disc valve variant, which can be close to 90% efficient, but it would be only within a tiny window of flow and pressure. I’ll stick with 80% for this example, which is generous. With the 6.4 hydraulic horsepower we have in our system, we’re left with 5.1 hp at the hydraulic motor’s shaft.

Why use hydraulics in the first place?

So with barely half of our input energy making its way to the output stage, it’s easy to see why I’m dubious of “hydraulic efficiency.” So why use hydraulics when we could have powered our machine straight from the electric motor and take advantage of 8.5 hp instead of 5.1? In that answer lies the reason hydraulics are awesome; with $300 worth of valving, you can infinitely vary torque and speed, and reverse direction. Our electric motor would require sophisticated electronic control to achieve the same features.

To be fair, I’m using one of the worst-case examples for hydraulic efficiency. Not only are there more efficient components available than gear pumps and orbital motors, there are ingenious approaches to using hydraulic components. Furthermore, recent advances in electronic control have not ignored the fluid power industry, and there are some tricks to further improve hydraulic efficiency.

Invest in better technology

I can’t stress enough that a hydraulic machine is really just an energy conversion device, and when you can convert your input energy into usable force with as

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• Pressure compensated

little heat waste as possible, you’re on the right track. A pump converts the mechanical energy of the prime mover into hydraulic energy in the form of pressure and flow. If I were to recommend one component you blow the bankroll on, it would be the pump.

A piston pump, especially a high-quality one, can be 95% efficient at converting input energy into hydraulic energy. Not only does this pump provide 27% more available hydraulic energy than our old gear pump, it creates 80% less waste heat than it, reducing or eliminating cooling requirements.

Not only does an efficient pump help, an efficient design works wonders. If you have a fixed displacement pump on a flow control, any unused fluid is wasted as heat.

For example, take even our 95% efficient fixed piston pump, giving us 9.5 gpm out of a theoretical 10 gpm. If your downstream priority flow control valve is set to 5 gpm, 4.5 gpm is bypassed to tank. However, all of the 9.5 gpm is still being created at full system pressure, and what’s dumped to tank is lost as heat. So now our 95% efficient pump is helping create a 50% inefficient system.

To get around this, pressure compensation was created. A pressure compensated pump is set to a particular standby pressure, and when this pressure is reached, the

pump reduces flow until downstream pressure drops below that standby pressure. For example, if you have a 10 gpm pump set at 3,000 psi, and flow is restricted below 10 gpm, the pump will reduce its displacement to exactly match the downstream flow and pressure drop at 3,000 psi.

Essentially, the pump only produces the flow being asked for, no more, but always at 3,000 psi.

• The use of variable

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pumps are set to a particular standby pressure, and when this pressure is reached, the pump reduces flow until downstream pressure drops below that standby pressure.

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speed technology can dramatically increase hydraulic efficiency.

Here, the new Green Hydraulic Power units use Siemen’s SINAMICS variable speed servo pump drive to increase efficiency by up to 70%.

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• A load-sensing pump will provide only the pressure and flow required of the

circuit and actuator, with only a few hundred psi worth of pressure drop as the waste by-product.

But what if we only want 1,000 psi for a particular operation? Well, you could use a pressure-reducing valve, but the pump is still producing 3,000 psi, so you’re not saving any energy. To remedy this, the load-sensing pump was invented. A load sensing pump has an additional compensator that is plumbed downstream of the metering valve. This configuration allows it to measure load pressure and compare it to compensator pressure.

The result is the pump will provide only the pressure and flow required of the circuit and actuator, with only a few hundred psi worth of pressure drop as the waste by-product.

Recent advancements in control technology have resulted in a similar concept of pressure and flow management, but using a combination of fixed displacement pumps, servo or VFD motors and pressure transducers. The pressure transducers measure pressure after the pump and after the metering

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valves, and PLC gives the signal to rotate the pump at a speed only fast enough to achieve the desired pressure and flow. It’s quite an advanced technology, and has progressed to the point a pump could hold a stationary load and rotate fractional speed just to compensate for leakage.

Another advantage to this technology is that the motor doesn’t even turn when no energy is required, and then again only with the energy required by demand of the hydraulic system.

Aside from choosing efficient pump designs, using efficient hydraulic actuators is the next best place to continue. Not much can be said of hydraulic cylinders, because most are close to 100% efficient already, depending on sealing technology. But just like with your hydraulic pump, the hydraulic motor has many variations, each with their own contribution to overall efficiency.

Ranking popular hydraulic motors in terms of efficiency, they range from radial piston, axial piston, vane, gear and orbital, with efficiencies around 95, 90, 85, 80 or less, respectively. Of course, these motors would have the same ranking in cost, so the adage of “you get what you pay for” applies here. Other than just choosing an efficient motor design, there isn’t much you can do to enhance efficiency, other than eliminating return port backpressure, and applying motors with the same load-sensing techniques described with pumps.

So for the most part, hydraulics is not an efficient technology. But neither are gasolinepowered cars, and millions of those are sold every day, because there is no better option for their task. Regardless, efficiency in hydraulics is progressing, and advancements in materials and technologies will further that. As long as you are aware of what it takes to create “hydraulic efficiency,” the term won’t seem curious like “seriously funny” or “virtual reality.”

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Aging, softening or hardening caused by excessive heat

can destroy a hydraulic hose's inner tube, cover and reinforcement.

How does

extreme heat affect hydraulic hose?

Edited by: Mary C. Gannon • Managing Editor

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In a previous article, the editors at Fluid Power World discussed how ultra-low temperatures can play havoc with the performance of typical rubber hose. Hydraulic hose used at high temperatures faces

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chain growth and crosslinking, which usually decreases elongation and increases tensile strength—resulting in a hard, brittle material. Or high heat causes chain rupture, which results in a weaker, more-pliable plastic or even a resinous mass. When exposed to elevated temperatures, some plastics will even show an initial hardening followed by softening. All aging phenomena are irreversible processes.

Nearly all plastics exhibit some degree of mechanical property degradation as temperatures increase. The same holds for hydraulic hose. Extremely high temperatures can affect a hose’s elastomeric and mechanical properties and cause problems like softening, discoloration, embrittlement or hardening. One visible indication of degradation is thermal-stress cracking, the crazing of some thermoplastic resins resulting from overexposure to elevated temperatures. The cover may show signs of being dried

Image: istockphoto.com

performance issues too, but for different reasons.

That’s because thermal exposure can cause aging of elastomers and plastics. (Other causes of aging include exposure to sunlight, oxygen, ozone and moisture, among others.) Thus, the polymers that make up the cover, inner tube and possibly the reinforcement can be at risk.

Extreme heat can affect plastics in two ways, both of which are bad. Properties can be degraded by molecular

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out and charred or may even crack when flexed. The assembly may remain “frozen” in its installed shape after it’s removed from a machine.

Hot fluids beyond recommended temperature limits may have a similar, detrimental effect on the inner tube. (Failure to use hydraulic oil with the necessary high-temperature viscosity can also accelerate hose degradation.) And non-petroleum hydraulic fluids like water/oil emulsions and glycol solutions sometimes require lower temperature limits.

Regardless, never exceed the recommended maximum operating temperature for a given fluid. If hose maximums for ambient and fluid temperatures differ, the lower limit takes precedence.

Some manufacturers say increasing external temperature by just 18° F (8° C) above maximum rated temperature can cut hose life in half. Actual service life at temperatures approaching the hose’s recommended limit depends on the application and fluid.

But simultaneously operating at maximum temperature and maximum working pressure can greatly reduce hose life.

Likewise, radiant heat from furnaces, hot manifolds and molten metal can destroy hose assemblies without physical contact. And welding flames or spatter can burn through a hose.

Engineers should select a hose that is designed for temperature extremes and ensure it is properly shielded. Reroute hose away from heat sources if at all possible. If high fluid temperature poses a problem, redesign the circuit so it is more efficient or install a heat exchanger to reduce fluid temperature.

At any rate, experts recommend that hose assemblies exposed to high-temperature conditions should be inspected frequently for any signs of deterioration, and damaged assemblies should be immediately replaced with ones with a higher temperature rating.

Hose manufacturers have developed heat-resistant products to meet these demands. For instance, they often specify thermally stable polymers, or add heat stabilizers, for use in hot conditions. One example is hose that uses chlorinated polyethylene (CPE) to replace traditional nitrile tube. CPE can handle constant temperatures to 275° F and intermittent temperatures of 300° F, while typical nitrile limitations are 212° and 230° F, respectively.

Rubber blends in typical hydraulic hose are rated for operation to 212° F (100° C). However, a number of hose manufactures offer a wide range of products suitable for higher temperatures. Here are a few examples:

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Conti Tech (contitech.us) Desert DR2SN is a two-wire braid reinforced hose that meets or exceeds the requirements of SAE 100R2AT. It is suited for high-pressure hydraulic lines in construction and ag equipment and machine tools that use high-temperature petroleum or water-based fluids. It has a CPE inner tube and blue CPE cover. Temperature range is -40° to 302° F (-40° to 150° C). Sizes range from -4 to -32 with pressure ratings from 5,800 to 1,160 psi, depending on the size.

Eaton (eaton.com) EC525 AQP Plus high-temperature, four-spiral hose is suitable for petroleum, fire-resistant and water-based hydraulic fluids. Its AQP compound for the inner tube and cover gives it an operating temperature range from -40° to 302° F (-40° to 150° C).

Sizes range from -12 to -32 with maximum operating pressure ranging from 5,000 to 3,250 psi.

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PEOPLE, PASSION & SOLUTIONS

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Intertraco (intertraco.it) FlexIT HT1 one-wire braid hose is rated for use with hydraulic oils at temperatures from -40° to 275° F (-40° to 135° C), with peaks to 302° F (150° C). For polyglycols, peak temperature is 185° F (85° C).

It is also suited for plant-based oils, water-oil emulsions and water. The hose has a synthetic rubber tube and MSHAapproved synthetic rubber cover. Sizes are from -4 to -32.

Parker Hannifin (parker.com) 436 hose withstands temperatures up to 302° F (150° C). The inner tube and cover are made of PKR rubber, and it has twowire braided reinforcement that meets SAE 100R16 specifications. Sizes range from -6 to -16 with operating pressures from 4,000 to 2,000 psi.

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11/17/16 10:20 AM

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Manuli (manuli-hydraulics.com) Gates (gates.com) MegaTech II is a multi-purpose hose for high-temperature (maximum 300° F or 149° C) applications with petroleum-based or phosphate-ester hydraulic fluids, as well as for air-compressor lines. It also meets SAE J1405 specs for hightemperature transmission and lubricating oil systems. Versions with two-wire braid reinforcement come in sizes -24 to -32 and meet SAE 100R2 requirements. It has a CPE synthetic rubber tube and abrasion-resistant CPE cover. Operating pressure range is from 2,250 to 1,300 psi.

Ryco (ryco.com.au) RQP2 is one of the company’s Survivor Series of hydraulic hoses. With a synthetic rubber tube and abrasion-resistant synthetic rubber cover, the RQP2 is rated for -40° to 302° F (-40° to 150°C). Its two-wire braid construction meets or exceeds performance requirements of SAE 100R2AT for hydraulic oil or phosphate-ester fluids. Sizes range from -4 to -32 and pressures from 5,800 to 1,300 psi.

Equator/2 extreme-temperature hose is rated for continuous service temperatures of -55° to 135° C (-67° to 275° F) with intermittent peaks to 300° F (150° C). It’s suited for hot conditions, such as in foundries and engine compartments. It has a twowire braid (SAE R2AT) construction in sizes from -4 to -32 with maximum working pressure from 5,800 to 1,300 psi. The hose handles mineral oils, glycols and aqueous emulsions.

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FLUID POWER

Vision for the future

Paul J.Heney Editorial Director @dw_editor

Looking to the future of AI What will the manufacturing world be like in 2026?

How will it be different? How will the job of a fluid power designer change? A lot of people will guess that something we’re well aware of today—such as 3D printing or nanotechnology or the Internet of Things—will explode and take over some aspect of manufacturing, if not the entire enterprise. While such a thing is certainly possible, and maybe even likely, I surmise that something totally new will be what we’re talking about in a decade. The jumps we’ve seen in technology over the last generation or two have mostly consisted of things that were almost unimaginable only a few years prior.

My gut feeling is that Artificial Intelligence will be the major change agent for our careers, but not in the “humanoid robots are taking over” way that TV and movies like to focus on. Instead, I think that AI will have evolved online to create a whole new suite of tools that engineers will use in designing systems—tools so complex that we can hardly even envision them today.

Perhaps you’ll describe every variable you know—say loads, speeds, pressures, physical dimensions, the task that is being completed—and the system will spit out the two or three most intelligent solutions. You’ll be able to select

the one that best fits your vision. Then, through a process that would appear to an engineer today as chatting with a coworker, questions will be asked about more specifications, how soon we need the system to be built, and other issues, and the final system design will be more and more refined.

The process could allow us to select a single component—say, a hydraulic cylinder or pump—that best fits into our existing system. Maybe we’re revamping a process, or maybe we’re simply looking for a more efficient solution to fit in that space. AI will take a lot of the specifying tasks—not to mention factoring in price and delivery, if we so wish—off of our shoulders. Maybe this AI will learn over time, so the tools that you use in your job will learn your specific preferences and understand industry regulations, safety protocols, your customers’ needs, and more.

Again, all of this seems impossibly complex to today’s engineer—there are too many variables, each with a different weight, and untold billions of possibilities. But computing power, Big Data’s growth online and the relentless evolution of AI may well converge in some quite interesting ways for the design engineer of 2026.

Stay tuned.

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FLUID POWER

Vision for the future

Mary Gannon Managing Editor @dw_marygannon

Reinventing engineering and technology training I am a big believer in the need of a good education for all young people. But not every student should follow the same career path. In the STEM field over the past 10 years, there has been great emphasis on four-year degrees in science, technology, mathematics, or engineering. But not every student is meant to sit in a classroom for four years, learning theories and principles. Some students learn better—and are happier—getting their hands dirty and learning in the real world.

As manufacturing continues to rapidly evolve with automation and AI—and as the current college format skids towards a bursting bubble of backbreaking debt—something is going to change. It has to. Too many young people and their parents are brainwashed into thinking the only path to a good career is through the four-year college path. And this has put a stigma on technical or vocational training in this country.

I hope we will see a return to greater prominence of the technical school, where students gain hands-on experience in machine operations and designs. For example, statistics shared by The Atlantic in 2014 indicated that only about 5% of American youth train in apprenticeship programs, while in Germany, that number is about 60%. There, these apprentices are paid to study and work at the same time.

This could lead to skilled labor entering the workforce to operate and maintain the complex, automated machinery that is key to modern manufacturing. Or perhaps some of these students will discover a passion for machinery design and move forward to traditional four-year colleges, where they will study engineering technology (see FluidLines on page 2 for a look at the difference between engineering technology and engineering science degrees).

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I would love to see more partnerships between manufacturers and two-year college institutions and technical schools, as more companies (particularly of German origin) are already starting programs to educate students in Mechatronics.

I am not sure why the apprenticeship idea has gone away in American manufacturing. If it still has a place in many other trades, however, I don’t see why more manufacturers don’t invest in future employees by teaching them the skills they will need to operate, maintain, design and build the machines of the future.

This may be the better option for individuals in a field where nearly 75% of all holders of bachelor’s degrees in STEM disciplines don’t have jobs in STEM occupations, according to a 2014 U.S. Census Bureau report.

Perhaps those students bought into the STEM hype without being truly passionate about those fields. Or perhaps they were not as prepared to enter the fields as they could have been. But with more hands-on technical training in the post-secondary arena, we could begin to see qualified, passionate engineers abound who are going to design the next big thing.

A revolution is coming in post-secondary education. And looking forward to 2026, it makes sense that the idea-makers, the designers, the inventors, will be the ones to push that particular needle forward.

www.fluidpowerworld.com

11/17/16 10:50 AM

FLUID POWER

Vision for the future

Ken Korane Contributing Editor @fpw_kenkorane

Seven reasons why fluid power will fare well Pundits have been predicting the demise of fluid power for decades, and yet the industry still prospers. Here are seven reasons fluid-power systems will be even better 10 years from now.

Digital decade. Top on the list has to be the marrying of hydraulics and pneumatics with digital electronics—as one expert terms it, the electronification of fluid power. It’s certainly not new, but the trend is accelerating unabated.

As just one example, valves with embedded electronics and built-in sensors will provide unprecedented controllability and feedback, like independently metering flow to actuators and adapting to changing load conditions. They’ll be teamed with the latest controllers and sophisticated software to ensure not only exacting precision, but capabilities like auto-tuning and remote diagnostics.

Energy recovery. Harnessing energy that is normally wasted will sizably increase the efficiency and economics of fluid-power systems. Manufacturers are just scratching the surface with products like exhaust-gas recovery and reuse in air cylinders and multi-pressure digital accumulators for hybrid vehicles that can cut operating costs by a third.

Non-traditional actuators. Virtually all fluid-power actuators provide linear or rotary motion. Researchers have developed, flexible pneumatic actuators called Fiber Reinforced Elastomeric Enclosures (FREEs) that permit controlled force and motion beyond pure extension and contraction, including angular translation, axial rotation and cork-screw motion. Lightweight FREEs lend themselves to use in patient mobility-assist devices and in robots that can reach, grip and twist—and are safe for human contact.

Predicting the future. Unexpected downtime is the bane of industrial production lines and mobile vehicles. We’ve already seen the development of “smart” components like hydraulic hoses that warn of impending failure. The trend will continue with everything from pumps and filters to even hydraulic fluids and pneumatic seals. Life-prediction maintenance programs will minimize costly failures or money wasted replacing perfectly good parts.

Power density. Greater power density usually connotes smaller components running at higher pressures. Now, researchers are looking to craft MEMS-type control valves using piezoelectric actuators. This technology may decrease the power required to drive valves by three orders of magnitude and yield ultra-fast operation. Extremely low power consumption makes them especially attractive for human-scale, battery-powered and portable applications.

IoT. The digital era is more than just embedding sensors into components and connecting them to a machine controller. The Internet of Things holds the promise of fully networked, adaptive production. IoT-enabled components will communicate with each other and with cloud-based enterprise management systems for analytics, diagnostics, equipmenteffectiveness reporting and many other tasks. Such units might configure themselves, independently meet varying production requirements and make adjustments while a machine is running, increasing flexibility and overall productivity. A number of fluid-power sensors, actuators and other devices already have the capability, and more are on the way.

Nanoscale manufacturing. Researchers formulating hydraulic fluids are moving beyond traditional laboratory methods and examining fluids and additives on a molecular scale. The goal is to simulate and, eventually, create fluids that reduce friction, enhance efficiency, tolerate abuse and are environmentally friendly. Similar techniques might be used to build better seals and hose.

www.fluidpowerworld.com

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FLUID POWER

Vision for the future

David Price Global Marketing Manager HydraForce, Inc.

In the past decade, HydraForce has expanded its line of

Custom Cartridge Valves

hydraulic control products to include more than 700 types of cartridge valves. These range from basic solenoids to electroproportional, directional control, flow control, and pressure control valves. Choosing which valve options to use for a control scheme is the challenge. To address this, HydraForce offers the tools that make hydraulic circuit design easier and faster.

For every standard valve HydraForce offers, there is a customizable option. Depending on the valve, it’s possible to add manual override, specify a higher or lower pressure setting, request a special poppet for more linear flow, or change the flow range by customizing the spring.

Seal options, coil options, and corrosion-resistant coatings are also available.

Custom Manifold Design

New Standard Cartridge Valves

The company has updated its i-Design 5 hydraulic circuit design software for custom hydraulic manifolds. i-Design 5 includes the latest HydraForce valves, such as the new G3 series of powertrain and pilot control valves. The software allows users to specify valve assembly layout and generate a bill of materials. Using “drag and drop” technology, the user can build a circuit specifying the location of valves, ports, mounting holes and other hydraulic components on the manifold surface. i-Design then generates a report and bill of materials, which can be used to develop a price with an authorized HydraForce distributor.

i-Design 5 can also be integrated with Automation Studio software—a powerful hydraulic simulation tool that allows virtual testing of the circuit prior to the actual manufacture of the hydraulic manifold.

New cartridge valve options include multi-function cartridge valves that incorporate two or more hydraulic functions, such as loadsensing, load-holding, directional and flow control, and pre- and postcompensation of hydraulic flow into a single valve.

Models HSPEC (a proportional solenoid with built-in compensator) and the recently patented TSEP (proportional pressurereducing valve, load sense check valve, and low-leakage logic element) are two examples of cartridge valves with multi-function capability.

HydraForce also recently launched a new torque-divider valve, the HTD10-40. It is a pressure-reducing/relieving valve, which can be used for traction control and other applications where series motors require some limited variation in speed.

Custom Electronic Control HydraForce has also developed a new line of configurable electronic valve drivers that allow greater customization of electrohydraulic controls. ECDR valve drivers come in several sizes and can control from one to five proportional valves. The ECDR valve drivers help bridge the gap between higher-priced programmable controllers and more affordable drivers. They can be configured for specialized applications, such as fan drives and transmission controls, using HydraForce HF-Impulse software.

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Resources for Custom Applications HydraForce has invested in additional resources needed to support development of custom hydraulic control solutions, including updated application engineering laboratories in Vernon Hills, Illinois in the U.S. and Birmingham, Great Britain in Europe. Fast prototyping, including 3D imaging and multi-axis prototype machining, is available. In addition to i-Design and Automation Studio, HydraForce uses computational fluid dynamics (CFD), finite-element analysis (FEA) and magnetic imaging in valve design.

Visit HydraForce.com to learn more.

11/17/16 10:43 AM

HF G3 AdF (FPW) 11-16_9 x 10.875 9/19/16 4:32 PM Page 1

NEW

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G3 valves operate with higher electro-magnetic force, which makes them less susceptible to contamination and reduces maintenance downtime. The improved design also reduces space claim and delivers reliable and precise linear control — with low hysteresis and even lower leakage.

For powertrain engineering assistance, visit hydraforce.com Lincolnshire, IL, USA 847-793-2300 © 2016 HydraForce, Inc.

HydraForce 11-16.indd 73

Birmingham, UK 44 121 333 1800

Changzhou, China 86 519 6988 1200

hydraforce.com

Image reproduced with the kind permission of J C Bamford Excavators Limited.

11/15/16 4:38 PM

FLUID POWER

Vision for the future

Jeff Behling President/CEO STAUFF Corporation

Q: How will new materials affect your business in the

coming decade?

A: At STAUFF we continue to add value to our clamp product line by utilizing special materials. We have materials that are tested and approved according to the UL 94 V0 vertical burning test, which is designed for flame retardant systems such as those found in passenger rail cars and wind turbines. Another material available is approved by the Defense Department which meets specific smoke, toxicity and flammability requirements. New materials continue to play an important role in the future of manufacturing.

Q: What technologies will most change manufacturing for the

machinery and off highway equipment, I can’t help to think of ways to incorporate sensors into this equipment to monitor these machines for predictive and preventive maintenance, conduct remote diagnostics and measure operating efficiencies.

If you add in the autonomous operation of automobiles, and very soon onto the scene tractors, trucks and other vehicles, the need for systems connectivity will be further escalated. At Stauff our oil condition sensing technology can monitor the health of plant’s centralized hydraulic system or an individual machine’s systems by monitoring and recording the temperature, cleanliness level and chemical makeup of the system’s hydraulic oil. This is a great start and there is still much more to do.

A: There are already high expectations of additive manufacturing,

better in the next 10 years, and why?

Q: Do you foresee your product (or certain components of it)

virtual reality, IoT, and nanotechnology in the manufacturing community. Additive manufacturing has already moved from rapid prototyping to low volume, high mix production methods allowing for designs that could never before be produced. A new world will open up as this technology advances and costs come down. Virtual Reality will allow design engineers to see their product before its even built in prototype form.

Customers too can see final products prior to production, ultimately shortening the development time by months or even years. The ability to better anticipate an outcome means plant engineers are able to design better processes for material flow, employee safety and ergonomics. Big Data and IoT will among other things improve machine OEE (overall equipment effectiveness) and increase collaboration between man and robot.

being manufactured via 3D printing in the future?

machines (metric fittings) and plastic injection presses (clamp bodies) it is difficult to imagine 3D printing capacities that can compete. I do however see a place for rapid prototyping and with some of our lower volume, higher mix products.

A: When I think of the high volume parts we manufacture in transfer

Q: How do you foresee Big Data changing the way you do business?

A: We see the value in data driven decision making. That said, the

variety, volume and velocity of this data will be overwhelming until we have the infrastructure and organization to best use it. There are also concerns about cybersecurity which play into this.

Nonetheless this takes analytics to a new level and we will find ways to utilize this information to improve our customer service and overall be easier to do business with.

Q: In 10 years, do you think the IoT/Industry 4.0 trend will have

faded or will connected machinery have become a way of life for diagnostics, maintenance and overall machine health?

A: When I think of how difficult it already is to find skilled labor for troubleshooting and repair of hydraulic systems, industrial 74

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The name worldwide for quality in port to port connectivity and reliability.

STAUFF USA and STAUFF Canada are part of an independent family owned group of companies with operations around the globe. The STAUFF Group develops, manufactures and distributes hydraulic port-to-port components and solutions, hydraulic accessories and hydraulic filtration systems and components to wherever your facility is located PIPE, TUBE & HOSE CLAMPS

More than five decades of experience, highly motivated and qualified staff, state-of-the-art manufacturing technologies and a foresighted management give us the reputation of being a competitive and reliable partner.

Our manufacturing and warehousing facilities all have quality certification to ISO 9001 and our main manufacturing plants in Germany are also certified to ISO 14001 and OHAS 18001 to ensure consistent product quality.

PRESSURE TESTING

In addition to our standard products we work with customers to develop customized products and solutions to improve both the quality and performance of your hydraulic system.

CUSTOM CLAMP SOLUTIONS

STANDARD & CUSTOM VALVES

METRIC TUBE FITTINGS

FILTRATION

QUICK RELEASE COUPLINGS

Local Solutions for Individual customers worldwide.

STAUFF Corporation Phone: 201.444.7800 www.stauffusa.com

STAUFF Canada Ltd. Phone: 416.282.4608 www.stauffcanada.com

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PRODUCT WORLD

Digitally compensated pressure transmitter range TT Electronics ttelectronics.com The TPM Series of industrial pressure transmitters have digital compensation to provide accurate, reliable pressure measurements and long-term stability over a temperature range from –20 to 125 °C. The TPM Series is suitable for applications in hydraulic and pneumatic systems, fuel and lubricant pressure sensing, leak detection, filter testing and tank level sensing. These transmitters also have a choice of pressure ports and electrical connections. The series supports options for gauge, sealed gauge, absolute and compound pressure types and offers 18 pressure ranges from 0-100 mbar to 0-600 bar.

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UPDATED

3/27/2015 4:00 PM

11/17/16 11:17 AM

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

COFFEE or

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You also have a choice for hydraulic cylinder positioning

Gripping tools for packaging and palletizing

Miniature Mounting

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Inside the cylinder?

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Piab piab.com

• Compact, robust design • Maintains ASAE pin dimensions

Kenos vacuum gripping systems use Piab’s

Absolute Signal

multi-stage vacuum ejector technology in combination with suction pads/foam

• Excellent *vibration capablity

Short Length Maintains Pin to Pin Dimensions

to make its packaging and palletizing/

*Tested to Mil-STD-202G

de-palletizing tools. They are available with either check valve or flow resistance No Extra End Cap Costs

technology, and configured to use either integrated vacuum generation or an external vacuum generator (pump/

On Site Replaceable

Or outside the cylinder?

Magnet Works Through Carbon Steel

• Easily field replaceable

blower). The general use KVG series offers gripping tools suitable for a wide range of

• No expensive SS cylinder tube needed

applications. The more specialised KSG sack gripper can be used for handling sacks of

• Ideal for steering cylinders

varying shape, material and weight. The

No Deep Drilling Costs

KVGL layer gripper is a modular system

Maintains Piston Rod and End Cap Strength

that can be designed to fit many different dimensions and requirements.

• Ideal for long cylinders up to 130 ft.

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Rota Engineering Ltd

UK Tel: +44 (0) 161 764 0424 US Tel: 972 359 1041 info@rota-eng.com www.rota-eng.com

Wellington Street, Bury, Manchester, BL8 2BD, UK

11 • 2016

FLUID POWER WORLD

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PRODUCT WORLD

Precision diaphragm regulators Clippard clippard.com The DR-2 Series provides greater accuracy and repeatability (±0.15 psi) while maintaining the same flow and performance characteristics as the MAR regulators. Regulators are offered in either relieving or non-relieving versions. They are designed for applications where zero air consumption is required (nonbleed). A special diaphragm seal provides excellent accuracy and repeatability. They offer high corrosion resistance and non-rising internal adjustment. A manifold mount option is available.

You Needed a Better Seal.

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Flaretite, Inc. Phone: 810-750-4140

A Leader for over 20 Years in the Pump Mounting Bracket Industry for Air Cooled Engines and Electric Motors.

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11/17/16 11:18 AM

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

New engine and oil cooling options for mining applications AKG of America akgts.com Two series of heavy-duty oil coolers are designed for harsh environmental conditions found in agriculture, construction, mining and more. The HD series efficiently cools hydraulic and heavy weight oils commonly used in mining equipment. Featuring an open fin system specifically developed for dusty and dirty operating conditions, the HD series ensures a longer operational lifetime of the oil cooler, as well as decreased maintenance and equipment downtime. The MCS Series (multiple cooler systems) is a new large cooler suitable for engines from 1,500 to 5,000 hp. The MCS System components can be replaced in the field without any special tools.

Hydraulic track motor Eaton eaton.com/HP50 The new HP50 track motor is designed to meet the growing trend of higher top speed and horsepower transfer. The motor is built for the harsh environments faced by compact tracked skid steer loaders (CTLs), skid steer loaders, harvesters, augers, forestry equipment, grinders and mixers, drilling equipment and sprayers. The HP50 is available in single-speed or two-speed models. This highpressure, high-flow motor can reach 6,000 psi of pressure and 70 gpm of flow. The motor is available with the option of a spring-applied hydraulic release brake and provides up to 50,000 in.-lb of torque.

www.fluidpowerworld.com

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Statement of Ownership, Management, and Circulation (Requester Publications Only) 1. Publication Title

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Eight issues/year: February; March; April; May; June; August; September; November

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Fluid Power World 4. Issue Frequency

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AD INDEX

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(Include direct written request from recipient, telemarketing and Internet reb. Requested Legitimate Distribution fromPaid/Requested recipient, paid subscriptions including nominal subscriptions, Paid and/or (2) quests In-County Mail Subscriptions stated on PSrate Form 3541.

(By Mail employer requests, advertiser’s proof copies, telemarketing and exchangeand copies.)

Requested (Include direct written request from recipient, Internet reand Distribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, Outside (By Mail employer requests, advertiser’s proof Street copies,Vendors, and exchange Sales Through Dealers and Carriers, Countercopies.) the andMail) (3) Sales, and Other Paid or Requested Distribution Outside USPS® Outside Sales Through Dealers and Carriers, Street Vendors, Counter the Mail) (3) Sales, and Copies Distributed

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g. Copies not Distributed (See Instructions to Publishers #4, (page #3)) h. Total (Sum of 15f and g)

11,971

10,908

10,899

0

0

0

0

0

0

10,908

10,899

585

593

c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4)) Outside County Nonrequested Copies Stated on PS Form 3541 (include (1) Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including Outside County Nonrequested Copies Stated Association on PS FormRequests, 3541 (include Names obtained from Business Directories, Lists, and other sources) (1) Sample copies, Requests Over 3 years old, Requests induced by a Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources) d. NonreIn-County Nonrequested Copies Stated on PS Form 3541 (include quested (2) Sample copies, Requests Over 3 years old, Requests induced by a Premium, Sales and Copies Requests including d. Distribution NonreIn-County Bulk Nonrequested Stated on PSAssociation Form 3541Requests, (include (By Mail from Business and other sources) quested Sampleobtained copies, Requests Over Directories, 3 years old, Lists, Requests induced by a (2) Names and Distribution Premium, Bulk Sales and Requests including Association Requests, Outside (By Mail Names obtained from Business Directories, Lists, and other sources) the Nonrequested Copies Distributed Through the USPS by Other Classes of andMail) (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Outside Limit mailed at Copies Standard Mail® or Package Services the Mail) Nonrequested Distributed Through the USPSRates)

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f. g.

No. Copies of Single Issue Published Nearest to Filing Date No. Copies of Single Issue Published Nearest to Filing Date

0

0

0

0

300

Aggressive Hydraulics .................. 9 Anderson Metals Corp. .............. 59 AutomationDirect ........................ 1 AutomationDirect .................Insert Bonfiglioli USA Inc ...................... 40 Brennan Industries ..................... 67 Clippard Instrument Laboratory, Inc. ...................... BC Eaton .......................................... 65 Eaton Hydraulics ........................ 31 FABCO-AIR, Inc. .......................... 17 Flaretite, Inc. .............................. 78 Flow Ezy Filters ........................... 53 FluiDyne Fluid Power ................. 43 Hawe Hydrauliks ........................ 21 HED ............................................. 35 Holmbury, Inc. ........................... IBC Hunger Hydraulics ...................... 64 Hy-Pro Filtration ......................... 19 HYDAC International .................... 5 Hydra Mount Corporation.......... 78 Hydraulex Global Attica Hydraulic Exchange ....... 3 IC-Fluid Power ............................ 29 Kocsis Technologies, Inc. ............ 22 Lillbacka ...................................... 23

Main Manufacturing .................... 4 Master Pneumatic ...................... 51 MICO, Inc. ................................... 32 Minnesota Rubber & Plastics ..... 12 Muncie Power Products ............. 15 Murrelektronic, Inc ...................... 2 NOSHOK, Inc. ............................. 51 O+P SrL ....................................... 63 OEM Controls, Inc ...................... 79 Panagon Systems ....................... 27 Peninsular Cylinder .................... 76 Permco ....................................... 58 PHD Inc. ...................................... 49 Prince Manufacturing Corp ....... 25 ROSS Controls ............................ 52 Rota Engineering Ltd. ................. 77 RYCO Hydraulics, Inc. ................. 30 Servo Kinetics, Inc. ..................... 68 SIKO Products, Inc. ..................... 41 Smalley Steel Ring Company ...... 10 Super Swivels ............................. 14 Tompkins Industries, Inc. ....... IFC,4 Trelleborg Sealing Solutions ....... 47 Veljan Hydrair Inc. ...................... 39 WAGO Corp ................................ 66 Yates Industries, Inc. .................... 7

290

885

883

11,793

11,782

189

FLUID POWER

189

11,982

11,971

92.5%

92.5%

Total (Sum ofand/or 15f and g) Paid Requested Circulation i.h. Percent (15c divided by f times 100) i. Percent Paid and/or Requested Circulation (15c divided by f times 100) 16.

X I certify that 50% of all my distributed (electronic and print) are legitimate or paid 16. Publication of Statement of Ownership forcopies a Requester Publication is required and willrequests be printed in thecopies. issue of this publication.

17. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the 16.

17. Signature and Title of Editor, Publisher, Business Manager, or Owner issue of this publication.

Date

17.

18. Signature and Title of Editor, Publisher, Business Manager, or Owner

Date

HydraForce ................................. 73 STAUFF Corporation ................... 75

November 2016

Pat Curran, Business Development Manager

10/10/16

I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

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LEADERSHIP TEAM Co-Founder, VP Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memic

CONNECT WITH US!

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Follow the whole team on twitter @FluidPowerWorld

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11 • 2016

www.fluidpowerworld.com

11/18/16 10:49 AM

Connect with quality - Connect with Holmbury

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