Reliability for high-speed hydraulics p.32
www.fluidpowerworld.com
Pneumatics makes quick work of packaging p.48
Pneumatic valves inspire unique applications p.54
September 2016
Engineering a groundbreaking hydraulic hybrid PAGE 38
COVER_FPW 9-16_Vs2 MG.indd 1
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Expanding your options online One of our passions here at Fluid Power World is providing you with all your need-to-know engineering information not just in print, but online—whether through traditional websites or via a host of social media platforms such as Twitter, LinkedIn and YouTube. In addition to our main web portal, FluidPowerWorld.com, which features a broad look at fluid power as does the print magazine, we have what we call more “vertical” websites that examine more specific aspects of the technology: MobileHydraulicTips.com, PneumaticTips.com and HoseAssemblyTips.com. These three sites provide you with in-depth detailed technical information, application stories, product release information, and industry news—as well as opinions from our dynamic editorial staff. Yet, as we’ve grown over the past few years, it’s become obvious that there was a need for another vertical site, and I’m proud to announce its launch here: Sealing and Contamination Control Tips, at SealingandContaminationTips.com. We’ve heard it all before: Contamination control is of the utmost importance to any fluid power system, and the numbers bear it out. An estimated 75 to 80% of hydraulic system failures can be directly attributed to improper filtration. Metal and other wear particles cause significant damage, especially at high pressures and when cycled through a system over and over.
On this new site, we’re looking at several different areas that I think you’ll find interesting, including:
• • • • •
Filters Contamination issues Seals Hydraulic fluids, and Testing equipment
Once again, we want to make it easier for you to find the specific technology answers on whatever may be concerning you, whether it’s about a particular component, system design, maintenance or troubleshooting. I hope you’ll check out SealingandContaminationTips.com today and I look forward to your feedback as to how we can evolve the site to best serve you and your fellow fluid power professionals. FPW
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SEPTEMBER 2016 • vol 3 no 7 • www.fluidpowerworld.com
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September 2016
C ontents |
vol 3 no 7
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fluidpowerworld.com
F E AT U R E S
INDUSTRIAL HYDRAULICS
Careful monitoring ensures reliability in high-speed hydraulics
32
Understanding the complex components and systems that make up high-speed industrial hydraulics is critical to well-maintained, efficient machines.
MOBILE HYDRAULICS
Engineering a groundbreaking hydraulic hybrid
38
Here’s an inside look at the concepts, engineering and testing behind Caterpillar’s highly successful 336EH hydraulic-hybrid excavator.
PNEUMATICS
Pneumatics makes quick work of packaging lane changes
32
Image: istockphoto.com
D E PA R T M E N T S
02 Editorial
48
08 Korane’s Outlook 11 Association Watch
A challenging reconfiguration for a high-speed conveyor finds a solution in fluid power.
16 Energy Efficiency 18 Design Notes
VALVES
Pneumatic valves continue to inspire unique applications
54
18
24 Training 28 Fundamentals 30 Safety
Pneumatic valves provide the cleanliness, safety and precision required in everything from medical to industrial applications.
6
FLUID POWER WORLD
Contents_FPW 9-16_Vs2 MG.indd 6
62 Product World 66 Component Focus
24
68 Ad Index
38 ON THE COVER
Hydraulic hybrid excavators increase fuel efficiency by more than 25%. Image: Caterpillar Inc. A | S |B |P|E
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Ko ra n e ’s O u t L o o k Ken Korane • Contributing Editor
Death spiral for mining hydraulics?
Atlas Copco hydraulic breaker
Hitachi ZX 470 LC excavator
The once-every-four-years MINExpo show takes place this month and, if you’re a pessimist, the timing couldn’t be worse. The boom-bust cycle in commodities has decimated sales of mining equipment and with it, their hydraulics-intensive systems and all the requisite pumps, valves, cylinders and hose. Unfortunately, it’s nothing new. Some years ago, I worked as a design engineer for a mining and construction-equipment manufacturer. When times were good, monthly sales ran into the dozens of million-dollar machines. Several hundred engineers, and the hourly workers in our two production plants, were working 55 hours per week. Everyone, it seemed, sported a new car or truck. Until the inevitable recession hit. Monthly sales dwindled to single digits and eventually, to none at all. Hours were cut and every two weeks another dozen people were trotted down to HR for their layoff notices. Morale was rotten, tensions ran high and we all wondered whose number was up next. When I fortunately found employment elsewhere, head count was down 80%. Eventually the company was forced into a merger that shuttered our facilities and moved all the jobs offshore. And so it goes today. Caterpillar, which a few years ago acquired Bucyrus International, just announced it will explore “strategic alternatives” for its mining products. That includes halting production of certain equipment, selling off product lines, reducing workforce and repurposing its North Carolina plant from a mining to a rail facility. In July, Komatsu agreed to buy mining-equipment maker Joy Global for about a third of its valuation of only five years ago. 8
FLUID POWER WORLD
Korane column 9-16 FPW_Vs3 MG.indd 8
9 • 2016
Hyundai R1200-9 excavator
The underlying reasons for current low commodity prices are well documented. According to economist Eli Lustgarten of ESL Consultants, slowing growth in China has put the brakes on commodities demand. As a result, exporters such as Australia and Brazil are faced with excess supplies of raw materials like iron ore and copper. In the U.S., stagnant electricity prices and the EPA’s de facto ban on new coalfired plants have coal production down significantly. Around the globe, mining firms have scaled back on capital spending or have gone bankrupt. Many companies have postponed normal machine replacement, cut maintenance and, when necessary, cannibalized their existing fleet. For example, mining trucks are normally replaced every 2.5 to 3 years, but that’s now stretched to 6 to 10 years, said Lustgarten. Demand peaked in 2012 at about 1,500 units, and has fallen to around 200 trucks per year today. The collapse of commodity and energy prices has triggered what Jim Meil of Act Research Co. termed a “death spiral” for mining and oilfield-equipment markets. The good news, he said, is the decline has slowed and is now near bottom. Many experts say population growth and urbanization will drive long-term demand. Optimists should hark back to the mining-machinery boom of the last decade, when miners complained of equipment shortages and long lead times. MINExpo is as much about future prospects and new technology as it is about current conditions. Around 60,000 people came in 2012. It will be interesting to gage this year’s attendance, and see if better times lie ahead. FPW
www.fluidpowerworldonline.com
9/13/16 6:12 PM
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ASSOCIATION WATCH
Beaulieu shares positive outlook moving forward
At last month’s NFPA Industry and Economic Outlook Conference in Wheeling, Ill., 300 attendees from fluid power manufacturers, distributors and users heard a somewhat mixed message from the economists who presented, but Dr. Alan Beaulieu, President, ITR Economics, had a more positive long range message for future growth. Beaulieu started off by telling the crowd that “You’re going to have a better year next year than you did this year.” But 2016 has turned out to be a worse year for the industrial sector than economists predicted, with mining being a particular drag on things. Beaulieu stressed that the presidential election this year will not affect the forecast. “Whether it’s a Democrat or a Republican, isn’t going to change the outlook for 2017 because it really doesn’t matter,” he said. “It takes a while for anybody who’s elected to have an impact.”
Beaulieu said that, from World War II on, his firm studied where the economy does better, under Democrats or under Republicans. “It’s statistically insignificant. We’re just as apt to have recovery under a Democrat or a Republican. We’re just as apt to have a recession under one or the other,” he said. Interestingly, Beaulieu, said, 53% of Americans think that China is the largest economy on the planet, but they’re wrong—by a long shot. The U.S. remains the largest, with 24.5% of the world GPD, compared to China’s 15.0%. (Japan and Germany come in next, at 5.6% and 4.6%.) 9 • 2016
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ASSOCIATION WATCH
What’s more, our share of the pie has increased over the past year. “We are alive and vibrant and doing well. We’re not old and dying,” Beaulieu assured the audience. Oil and gas has been a challenging sector, said Beaulieu, and we have really curtailed production in the U.S. Some of that has been painful, but some has been good, too. “For right now, the good thing is that we, and other nations, are cutting back on production, mostly non-OPEC,” he said. “As we’re cutting back on production, that’s taking care of the glut that’s out there in the world. As we’re beginning to take care of the glut … these prices are going to be seeing some more upside pressure.” But this eventual upward pressure, combined with the increased reliance on renewables, will mean that eventually
all other costs will go up, leading to inflation. Beaulieu said to expect some mild inflationary pressures in 2017. Beaulieu feels that overall, the U.S. is in good shape and poised for growth for the next 14 years He said we’ll have our minor recessions, but nothing really bad will happen until a predicted major depression in 2030, which is tied to global demographic trends and a massive amount of retirees then. “In between, you need to be aggressive,” he said. “You need to hire, you need to train, you need to optimize, you need to make sure your marketing’s in place, your competitive advantages are in place. … If you do all of those things and plan for higher profits, you’re going to find yourself ahead of those who are still waiting.”
Discuss This and other engineering topics at www.engineeringexchange.com
FPW
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MANUFACTURING CUSTOM ACCUMULATORS
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Alsip, IL 60803 USA
www.kocsistech.com 9/13/16 5:57 PM 8/2/2016 10:33:40 PM
Edited by Mike Santora • Associate Editor
ASSOCIATION WATCH
Fluid Power Innovation and Research Conference 2016 The National Fluid Power Association and Center for Compact and Efficient Fluid Power will be bringing the Fluid Power Innovation and Research Conference to Minneapolis, October 10-12.
NFPA and the Center for Compact and Efficient Fluid Power (CCEPP) will be bringing the Fluid Power Innovation and Research Conference to Minneapolis, October 10-12. In addition to FPIRC’s collaborative technical breakout sessions, networking opportunities, and local industry and laboratory tours, keynote presentations provide another opportunity for attendees to learn more about what’s happening in the fluid power industry. This year’s presentations are: Keynote: Wearable Robots: Exoskeletons, Orthoses, and Prostheses – Tuesday, October 11, 10:45 – 11:45 AM Dr. Thomas Sugar of Arizona State University will present the challenges and opportunities for building powerful lightweight systems to assist legged locomotion and enhanced gait performance. Developments in these areas should highlight the potential for new applications and markets in the fluid power industry.
14
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9 • 2016
Commercialization Pitch Competition – Tuesday, October 11, 12:00 – 1:30 PM Learn about the latest innovations in fluid power research. The CCEFP research community will pitch research as potential candidates for commercialization. The competition will be judged by a panel of three experienced industry experts. Cash prizes will be given to the top three winners. Keynote: Via Negativa – Wednesday, October 12, 8:30 – 9:30 AM Dr. Peter Achten of INNAS, an engineering and innovation company in Breda, the Netherlands will present Via Negativa—a way of finding the right solution and best design from a pool of thousands of ideas. The presentation will explore the methodology behind creativity, solution-finding, innovation, and revitalization specifically in relation to the hydraulic industry.
www.fluidpowerworld.com
9/13/16 5:57 PM
Breakout sessions will cover the following topics: fluids and lubrication; modeling and control systems; and mobile, industrial and new applications. Two panel discussions will cover the “Role of StartUps in a Healthy Industry” and “External Technology Trends.” The event will also include Speed Meetings, where industry members can meet with students seeking mentorships, internships and employment. A poster session will also be offered. FPW
NFPA www.nfpa.com
In addition to FPIRC’s collaborative technical breakout sessions, local industry and laboratory tours, and keynote presentations, networking opportunities such as the Poster Sessions (above) and Speed Meetings allow industry members to meet students seeking mentorships, internships and employment.
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FLUID POWER WORLD
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ENERGY EFFICIENCY
Ron Marshall • For the Compressed Air Challenge
Compressed air fail: Missed compressor adjustment wastes money A metal fabrication facility ran two separate systems to feed tools and equipment in two shops on their premises. One compressor ran load/unload, the other was a VSD controlled compressor. The plant maintenance engineer attended a Compressed Air Challenge seminar and as a result came to realize how much compressed air costs and what to do about it. Inspired by what he learned, he went out and purchased flowmeters—and used his existing power measurement instruments to do a self-assessment of his system efficiency. The data logging showed that both systems were lightly loaded and running very inefficiently. Because the system piping for both systems are very close together, there was an opportunity to tie the systems together and save power. This had to be done on an emergency basis one particular day, because the smaller compressor unexpectedly failed. Because he expected some significant savings, the plant engineer measured the new flow and power of the remaining compressor and calculated the system efficiency. The analysis showed that even though there were savings, the VSD compressor was operating at a specific power as high as 60 kW per 100 cfm—very poor for a compressor of this type. Normal is about 25 kW per cfm at minimum speed. 16
FLUID POWER WORLD
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9 • 2016
The plant engineer did not realize that this type of compressor, even though it is a VSD controlled unit, comes from the factory with the default set to modulate at lighter loads. This modulation pushes the compressor into very inefficient operation at near minimum compressor speed. Typically, the supplier of this equipment adjusts the compressor so that this modulation does not happen. The adjustment was forgotten on this unit. The manufacturer was contacted and offered to make the adjustment to get things back within specification. By combining the two systems, they have seen an estimated savings of up to $9,600 per year, for a 43% savings in energy costs. FPW
Learn more about system optimization in our next Compressed Air Challenge seminar in your area. Visit www. compressedairchallenge.org for more information. Discuss This
Compressed Air Challenge compressedairchallenge.org
and other engineering topics at www.engineeringexchange.com
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DESIGN NOTES
Edited by: Mike Santora • Associate Editor
Pneumatic safety for truck-mounted forklifts Picture this. A truck driver has to load and unload construction materials at twenty stations. The driver repeatedly parks, exits the vehicle and climbs underneath the truck-mounted forklift attached to the vehicle’s rear. There, the driver manually triggers two metal bars that secure the forklift. This is dangerous and tedious ... and no longer necessary. To solve the problem, Aventics created a preassembled all-in-one truck-mounted forklift in the Netherlands, with pneumatics assuming the work behind this task. With truck-mounted forklifts, truck drivers no longer have to wait for the customer to provide a means of transportation; they are able to complete more loading processes each day. But commercial vehicle traffic has strict safety requirements. The mountings must be able to hold machines heavier than 1,000 kg, even when potholes or speed bumps strain the mountings or cobblestones give the vehicle a shake. This is the role of the two safety bars under the truck-mounted forklift. Aventics specialists have now put together a system solution for a trailer manufacturer that the company delivers preassembled. This system covers different designs for all brands of truck-mounted forklift models. The complete package consists of two PRA ISO pneumatic cylinders (50-mm bore by 800mm stroke) with trunnion mounting, one manually operated valve, one AS2 pressure regulator, and the pneumatic tubing/fittings as well as the required mounting components.
Drivers no longer have to climb underneath the forklifts and manually remove the safety bars.
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LunchBox SESSIONS
Continuous, Just-In-Time Hydraulics & Electrical Training
With this equipment, the driver pushes the lever on the valve downward and the two cylinders pull the safety bars below the forklift away. This increases safety for the driver. Once the truck-mounted forklift is loaded, the pneumatics return the safety bars back to their original position. The components are tailored to the special requirements of harsh truck applications. They are resistant to wind and weather, water splash, and the vibrations and shocks that occur during daily operation. This is where pneumatics can truly shine as a robust, easy-to-operate technology. The Aventics team created a single material number for each material kit. The Laatzen plant in Germany sends the components to Boxtel, in the Netherlands. There, they are preassembled into ready-to-install modules by the Dutch employees and then delivered to the customer. As of this year, AVENTICS also collaborates with Quickstra and De Kruif, two dealers and maintenance specialists for truck-mounted forklifts in the Netherlands, because the pneumatically automated safety system is also suitable for retrofitting. In the Netherlands alone, more than 3,000 truckmounted forklifts are currently in use. FPW
Learn ONLINE, ANYWHERE, ANYTIME, with interactive industrial training from CD Industrial Group Inc.
Aventics www.aventics.com/us Truck-mounted forklifts attached at the rear of a truck speed up loading and unloading.
CD Industrial Group Inc. 1·866·628·3224 www.lunchboxsessions.com info@lunchboxsessions.com
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DESIGN NOTES
Edited by: Mike Santora • Associate Editor
Multi-axis electrohydraulic motion controller When Delta Computer Systems designed its new RMC200 closed-loop electro-hydraulic motion controller, the goal was to extend the capabilities of previous generations of RMC motion controllers. The new motion controller increased its number of axes, making the Delta RMC200 more versatile. Feedback from users showed they wanted ease-of-use with their motion controllers but they needed more axes than were offered in one controller. “The RMC200 removes the 8-axis limit, and offers ample processing power for future capabilities. The RMC200 controllers use Delta’s RMCTools software for setup, tuning, programming and diagnostics,” said Steve Nylund, Delta Computer Systems CEO. RMCTools shortens application development and deployment times with a graphical programming interface, a motion plotting tool, and a Tuning Wizard that automates the process of setting control loop gains. With the capacity to handle closedloop control of up to 32 motion axes, a single RMC200 can manage the motion of a complete forest products or metals processing production line. It can also handle testing applications with a large number of sensor inputs. As with other Delta controllers—RMC75 (which can control 1 or 2 axes) and RMC150 (which can control up to 8 axes)—the RMC200 can synchronize the motion of multiple axes. These functions allow the construction of machines with scalable performance and quick production changeovers. The RMC200 provides engineers with built-in support for controlling pressure/force as well as position/velocity/ acceleration. The controller can transition smoothly between these control modes, enabling smooth, reliable motion. Through use of a programmable “Feature Key,” the RMC200 will enable only the number of control loops that an 20
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The RMC200 removes the 8-axis limit, and offers ample processing power for future capabilities. The RMC200 controllers use Delta’s RMCTools software for setup, tuning, programming and diagnostics
application requires. This helps deliver flexibility and charge for the exact functionality that is required. Other physical enhancements include a display screen on the CPU, I/O modules with push-in wire connectors, and fullyencased, user-installable modules that “rock-in” to provide power-sequencing capability. The unit’s modular expandability makes RMC200 virtually “future-proof,” supporting expanded control and I/O interfacing compatibility
as new modules are developed, ensuring that it will continue to be a capable electrohydraulic motion controller. FPW
Delta Computer Systems www.deltamotion.com
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DESIGN NOTES
Edited by: Mike Santora • Associate Editor
Hydraulic testers help crush it
Worsley Plant was established in 1996 as a contract crushing company that
For Worsley Plant, an integral
processes stone at rock face or demolition sites on a pay per ton basis. Its job is to crush stone and remove it. Any breakdowns and consequent downtime can be very expensive in terms of losses, and equipment costs. In 2003, the company saw a need for smaller jobs, involving crushing buckets attached to excavators. For Worsley Plant, an integral part of the installation is making sure the excavator is set-up correctly for the bucket to do it’s work. If the excavator isn’t set properly, then the bucket won’t function to specification. As a result, since 2006, all sales include training and commissioning during which a Webtec portable flow tester is used to test the hydraulics. In the last few years, excavators have become far more efficient and are geared toward carrying attachments, whereas five years ago an excavator was only an onsite digging tool. Now that they are more of a tool carrier, they come ready with hydraulic circuitry to control a wide range of rotating, vibrating or sorting attachments, and the pumps are more efficient. The demand for flow from the excavator to the attachment has increased, so now there is a need to test not only the inlet flow, but also the outlet flow as the ‘regeneration’ on some attachments with 400-lpm in could result in 800-lpm out, for example. Hydraulic back
part of its installation is to make sure the excavator is setup correctly for the bucket to do it’s work. If the excavator isn’t set properly, then the bucket won’t function to specification.
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pressure needs to be tested too, so you must not test just how much flow is coming in, but that the hydraulic system is efficient and can achieve the working pressures that are required for the bucket to operate correctly. The larger 800-lpm Webtec tester enables Worsley Plant to do this. At every installation Worsley sends out a service engineer with his flow meter, and the first thing they do when they arrive is to check the hydraulic flow rates. To properly test the excavator, Worsley staff builds a relationship with the driver or operator. They must ensure the equipment is working correctly by adjusting the required hydraulic flow and pressures, then testing the backpressure prior to connecting the crushing bucket and demonstrating how to operate it. Worsley Plant now flow tests in the region of 20 excavators a week. It sold around 150 attachments last year and with a hire fleet of 60 attachments (increasing this year to 75) they will have carried out over 1,000 flow tests. The hire business means they are installing between 10 to 15 buckets a week, as well as selling buckets. Since 2008 they have sold in the region of 600 crushing buckets. Testers from Webtec gives Worsley Plant the ability to fit and test large hydraulic attachments and make sure they function correctly every time.
Stackable Valves using one common inlet and exhaust ports with one standard bolt length. Provides various bankable applications wet line kits, dump pump controls, municipal snowplow vehicles, dump bodies, refuse vehicles and more. FEATURES: • 0-120 PSI proportional control, able to stack valves into bankable configurations. • Offset handles allow for very clean installation that reduces labor cost. OPTIONS: • Lit Knobs for all driving conditions, even at night. • Neutral Detent • 3-Position Detent • Detent Clip • Spacer to accept various straight-handle configurations • Magnifying Cap and Decal clearly shows functions and control instructions.
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The demand for flow from the excavator to the attachment has increased, so now there is a need to test not only the inlet flow, but also the outlet flow as the ‘regeneration’ on some attachments with 400 lpm in, could result in 800 lpm out, for example. Hydraulic back pressure needs to be tested too, so not just how much flow is coming in, but that the hy-
Tel: 716.853.7996 • Fax: 716.853.8003 571 Howard Street, Buffalo, NY 14206 www.delhydraulics.com
draulic system is efficient and can achieve the working pressures that are required for the bucket to operate correctly.
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TRAINING
David Marlowe • Owner/CEO • DMAR Technical Training and DMAR Business Centers USA
Why is it important to minimize overheating in your hydraulic system?
In a previous article, I stated that the
most important consideration in the selection of a hydraulic fluid was selecting an oil of the right viscosity. I also explained the difference between viscosity and viscosity index. Now we’ll share insights for the operator and maintenance person responsible for ensuring proper system operation.
Minimize, maintain and prevent system overheating Maintaining a normal oil temperature in all hydraulic systems is important for successful system operation. Normal operating temperatures for hydraulic systems is 110 to 130° F (unless specified by the equipment manufacturer). If the oil temperature is maintained in the normal range, all the system components will operate efficiently and do what they are designed to do—the pump will create flow; the valves will isolate, direct or regulate flow; the actuator will extend or retract while transferring energy to do work; and seals will prevent internal slippage. Maintaining normal oil temperature also reduces undesirable chemical compounds such as acids—not to mention sludge build up in the system. Undesirable compounds in the oil from excessive temperatures not only affect the viscosity index and system equipment operation but will cause accelerated wear on the moving parts. This can lead to premature equipment failure. It’s important to note that hydraulic systems are permitted to operate in a temperature range of 130 to 160° F; however, temperatures this high will reduce the lifespan of system components and increase the chances of a system breakdown.
Monitoring oil temperature with gauges like the 820/821 Series digital temperature gauges from Noshok is necessary to maintain fluid ranges between 110 and 130° F.
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HED 6-
TRAINING Mobile units seem to run at higher than normal temperatures. Keeping the oil temperature below 160° F is a challenge, as there is no practical way of removing heat. Because mobile units aren’t run like an industrial system, attention to the oil’s additive package, and a preventative maintenance schedule where the oil is changed based on the severity of operation (annually, number of hours of operation, etc.) is a necessity. It is imperative that the operator monitor oil temperatures when the system is in operation. If the oil temperature rises above normal operating temperature, finding the cause in a timely manner will reduce the odds of system breakdown. Manufacturer service manuals contain a troubleshooting section that list the
Oil sight glasses, indicators and level monitors should be installed on all reservoirs to allow for visual inspection of fluid levels and qualities. Image courtesy of Des-Case Corp.
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TRAINING
possible causes. If you don’t have a service manual, carefully examine the following:
in direct contact with the reservoir and components (this includes direct sunlight).
Application—Ensure the system is operating within its limits (the system is not being asked to do more than it was designed for).
Pump unloading—Make sure that the pressure in the pump line falls to a low value when the actuators are not operating.
Relief valve—This should be set at the lowest pressure setting that allows actuator operation. (Anytime you have flow across a pressure drop without work being accomplished, there is heat generated). Reservoir—Check proper oil level; it should be three times pump capacity. Also confirm that the reservoir is not covered with dirt or oil and all sides, top and bottom are open and free to air currents. The reservoir should be free of external heat sources
Speed controls—If flow control valves are supplying excessive power to the cylinder but not doing any work, ensure proper actuator speed by reviewing all pressurecompensated flow control valves and manual flow control valves (needle valve). Pressure reducing valve—Heat is generated across the metering orifice. Normal component and system operation require that the oil temperature is maintained in the normal temperature
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range. If the system temperature runs above normal and you decide to incorporate a heat exchanger, proper heat exchanger size and efforts to prevent the addition of cooling water into the hydraulic system is imperative. FPW
DMAR Technical Training dmartechtraining.biz
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FUNDAMENTALS
Edited by: Paul J. Heney • Editorial Director
A look at LVIT Technology
Microprocessor Based Smart Electronics
Sensing Element Precision Ground Stainless Steel Probe
Radial Connector or Cable I/O High Performance Low Friction Spoiler Guide
Stainless Steel or Anodized Aluminum Housing Engineering Plastic Non-corrosive Rod Eyes
LVITs—Linear Variable Inductive Transducers—have been around for more than 30 years, and are becoming very popular, due to their relatively low cost and flexibility to be packaged in many different forms. LVITs are contactless position sensing devices. They use eddy currents developed by an inductor in the surface of a conductive movable element to vary the resonant frequency of an L-C tank circuit. The most common form of an LVIT uses a small diameter inductive
Extreme Duty LV-45 Series
Industrial Duty LR-27 Series
Automation Duty LR-19 Series
Figure 1. A wide range of housing sizes are available for LVITs.
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probe surrounded by a conductive tube called a spoiler that is mechanically coupled to the moving object. Typical LVITs have full ranges from fractions of an inch to 30 in. or more. Modern electronics using microprocessors and small component size makes outstanding performance possible, achieving linearity errors of less than ±0.1% and temperature coefficients of 50 ppm/°F, along with either analog or digital outputs. The range of housing sizes for LVITs can be seen in Figure 1. LVITs are found in a wide variety of different applications that require position information or feedback. Typical LVIT applications include mobile hydraulics, subsea hardware, civil engineering testing as well as factory automation. In mobile hydraulics, the LVIT is commonly used to measure hydraulic or pneumatic cylinder position. Usually the sensor has a pressure-sealed head and a probe long enough to insert into a gun-drilled hole in the cylinder’s ram. The ID of this hole in the ram then acts as the spoiler. The sensor head can
Figure 2. Example of an in-cylinder installation of an LVIT
Figure 3. Subsea LVITs work in underground drilling or deep ocean environments.
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FUNDAMENTALS
either be port mounted or embedded into the cylinder’s end cap. A typical in-cylinder LVIT installation is shown in Figure 2. This packaging fulfills many different applications in mobile hydraulics such as positioning of bulldozer shovels or snow plows, boom positioning on hydraulic cranes and manlifts, and in a variety of agricultural vehicle accessory position feedback requirements. For subsea cylinder applications involving pumps, chokes, blowout preventers, and ROV-based actuators, the LVIT is designed to withstand the internal and/ or external pressures of a PBOF (pressurebalanced, oil-filled) system. Other technologies commonly used to satisfy these applications require additional hardware like a ring magnet to operate, which adds cost to the machining of the cylinder ram and complexity to the installation. Typical subsea LVITs are shown in Figure 3. LVITs are used in many factory automation applications, including packaging and material handling equipment, die platen position in plastic molding machines, roller position and web tension controls in paper mills or converting facilities, and robotic spray painting systems. Being contactless, the basic measurement mechanism of an LVIT does not wear out over time. LVITs also do not have the higher installed cost associated with other contactless technologies.
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SAFETY
Mary Gannon • Managing Editor
HoseGuard airfuse protection from ProportionAir
How do you prevent whiplash of pneumatic hoses? Although pneumatic systems operate at much lower pressures than hydraulic ones, ISO and OSHA standards are firm about the need to prevent whiplash hazards, in case a compressed air hose breaks lose from its couplings. These hoses must be restrained or shielded from workers and machines—or designed with airfuses to automatically turn off if a break occurs. A common method of protecting against hose whip in most fluid power systems is to use some sort of hose restraint system, which prevents a hose from whipping around after breaking loose from its fittings. These devices can be as simple as a clamp and cable, which secure the hose to the machine. However, another option is available if a compressed air hose or pipe should break. Airfuse protection, such as the HoseGuard from ProportionAir or AirGuard from Parker Hannifin, immediately shuts 30
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off air supply if the volume of air exceeds a set value due to broken pipes or hoses. These devices protect personnel and plant machinery by reducing pressure when a hose ruptures or accidentally comes loose from its coupling. This eliminates the dangerous occurrence of hose whip. The system features a factory preset value to allow normal air consumption when using air tools. If the air consumption exceeds this preset value, an internal piston instantly shuts off the main flow. Then, an integral bleed hole allows some air to flow through. This enables the line pressure to automatically reset the airfuse device once the main break is repaired. The function of these devices is simple. Compressed air passes through the inlet of the airfuse, and as it passes the piston, it is slowed down by lengthwise grooves on the outer side of the piston. Air cannot pass the
piston if flow is too high, so the piston is forced against the spring and to the seat. A bleed hole allows the airfuse device to reset and open after the hose is repaired. When selecting an airfuse device, you must know the internal diameter of the hose, pipe or tube, as well as its length. Application data is also required when selecting the material, as they are available in aluminum, stainless steel, Nitrile rubber, and plastic, among others. A key benefit to these devices is that they allow personnel to safely maintain and repair the hose system while the plant is still operational. FPW
Proportion-Air Inc. proportionair.com Parker Hannifin Corp. parker.com
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Careful monitoring ensures reliability in high-speed hydraulics
Understanding the complex components and systems that make up high-speed industrial hydraulics is critical to well-maintained, efficient machines. Carl Dyke • Contributing Editor
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Control surfaces on the wings of aircraft have to move into position very quickly. Aerobatic or military aircraft pilots may choose to maneuver through the three axes of roll, pitch and yaw simultaneously. A sudden change in flight path may require snap-action aileron, elevator and rudder positioning, against an opposing rush of air. In a lumber mill where heavy logs and massive timbers must be moved into precise position quickly for the next stage of milling, similar fast motions are required. In some cases it’s the heavy cutterhead of the machine that must be moved quickly into a very precise position. Pneumatics won’t work for these applications due to the high forces and therefore the high pressures required in the relatively small diameter cylinders. In some manufacturing applications such as a composite panel board plant, a hydraulic hoist table is lowered slowly, one layer at a time as product is added to the top of a heavy stack. When the stack is complete and has been moved to the next department, the unloaded hoist is shuttled all the way back to the top at high speed to start building the next stack. While not a precise positioning application, this machine needs high flow rates. These are a few examples of high-speed hydraulics in industrial systems. Let’s examine some of the unique components and design parameters that accompany these systems and the basic maintenance requirements.
Pumps don’t always need to be sized for the maximum system flow rate. In high flow applications such as positioning cylinders in a sawmill, or in any plant where heavy materials or machine slides need to be moved quickly, the pump can often be sized for average flow rates or just slightly higher. With flow and directional valves open for only short durations within the larger machine cycle, an accumulator can supplement the pump and make up the needed flow rates. In fact, the decompressing gas precharge in the accumulator can offer some acceleration to the rate of hydraulic flow that the pump cannot. In the case of the unloaded stack hoist being returned quickly to the upper starting position, the simple trick of flow regeneration avoids the need for a large pump or an accumulator. Regeneration which routes the flow from the rod-end port to the blind-end cylinder port, combined with flow from the pump, gives a big flow/speed boost. This trick works well for returning the empty and unloaded stack to hoist.
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• Positioning cylinders use a servovalve and an MDT position sensor for precision and speed.
Accumulators
The hydro-pneumatic accumulator is often known in a hydraulic system as a shock absorber and pulsation dampener. But it does equally well for supplementing flow rates in high-speed hydraulic systems. In these systems the accumulators are often relatively large. They may even appear oversized to the untrained eye. For fine cylinder positioning at high speeds, the oversized accumulator with a fairly high gas precharge pressure delivers needed bursts of flow with very little change to the large gas volume. This helps keep the feed pressures steady to the directional valves. An accumulator in this application performs at its most efficient when located very close to the flow and directional valves. Valves
• Regenerating flow from the rod port to the blind-end port can
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The valves needed to achieve only high-speed cylinder motion or high motor speed are not that sophisticated. In many cases they need only be large. If basic electrical on-off control is needed, then the valve may have a simple electric-to-hydraulic pilot stage. These components are referred to as solenoid-controlled, pilot-operated directional control valves. If opening a large spool valve to suddenly direct a high flow to a cylinder or motor is too sudden of a shock, an adjustable flow control often referred to as a choke—located between pilot stage and main stage—helps to slow the rate of spool travel. If a cylinder needs to begin moving without any delay after the valve has been signaled, then the valve design becomes more complex. The valve spool may have zero overlap or even an underlap to ensure good response. If the spool must still overlap the valve ports to guarantee periods without any cylinder drift, the valve control electronics will feature a deadband compensator to jump the spool to the open and flowing position quickly. Many of these features are common for proportional valves. If all of the above valve features do not provide sufficient performance and response time and if preventing a cylinder position-overshoot becomes important, a true hydraulic servowww.fluidpowerworld.com
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I valve is needed. The valve will typically be mounted on the cylinder where a magnetostrictive displacement transducer (MDT) has also been installed. Moving a heavy load quickly to a precise position and then stopping instantly is a requirement that makes hydraulics—with its stiff fluid medium—more suitable than pneumatics. Stopping the cylinder motion in exactly the right place is still tricky enough to require position measurement from the MDT and a complete closed-loop control system for the servovalves.
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• Cylinders with cushions reduce mechanical shock.
Cylinders
Cylinders for high-speed applications need to chosen carefully. The tube must be honed and finished with great care. The piston seals must be suitable for high speeds and offer low friction. In the case of the stack hoist cylinder that just has one high-speed motion, during full rod length extension, an adjustable cushion on the rod end will minimize shock and help keep the piston from being broken from the rod. Regeneration on the hoist extend motion reduces the cylinder’s force capabilities because there is near equal pressures on both sides of the piston. This means
that the rod diameter—or more precisely, the ratio of rod side piston to blind side piston surface area—is an important design decision. High-speed motors
In the plywood and engineered flooring product plant, flying circular saws that trim the panels as they move along the line often require the most compact prime movers. Hydraulic motors are sometimes chosen over electrical motors. Special model series of hydraulic motors rated for shaft speeds of 5,000 to 7,500 rpm help achieve the required saw speed for a clean finish cut. These motors feature carefully machined ports and internal parts with bearings and seals designed for the high shaft speeds.
• Solenoid
controlled, pilot operated valves handle high flow rates well.
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Fittings, hoses and tubing
For systems that feature high flow rates, keeping elbow fittings to a minimum is key to minimizing flow turbulence. Turbulence will cause increased pressure drops through the system plumbing and will reduce energy efficiency among other negative effects. The use of wide radius hose bends and bent tubing for 90° plumbing is greatly preferred. Taking the time to consult with hose and tubing vendors regarding proper diameters for hoses and the internal finishes of hoses and tubing minimizes friction and inefficiency. Maintaining high-speed systems
Maintenance requirements for high-flow and high-speed hydraulic systems may require more attention paid to the maintenance of accumulators if they are used to boost flow rates. Gas precharge pressures may need to be checked more frequently. The use of electrohydraulic proportional or servovalves for high-speed positioning cylinders demands extra vigilance over the condition of the fluid with careful monitoring of the particle count. Servovalves feature some of the tightest internal clearances and demand the highest levels of fluid cleanliness to maintain reliability and long life. An industrial fluid analysis lab can be a valued maintenance partner. Cylinders that cycle often and move large masses may need mount bolts as well as tie rod torque values checked with greater frequency. Valve control adjustments are often commonly made to servo-positioning 9 • 2016
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systems in factories where product parameters and production demands change. Keeping a watchful eye for any axis of motion that makes a heavy thud as the cylinder stops at a precise position might require some additional valve signal tuning to keep these shocks from damaging the cylinders. In the overall analysis of high-speed hydraulic applications in industry, the systems still consist of pumps, valves and actuators like any other. High flows, high cycle rates and high-speed cylinder motions simply mean attention to the unique design requirements and more frequent checks for fluid quality and proper functioning of the system components.
H Y D R AU L I C S
• Check the gas precharge
often on accumulators that
support peak flow rates.
FPW
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Extensive repair and manufacturing at our Toledo, Ohio facility since 1981
info@hunger-hydraulics.com • www.hunger-hydraulics.com • +1.800.248.9232 www.fluidpowerworld.com
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Here’s an inside look at the concepts, engineering and testing behind Caterpillar’s highly successful 336EH hydraulic-hybrid excavator.
Engineering a groundbreaking
hydraulic hybrid Aleksandar Egelja
Engineering Manager • Advanced Hydraulic Systems • Caterpillar Inc.
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Recently, I had the pleasure of addressing Fluid Power World’s inaugural Technology Conference in Milwaukee. The discussion centered on Caterpillar’s innovative 336EH hydraulic-hybrid excavator, and how this novel design increases fuel efficiency by more than 25%. Based on this talk, here’s a behind-thescenes look at the project from initial concept to product introduction, and some lessons learned along the way. Customer expectations Think back to 2008. Just like car owners, mobileequipment operators were feeling pain at the fuel pump. High diesel prices were squeezing operating margins for construction equipment fleets, and they needed more-efficient machines. That, in a nutshell, was the motivation behind the development and launch of the 336EH excavator. But the project was about more than just cutting fuel costs. Before we started the engineering process, we surveyed our customers to fully understand all their requirements. Yes, companies were looking to improve their overall ownership and operating costs by reducing fuel consumption and carbon footprint, but not at the expense of lower performance, quality and reliability. The trade-offs were important when it comes to fuel efficiency. The simple solution is to reduce engine power, but many customers measure productivity by the tons of material per hour they produce and move. Dialing down the engine power hurts productivity and does not improve overall efficiency. We had to ensure that any new product at least matched the performance and quality of non-hybrid models while reducing operating costs.
The Cat 336F H is a newer generation hydraulichybrid excavator that builds on technology pioneered in the 336EH.
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Hybrid basics Before we dive into the engineering details, let’s first define a “hybrid” as a machine designed to collect, store and reuse energy as it operates. That differs from machines with electric drives that do not store energy. Many machines have the opportunity for energy storage and reuse. For instance, wheel loaders and excavators dig, lift and dump material in a truck, and then lower the bucket for the next work cycle. Lifting creates future opportunity for capturing potential energy that typically converts to waste heat (by throttling hydraulic flow) when the bucket lowers. Also, engines are sized to deliver peak power, for example, when an excavator must lift its maximum rated load. But most machines do not operate continuously at peak power. This creates an opportunity to store energy, release it later and minimize demand from the engine. This was the basis for hybrid technology in a new excavator design: how to smartly capture and reuse power—and substantially reduce fuel consumption. Another option would be to downsize the engine and use stored energy for peak demands, when that downsized engine is not capable of delivering sufficient power. Hydraulic versus electric Based on customer input, in 2009 we began concepts for both electric and hydraulic hybrid solutions, concentrating on recovering energy from the excavator swing movements. It’s no secret that in recent years, some of our competitors have introduced electric-swing hybrid excavators. We considered both technologies, and took a dual-path approach that let engineers fully understand the pros and cons of both options. We started development of electric and hydraulic versions in parallel. However, an electric hybrid eliminates the hydraulic motor and circuit that controls excavator swing motion, and replaces it with electric motors, generators, ultracapacitors to store energy, a cooling system for the power 40
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Key components of the 336EH include the 1: hydraulic hybrid swing system; 2: electronic standardized programmable (ESP) pump; and 3: adaptive control system (ACS) valve.
electronics and many other components. While our customers wanted fuel efficiency, they also wanted a system that’s easy to understand and service. In comparison to electric high-voltage technology, accumulators are simple, proven devices for hydraulic energy storage. A hybrid excavator also had to be commercially viable and profitable for our customers. Our research showed system costs, and the potential savings and payback time, weighed in favor of the hydraulic hybrid. After much study and intense discussions regarding fuel efficiency, performance and cost of both technologies, we decided to move ahead with the hydraulic hybrid using our standard 336 excavator as a baseline machine. Technology building-blocks Here is a bit more insight into how the hybrid system works. Excavators routinely dig material and dump it in a truck. Each cycle the machine raises the load, swings the upper structure to the truck, stops, and finally dumps the load. To brake the pivot motion, conventional excavators use crossover circuits on swing motors to
throttle flow and route it to tank, which generates heat. In contrast, the hydraulichybrid system uses accumulators to store swing braking energy and release it to accelerate in the opposite direction. High-production excavators that work continuously provide an excellent opportunity to capture and reuse energy. To design a system that provides the needed performance and fuel savings, Cat engineers faced an intensive development timeline centered around three buildingblock technologies, called conserve, optimize and reuse. Conserve essentially entails improving fuel efficiency. Based on brakespecific fuel consumption (a measure of fuel efficiency in IC engines) and engine maps, we understood it was important to lower engine speed and operate at torque values that provide the best efficiency. To get the required performance with a lower engine speed, we paired the engine with a larger-displacement pump: the Cat electronic standardized programmable pump. The pump and electrohydraulic controls ensure smooth transitions between accumulator and engine-driven
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pump flow, conserving energy and fuel. Optimize can be considered the brain of the hybrid system. Its Adaptive Control System and independent metering valve (IMV) improve performance by intelligently managing flow to control motion and deliver power precisely where it is needed. The IMV replaces traditional single-spool valves on the 336 and significantly reduces fuel consumption. Being electronically controlled, the IMV operates in different modes for various conditions—such as for resistive, over-running or regeneration— and optimizes machine performance for each. Reuse is the final technology block. Two piston-type hydraulic accumulators charged with nitrogen mount in the rear of the 336EH. An energy-recovery (ER) valve connects the hydraulic swing motor and accumulators. When the machine swings from side to side, the accumulators collect the available hydraulic braking energy, and the ER valve subsequently releases pressurized fluid when needed to power the motor. Integrating these three subsystems, while challenging, led to significant efficiency improvements; integrating the overall hybrid system with the power-management systems of the new Tier 4 engine were key to improving overall performance. Control systems Thus, deep integration of the components, and the algorithms developed to control them, were essential for this technology to succeed. We are big proponents of virtual product development. The first step was to create control logic and dynamic models that work together in the virtual space to predict and also refine machine performance.
The 336F LN XE was a centerpiece of Caterpillar’s display at this year’s Bauma exhibition.
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M O B I L E For instance, the reuse system delivers energy back to the swing system, and managing pump flow versus accumulator output guarantees adequate cycle times while saving energy. Electronic controls seamlessly transition the circuit to ramp up the pump when the accumulators have discharged, regardless of the speed and load requirements of a particular application. Thus, we had to develop
highly sophisticated control algorithms so the hydraulics maintains performance and efficiency, and also ensures that these actions are completely transparent to the operator. Our engineers created software models, predicted and validated performance and efficiency and, if we didn’t achieve our goals, then further algorithm tuning was performed. As the design
“As the design progressed, engineers
gained a deeper understanding of different
types of operating cycles to better optimize the software—before ever building a machine.”
progressed, engineers gained a deeper understanding of different types of operating cycles to better optimize the software— before ever building a machine. Next, we prototyped a machine with new hardware and software to validate the models’ predictions. Machine testing gave us a better understanding of the differences between virtual and actual machine dynamics, and let us refine algorithms based on fuel efficiency, controllability and performance. Validating results Productivity, efficiency and controllability generally involve trade-offs: improving one could have negative implications on others. In this case, however, we maintained or improved productivity while dramatically increasing efficiency. At the same time, the controls proved to be solid and robust so
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operators didn’t experience a difference in performance between new and old machines. Nonetheless, when you adopt new technology, people naturally worry, “Is it going to work?” Fuel efficiency was one of the key deliverables, and we applied a rigorous evaluation process to measure and verify results. To do that, we used our standard 336E and hydraulic-hybrid 336EH machines in side-by-side comparisons. The first tests were run at the Caterpillar’s proving grounds, using our own operators to perform operations like trenching, digging, loading and leveling. Fuel efficiency improved anywhere between 20 to 48% with the 336EH, depending on the application. Fuel efficiency was tracked in terms of tons per liter, so we measured both the amount of material moved as well as the liters of fuel burned in doing so. We also stressed gathering statistically significant data, thanks to tightly controlled measurements of payload and fuel consumption, to ensure accurate results. Next, the machines moved to various customer sites to track realworld performance. Here, the customers’ operators worked the machines with baseline and hybrid technology. Again, we measured performance parameters and generated a substantial amount of statistically significant data. It showed productivity improved 7%, fuel consumption was reduced by 27%, and overall fuel efficiency in tons per liter improved about 46%, which was quite significant in the eyes of our customers. Given the excellent results, we began production of the 336EH hydraulic hybrid in 2012 and formally introduced it in April of 2013 at the Bauma exposition in Munich. We now have hundreds in the field. They’re versatile machines used in different regions, with different operators, performing many different jobs in varied soil conditions. Regardless, they deliver the sizeable fuel savings our customers expect. But validation did not stop there. We 44
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M O B I L E
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no longer track how any specific machine is used. But we have telematics capability that tells us, on a daily basis, how each machine performs in terms of fuel consumption, work time versus idle time, and so on. So, we compared EH machines against the significant population of standard 336E excavators in the field, compiling a sample size of 22,000 machine-months of data on the two. Results show the 336EH has an average fuel savings of about 25%, regardless of the application. This is an excellent use of Big Data, if you will, in that our data analytics adds confidence that the machines provide significant fuel savings to our customers. As this project shows, we approach hybrid technology with an open mind. If electric hybrids or some other type of hybrid solution someday surpasses hydraulics in terms of component costs, power density, reliability and other key areas, then we may consider that technology in future machines. Looking forward: The 336EH is well-aligned with Caterpillar’s future-technology vision that revolves around “Smart Iron.” At last April’s Bauma, our CEO Doug Oberhelman explained the importance of taking our machines, that already work well, and making them more intelligent by marrying Big Data and digital technology. That furthers our customers’ goals of improving productivity, efficiency, reliability and safety. From a hydraulics perspective, we need to continually develop components, systems and algorithms to support this vision. FPW
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Pneumatics
makes quick work of packaging lane changes A challenging reconfiguration for a high-speed conveyor finds a solution in fluid power.
Bernie Moltchan • Simplimatic Automation Sales Manager - Beverage • Simplimatic Automation
Simplimatic Automation, Forest, Va., manufactures material handling systems and automation for the packaging, semiconductor, electronics, assembly, pharmaceutical, medical device, optical and automotive industries. Recently, the company’s beverage industry team worked on the design details of a high-speed conveyor that would serve as the overall control and coordination backbone for a new multi-million dollar canning line for a premium beverage brand. In the midst of their initial planning, the design team was handed a new challenge: Due to a new configuration of the packaging line, a long curving section of conveyor had to be moved and shoehorned into a short section between two critical stations on the line. The new section, now straightened and only 6 ft long, would carry one, two, or three lanes of packs to a shrink film bundler/tray packer. 48
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Other requirements for the reconfigured line included: • Automatic changeover to maintain the integrity of one, two, or three lanes of packs as they enter the shrink bundler/ tray packer • Accommodate multiple lane widths • Ensure precise and repeatable operation • Maintain high throughput by providing long life and trouble-free operation • Resist corrosion • Feature food-safe lubricants • Operate via Ethernet-based communications
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P N E U M A T I C S
Mounting a valve directly on a cylinder can save energy and shorten response times.
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regarding the types of machines to be used at the end of line, the new 6-ft section of conveyor had to be sandwiched in between the lane switch device and the tray packer. The design team needed to develop a lane divider solution that would ensure that packs entering the 6-ft section—at a maximum of 62 packs per minute—maintained their precise orientation within their designated lanes. Not only were one, two, or three lanes required for various tray patterns, but also those lanes needed different widths, depending on the packs. Electric or pneumatic actuation?
CAD model of a two lane configuration shows the middle divider lowered.
Overview of the new canning line
The design team
needed to develop a lane divider solution that would ensure that packs entering the 6-ft section—at a maximum of 62 packs per minute—maintained their precise orientation within their designated lanes. 50
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A conveyor system unifies the new line. Empty cans are de-palletized and enter the line; filled cans are bundled and shrink-wrapped—then trays of packs are routed to a palletizer. On average, 1,450 cans of beverage are filled and seamed per minute. Filled cans are fed into a pack cartoner that produces 4-, 6-, 8-, 10-, and 12-packs of 12- and 16oz cans, depending on the run. This line accommodates more than 100 SKUs. After cartoning, packs are divided into lanes via an active roller wheel conveyor before being fed into the bundler/tray packer. One of the highlights of this new line is that it produces a wide range of bundle and tray pack patterns to accommodate retailer preferences. Different combinations of packs and lanes facilitate the diversity of pack patterns. Due to topological considerations and choices made late in the project
The most elegant design would be to lower metal plates—dividers—between the lanes. The divider design had the advantage of being a simple, low cost solution that would maintain lane separation. Lowering the middle divider, for example, would maintain a two lane infeed. Lowering the outer plates, while the middle remained up, would maintain three lanes. Having all the plates raised would allow for one lane operation. Guide bars on the sides of the conveyor would extend or retract to maintain proper width of the lanes. Working with Festo, one of the company’s suppliers, the design team ran cost benefit and performance analyses on whether electric or pneumatic actuators would be the optimum choice for lowering and raising the dividers and extending and retracting the width guides. These applications require relatively few movements per day. In terms of long service life, low cost, and high reliability in this application, pneumatic actuation clearly was the most cost effective choice. For the raising and lowering lane-maintaining actuators, a Festo design engineer suggested double rod actuators with 100mm stroke. “Double rod actuators provide exceptional rigidity,” said Mark Eanes, Sales Engineer. “The assured rigidity would be
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an asset in maintaining the specified orientation of the dividers over their service life.” Because this section of conveyor is near a washdown area, light amounts of over spray would be part of the environment. Eanes made sure Simplimatic would receive corrosion resistant cylinders, which have-food grade grease and seals incorporated into the bodies. Adding the NSF-H1 rated grease was a custom feature, but did not require any extra time in delivery due to fast handling by the Festo Customer Solutions Group. These cylinders incorporate the company’s PPS self-adjusting air cushioning feature that provides for fast set up (no adjusting screws needed) and long service life, due to the soft stop at the end of the stroke. For the changing width requirement, Eanes identified four position cylinders for the application. These pneumatic actuators extend or retract to four unique positions. The cylinders were also specified as corrosion resistant with food grade lubrication. Festo supplied its IP67 rated MPA-L valve manifold to control the actuators. The unit for the Simplimatic application was a 16-station manifold. Dual 3/2 solenoid valves were used to control the four-position cylinders. The MPA-L is a compact manifold with direct fieldbus communications through the Festo CPX bus node. Only one power line and one Ethernet cable had to be run to the valve bank for a clean installation. CAD models were supplied for all key components, which streamlined fabrication for Simplimatic. Eanes provided schematics of the pneumatic system early in the project, via the company’s FluidDraw software, ensuring that the functionality of the valves matched the demands of the application. “Overall, the close collaboration with a long time supplier meant that design solutions came in faster and with more assured results,” said Ray Moltchan, Senior Mechanical Engineer, Simplimatic. “This freed up our design team to move on to new challenges. It also lowered our engineering overhead.” FPW
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Pneumatic valves continue to inspire unique applications
Pneumatic valves provide the cleanliness, safety and precision required in everything from medical to industrial applications. Josh Cosford • Contributing Editor
Pneumatic valves are common in every industry, in appli-
cations from medical to chemical and automation to corrugation. Compressed air is readily available, clean and easy to use, so the number of markets taking advantage of this technology is no surprise. Two of the larger industries are automation—which uses cylinders and other actuators to produce or process goods at a blinding rate—and the food industry—which can take advantage of the same quick processing of goods without contaminating the final product, while being resistant to liquids or other food additives. Before the proliferation of electronics, pneumatic valves were used to create automation cells. The vast combinations of valve configurations combined with myriad plungers, cams, rollers and pilots allowed compressed air alone to operate massive and complex automated machinery. Without a single electrical wire, an entire packaging machine, for example, would operate and cycle, coursing and flowing endlessly, requiring only a palm button to initiate. Pneumatics is an old technology, and for years, there have been basic methods of design and construction. There are common configu54
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rations built with spool valves, poppets or other forms, and these configurations are based on the number of ports the valve has and the number of valve positions available. The ports are called ways, for some reason, but this adds clarity to the term “5-way, 3-position,” which describes a directional valve with a pressure, two work and two exhaust ports, that are moving between two energized and one neutral position. But this topic isn’t about those standard 5/3 valves. For machinery or applications outside the standard apparatus, unique valves exist for specialized equipment and processes.
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SERPAR Crossflow 35 Series valves from ROSS Controls can be integrated with external monitoring systems to provide for lockout—this inhibits further machine operation until the controls system is reset. There are industries needing attention, and with a market saturated with me-too products, manufacturers are increasingly applying their engineering and marketing capacity to niche products. These products fill gaps required by OEMs and machine builders, themselves trying to stand apart in a competitive world of commodity products. Pneumatics provides cleanliness for medical applications
The medical industry is unique in its pneumatic applications. Often times, the system or machine is simply part of a process—such as cleaning instruments or testing samples. Equipment manufactured for the medical industry must meet stringent standards for quality, cleanliness and safety. Not only must pneumatic valves be reliable when lives are on the line, they must be manufactured with utmost attention to cleanliness. By-products of the manufacturing process cannot be left behind to be ingested or infected into a patient. No greater importance for cleanliness can be found than with equipment designed to clean and sterilize surgical tools and equipment. Although the techniques for the process can vary, the goal is to efficiently 56
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destroy microbes existing on chisels and choppers or specula and strippers, which guarantees the surgical process isn’t a contributor to a patient’s ill health. SMC is a pneumatic product manufacturer, and you wouldn’t be surprised to discover they have product lines suitable for surgical equipment sterilization. Their VQZ valve line has been approved and licensed by both the FDA and Heath Canada for a proprietary sterilization process. Using low temperature sterilization vastly hastens the sterilization process time from five hours down to one hour, using vaporized hydrogen peroxide and ozone to destroy pathogens. Using various valves, the sterilization chamber is first subjected to a vacuum of 1 Torr before the vaporous hydrogen peroxide is injected at a fixed rate through micropulsation of the VQZ valve, which has rapid response time, especially with the metal seals required for this application. The pulsing of the hydrogen peroxide continues until the chamber pressure reaches 19 Torr, and then the reduction cycle begins. Ozone is now injected to react to the hydrogen peroxide to form hydroxyl radicals, further increasing lethality to the microbes. After www.fluidpowerworld.com
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the process is complete, and using a catalytic converter, the by-products of the process are oxygen and water, making the chamber safe to open and remove the surgical instruments. It goes without saying, a standard, off-the-shelf valve wouldn’t work well in a high-performance, demanding application such as this. The VQZ valve is available with metal seals, high-powered solenoids, IP65 rating and CE certification. Some valves may be available with some of these options, but it’s the combination of these features that allows it to be used in such a demanding duty. SMC also makes valves and components for blood analyzing equipment. If you’ve been to a medical lab recently to give blood, you know they process patients like concert goers in line at Wembley Stadium. The volume of blood samples, and the number of available tests to those samples, is extraordinary, and would be impossible using the old method of testing individual cartridges by a lab technician. Modern laboratories use automated machinery to perform biochemical analysis. The process to analyze blood requires cuvettes (sample cups) to be placed into carousels via pneumatic robots. The valves and actuators used are too numerous to describe here, but nearly every function and process uses an SMC component. Even the chilling and handling of reagents is handled via their equipment, and once the process is complete, SMC’s LVM series pneumatic diaphragm valves process the saline and bleach for cleansing.
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Using pneumatic components for these applications requires special materials, such as acrylic manifolds for fluidic circuits, similar in concept to those made for compact hydraulic manifolds using cartridge valves. Fluidics are used for the precision logical control of some of the components in the blood analyzer machine, and the special manifolds prevent leaks caused by tubes and fittings. The best way to describe fluidics is to imagine an electronic circuit—but instead of electrons, there are fluid molecules. Jets of fluid can create fluidic amplifiers, triodes and logic elements. This type of unique application of pneumatic valves ensures fluid power has a place in the modern world of technological advancements, and even nanotechnology considers fluidics as an important concept under its umbrella.
Expect more than Automation Control! Motion Control Custom control of hand forces Vibration Control Isolate unwanted vibrations
Safe, precise control for industry
The medical industry alone does not hold the monopoly on unique valve applications. Even though the typical domain of high-powered hydraulics has a pneumatic counterpart, the hydraulic press has long been the poster child of industrial power. But pneumatic presses are common for their rapid cycle rate, and are used for riveting, punching, crimping and swaging, for example. The challenge with presses closing at a rapid velocity is the potential for human interference as parts are loaded in and out of the machine. Also, the press must be safe during tooling changeover or maintenance. Because of the potential for danger, regulations for press safety are stringent, and all precaution must be made to prevent
Safety Products Protection for all machine designs under any condition
Automation Control Optimum tuning for any design
In short, the realm of pneumatics is more
vast, and specialized, than what can be found in off-the-shelf 5/2 valves and FRLs. As long as there is a demand for a unique application, manufacturers will create it.
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by ACE
More Info? Tel. 800-521-3320 Email: shocks@acecontrols.com
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Download a CAD file or our product sizing software at: www.acecontrols.com
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unintentional movement of the press and its platen. If the press is mechanical, clutches and brakes are used to ensure the press doesn’t cycle when not intended, and often the clutch and brake are pneumatically controlled. The pneumatic circuit to control the movement of pneumatic pressure—or the clutch and brake of mechanical presses—should be inherently safe, but with redundant controls to prevent accidental operation, or prevent operation when there is a problem. You could use two pneumatic valves in tandem to create a circuit requiring both valves to function simultaneously to allow press operation, but it just so happens ROSS
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Surgical sterilization equipment features vacuum chambers that use pneumatic valves to ensure cleanliness in their design and function. Image courtesy of Shutterstock
Controls manufactures its Double Valve, itself a press safety valve operating two valve elements in one body. The double valve contains two unique valve elements with combination shapes of pistons, poppets and spools, mounted
abreast in a single valve body. The internal porting plumbs each element in series so that both are required to be energized simultaneously for airflow to occur. Should
NETWORKED VALVE CONTROL. COMPACT. FLEXIBLE. E
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WAGO-I/O-SYSTEM 750 750-632 Proportional Valve I/O Module • Compact, 12 mm wide module • Control two valves up to 24V and 1.6A each • Integrate with a variety of networks and I/O modules www.wago.us/valve_control
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one valve element fail open or closed, the valve limits work port pressure to a fraction of inlet pressure, preventing the pneumatic press cylinder or clutch from engaging, or prevents the brake from releasing. The valve works via pressure differential on each valve element, and the function is impossible to defeat since the plumbing is internal. On top of its inherently safe design, the valve is available with dual pressure switches to monitor the pressure at each valve element. When the valve is not actuated, a signal is present at the normally closed output line of each pressure switch. When the valve is actuated, the switch circuits are reversed and a signal is present at the normally open output lines. The redundant electrical safety provides an extra step of security should machine failure be imminent, and with these features, this
safety valve has been popular for years. In short, the realm of pneumatics is more vast, and specialized, than what can be found in off-the-shelf 5/2 valves and FRLs. As long as there is demand for a unique application, manufacturers will create it. As a result, pneumatics will continue to be a top choice for solving difficult applications. FPW
SMC smcusa.com ROSS Controls rosscontrols.com Discuss This and other engineering topics at www.engineeringexchange.com
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PRODUCT WORLD
High-pressure hose for more flexibility Eaton eaton.com/100R15 The EC600 X-FLEX is designed for applications requiring high pressure performance in small areas. The EC600 has a synthetic rubber inner tube that is compatible with all common hydraulic oils up to a maximum temperature of 121°C (250°F). The EC600-12 reinforcement hose has four layers of steel reinforcement applied in a spiral pattern. The EC600 uses Eaton’s abrasion resistant DURA-Tuff cover. The high-pressure hose offers both four and six spiral wire construction that is operable at temperatures from –40 (–40°F) to 121°C (250°F) with no fluid leakage between hose and fitting when the machine shuts down and the system cools. The EC600 X-FLEX is compatible with Eaton’s 4S fitting series in sizes -12 and -16 and 6S fitting series in size -20.
Rugged all-stainless industrial pressure transmitters Viatran viatran.com
Leak detection lamp kit Spectronics Corp. spectroline.com The EagleEye UV/White Light LED Leak Detection Lamp Kit (EK-365) is hands-free and helps locate leaks in cramped areas larger lamps can’t.
Model 24A/34A series industrial pressure
This kit has a palm-sized (3.75 x 2.25 x 1.85 in. [9.5 x 5.7 x 4.7 cm.]),
transmitters feature all stainless-steel
lightweight (8 oz/ 227 g), cool-running, versatile
housings and wetted parts for high
lamp. It has two UV LEDs for fluorescent
resistance to humidity and corrosion.
leak detection—plus a three-LED
They are available in 34 standard ranges,
white light assembly for
from 3 and 5,000 psi (0.2 and 345 bar), and choices of gauge, sealed gauge, absolute and vacuum pressure types. Model 24A features a 0-5 Vdc output signal, while the Model 34A features a 4-20 mA output signal. A nonlinearity specification of ≤±0.25% is standard, with optional improvement to ±0.15% or ±0.10% (BFSL).
illuminating dark work areas. The EagleEye runs on a rechargeable lithium-ion battery that provides up to 75 minutes of continuous inspection between charges. It has an inspection range of up to 12-ft (3.6 m.) and a 100,000-hour LED service life.
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For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com
Distribution blocks for the mobile market Murrelektronik murrinc.com This distribution block delivers more power and performance to the mobile vehicles market. With ports for Deutsch connectors, the xtreme DB has three times the current carrying capacity compared to blocks of similar size. The xtreme DB blocks have eight I/O ports and 16 configurable outputs and use standard M12 connectors. The xtreme DB comes in five configurations and uses J1939, the standard communications network for sharing control and diagnostic information between electronic control units on heavy duty and commercial vehicles.
Desiccant dryers Walker Filtration walkerfiltration.com Pro Dry compressed-air desiccant dryers are designed for smooth, controlled and uninterrupted delivery of extremely dry compressed air. The desiccant dryers cover flow rates from 1.9 to 172 l/sec (4 to 365 scfm). Working pressure is 4 to 16 bar (58 to 232 psig) and inlet air temperature can range from 1.5 to 50° C (34 to 122° F). Minimum ambient temperature is 5° C (41° F). The units are suited for general industrial use, as well as in automotive, paint spraying, instrumentation, packaging, pharmaceutical manufacturing and many other applications.
www.fluidpowerworld.com
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PRODUCT WORLD
Rotary screw air compressors with variable speed drive Ingersoll IngersollRandProducts.com/ NextGenRSeries Next Generation R-Series compressors increase air flow output by up to 15% and reduce energy costs by up to 35%. The RS30n and RS37n VSD models contain: • braided PTFE hoses • an integrated dryer that is ISO 1.5.1 classified for higher air purity • a NEMA 12 rated enclosure and standard pre-filter enhanced separators and coolers, and standard coolant
Digital logic valve
Semi-rotary drive for fast installations
Sun Hydraulics sunhydraulics.com The solenoid-operated Digital Logic Valve (DLV) is the industry’s smallest, high-speed, reducedpower logic valve—offering 10-msec typical response times and few moving parts. The DLVB is a two-way, two-position,
Festo festo.us This pneumatic semi-rotary vane drive and matched contactless position sensor creates a simple, sealed-housing drive that is fast and easy to install. Standard swivel angles for the DRVS semi-
solenoid-operated directional
rotary drive are 90, 180, and 270°. Custom swivel
spool valve rated up to 5,000 psi
angles are possible with a stop bracket
(350 bar) at 0.25 gpm (1 lpm)
accessory. At 6-bar pressure,
but weighing 2 oz (58 g)
the seven different sizes
and measuring only
in the DRVS line
2.2-in. high (57.2 mm).
deliver a torque range of 0.15 to 20 Nm.
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For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com
Pneumatic actuators with enhanced positional tolerance Senior Operations LLC Metal Bellows metalbellows.com The Prime Mover has axial motion with no rotational forces involved. The actuator uses all metal construction (no elastomers), for use in temperature extremes, cryogenic to 450°F. Additionally, the all-metal construction makes it compatible with the harshest chemicals, plasma, and fluids. Up and down stop Z-axis positional accuracy is ±0.001-in. The Prime Mover is designed for 60-105psid pressure range, which produces actuation forces of 40 to 80 lb. With larger diameter actuators, actuation forces of up to 1,000 lb are possible. The actuator meets ISO 14644 Class 1 requirements. Lateral positional accuracy is ±0.002-in. and repeatability is ±0.0005-in. Unit-to-unit uniformity is within 0.005-in. over the entire stroke.
Three-line system prevents dump pump failure Muncie Power Products Inc. munciepower.com E and S series of dump pumps feature a three-line system option to prevent the most common dump pump failure of high temperatures resulting from the pump being operated too long in neutral. A three-line system includes a separate line to return hydraulic oil from the cylinder directly to the reservoir instead of forcing its way back through the inlet line. This three-line design allows faster down cycles and ultimately runs cooler. E Series has a maximum pressure of 2,500 psi. Its pressure-balanced wear plates promote high efficiency. S Series is available in 6, 11 and 15 gpm at 1,000 rpm sizes. The three-way dump pump valve allows for proper singleacting hoist operation on smaller dump truck applications.
www.fluidpowerworld.com
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COMPONENT FOCUS
Todd Degler • Product Manager • Eaton Hydraulic Motors
Five things
to consider when choosing a gerotor motor
When selecting a gerotor motor, there are many items to consider, including performance, quality, reliability and cost. Choosing the wrong one could lead you down a path of frustration. Before selecting your motor, let’s discuss the basics of gerotor motors. The gerotor motor, or generated rotor motor, has been around for decades. In fact, the first gerotor motor in Eaton’s portfolio was manufactured more than 65 years ago. Soon after, the company invented the Geroler motor to meet the needs of the market and improve upon performance and reliability.
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COMPONENT FOCUS
These two motor types use what is termed as the orbit principle, which is what gives the motors their tremendous power density and compact size. A gerotor motor star has six teeth and seven lobes. The spaces among them are pressure chambers. Pumped fluid flows into these pockets, creating high pressure in one chamber and low pressure in another. This creates an imbalance of forces, which causes the gerotor motor star to rotate, or orbit. A gerotor motor star orbits multiple times, Figure 1, typically six to eight times depending on the specific star and ring geometry—for each complete single revolution within the outer ring. Geroler motors use the gerotor principle, but use rollers instead of lobes. This reduces friction and wear—and improves low-speed performance, extending the motor’s life. Gerotor and Geroler motors deliver from 10 to 50,000 in.-lb of torque and can operate at speeds up to 2,000 rpm. Because of their simple design and compact size, they can be used in both mobile and industrial applications. However, they are wellsuited for mobile applications—especially agriculture, material handling and construction—because of their incredible power density. The speed and torque requirements of the application will determine the size of motor. This will point users to the what displacement (how much fluid is needed to turn one revolution) is needed. Speed and torque can be determined with the following basic motor equations. These are the starting points for finding the properly sized motor.
3 4 5
• Look for high-quality materials and ensure that inferior materials (with processes like heat treating and form grinding) are not being used. • Compare the warranty options.
Reliability: • Reliability is quality over time. Look for a product with a track record—history is the best predictor of the future.
Support: • Investigate the options for additional support. Would you benefit from CAD modeling support or the creation of a custom solution? Remember that this can differentiate your machine from the competitor. • Do you just want a part or do you want a system of solutions? Some manufacturers can provide a custom system of solutions for your machine, while others specialize in providing a singular part.
Cost: • Obviously cost is very important, but it is really a function of all the previous items. Sacrificing the above items can provide a lower cost, but consider what will happen to your machine (and your customer) when issues arise. • Some companies try to keep costs low by having a “one size fits all” approach to their motor portfolio. This may work for some, but make sure the solution you choose really works the way it should on your machine. FPW
Theoretical torque (in.-lbs) = in. /rev x pressure differential/(2Pi) Theoretical speed (rpm) = gpm x 231 / in.3/rev 3
1 2
Eaton Corp. eaton.com/hydraulics
Here are five things to consider when deciding on the right gerotor or Geroler motor for your needs:
Performance: • Ask for mechanical and volumetric efficiency data, and make sure the test data is over an extended period of time. Some manufacturers may tune performance to peak in the first few hours of operation, but then degrade quickly. Performance that degrades quickly will not do your machine justice. • Compare apples to apples; hydraulic motor performance data is not standardized. Be wary of ratings and test data that do not include all of the performance test parameters.
Discuss This and other engineering topics at www.engineeringexchange.com
Quality: • Does the manufacturer have a history of consistent quality? Ask for the quality data. • Motor grinding is not all the same. Grinding star profiles outside the capabilities of the form grinding machine will cause inconsistent results.
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AD INDEX
ACE Controls .............................. 57 Anderson Metals Corp. .............. 44 AutomationDirect ........................ 1 Beswick Engineering .................. 15 Bimba ........................................... 9 C.matic ....................................... 63 CD Industrial Group ................... 19 Clippard Instrument Laboratory, Inc. ..................... BC CS Hyde ...................................... 56 DEL Hydraulics ............................ 23 Eaton ..................................... 21,36 FABCO-AIR, Inc. .......................... 17 FASTER, Inc. ................................ 61 Flaretite ...................................... 60 FluiDyne Fluid Power ................. 47
Haskel ......................................... 26 Hawe Hydrauliks ........................ 31 HED ............................................. 25 Holmbury, Inc. ........................... IBC Hunger Hydraulics ...................... 37 Hy-Pro Filtration ......................... 41 Hyde Tools, Inc. .......................... 60 HydraForce ................................... 5 Kawasaki Precision Machinery (U.S.A.) Inc. .......... 45 Kocsis Technologies, Inc. ............ 13 Lillbacka USA, Inc. ...................... 53 Main Manufacturing Products ..... 4 Minnesota Rubber & Plastics ..... 12 MP Filtri USA Inc. ......................... 3 Muncie Powers Products ........... 55
Panagon Systems ....................... 29 Peninsular Cylinder .................... 43 PHD Inc. ...................................... 52 Prince Manufacturing Corp ....... 27 RYCO Hydraulics, Inc. ................. 46 Servo Kinetics, Inc. ..................... 58 Smalley Steel Ring Company ...... 10 Super Swivels ............................... 2 Tompkins Industries, Inc. ....... IFC,4 Trelleborg Sealing Solutions ....... 51 Veljan Hydrair Inc. ...................... 42 WAGO Corp. ............................... 59 Yates Industries, Inc. .................... 7
LEADERSHIP TEAM Co-Founder, VP Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memic Co-Founder, Managing Partner Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty
EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson
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