Easy hose and fittings maintenance p. 26
Hydraulics in waste management p. 38
IoT pneumatics simplifies food and beverage p. 42
www.fluidpowerworld.com
April 2020
Hydraulics harnesses offshore wind PAGE 32
New Year, New Quality Enclosures In your choice of stainless steel, aluminum and carbon steel
As if AutomationDirect’s already-wide selection of quality enclosures wasn’t enough, we are proud to announce the addition of stainless steel, carbon steel and aluminum enclosures from another top quality manufacturer, Hammond Manufacturing. Along with AttaBox, Integra and Hubbell-Wiegmann lines, the new Hammond Manufacturing additions provide you with a choice of almost 4,500 top-notch enclosures, all at great prices. Carbon Steel Enclosures starting at:
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•Indoor / outdoor use •One piece foam gasket •Sturdy hidden hinges allow 130° cover opening and include removable hinge pins for easy door removal •Liquid channeling flanged trough collar encircles door opening •Materials available include stainless steel and carbon steel •Models available in ANSI 61 gray smooth finish, textured RAL 7035 light gray, RAL 9003 white, and brushed stainless steel •Galvanized steel inner panel with superior grounding is included in some models •Accessories include swing-out panels, 19” rack mount swing frames, and DIN rail kits •Models with 1/4 turn latch or handle systems are available •NEMA ratings of 3R, 4, 4X, 12, and 13, and also IP66 approvals •Available sizes range from 12” x 10” x 6” up to 72” x 36” x 12”
Also Available Hubbell-Wiegmann, Integra and AttaBox Enclosures
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Order Today, Ships Today! * See our Web site for details and restrictions. © Copyright 2019 AutomationDirect, Cumming, GA USA. All rights reserved.
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FLUIDLINES Mary C. Gannon • Editor
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and I juggling three full-time jobs — mom to three very active girls, teacher and editor — I am reminded of some wise words of advice that my girls’ teachers have reiterated since they were in preschool. Children need a routine and consistency throughout their days, when in school or not. That routine has become critical now as they work through days without a bell telling them when to get to their next class. But I also see this need for the routine in our daily lives, too, as we face the crisis brought on by COVID-19. As the world comes to grips with COVID-19, the pandemic that’s sent many of us to remote working from home, we at Fluid Power World continue to bring you the best knowledge from experts and leaders in the industry. We’re sharing their stories about how they are working through this crisis and helping solve many of the emergency roadblocks that we face to keep our medical personnel safe and patients healthy. What we’ve learned from most fluid power manufacturers is that they are essential businesses, providing the pneumatics used in ventilators, seals used in medical devices and more. In our Hack the Crisis series, readers can learn about how fluid power manufacturers — almost all considered essential businesses — are responding to the complications of remote working, social distancing, and for many, needing to ramp up production on key technologies. Clippard in Cincinnati, for example, is looking to hire up to 75 people to ensure it can meet the demand for its critical components and subassemblies for ventilators, diagnostic equipment, and other critical care devices to help fight the Coronavirus. Emerson’s AVENTICS and ASCO brands are also increasing production of key pneumatics technologies for breathing technologies, by using shift 2
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schedules at its plants around the world to ramp up production. Sealing manufacturers, such as MFP Seals and Precision Associates are also deemed essential technologies to key medical device manufacturers. MFP Seals said its machine operators are working hard to meet the demands of COVID-19 related parts that they are designing and manufacturing (or adapting someone else’s design with its injection mold and CNC machines). Precision Associates is also ramping up its production of several essential rubber components for ventilator manufacturer Ventec Life Systems. Ventec recently announced plans to partner with GM to increase the output of these crucial units in response to the COVID-19 pandemic. And even on the non-medical side, fluid power manufacturers are realizing just how essential they are. For example, Yates Industries learned quickly that as a supplier to essential businesses, they needed to maintain their operations. The company has switched to remote work where it could and limited manufacturing staff to ensure social distancing guidelines are in place. We’re sharing these and many other stories of fluid power companies in our Hack the Crisis series, found on our website (and our sister publications’ sites as well), under a special COVID-19 tab. We hope you enjoy learning how our industry is working to keep the world moving and safe. And if you have stories to share, we’d love to hear from you. Because even though we’re all in home offices now, we are still committed to bringing you the best technical content available for fluid power system design engineers and users. FPW
Mary C. Gannon Editor mgannon@wtwhmedia.com On Twitter @DW_marygannon www.fluidpowerworld.com
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FROM THE FIELD Paul J. Heney • VP, Editorial Director
Komatsu focusing on smart hydraulic control At this year’s CONEXPO-CON/AGG and IFPE shows in Las Vegas, Komatsu unveiled a suite of new products, under the theme of “creating connections.” Many of the company’s new products boasted more intelligent hydraulic systems and advanced hydraulic control. So, I asked Rich Smith, VP of Products and Services for Komatsu North America about how the company looks at hydraulic technology moving forward over the coming years. “When we look at hydraulic technology, you still have gear pumps, swash plates, and things like that, but it really comes into the controlling of those systems. Komatsu’s been innovative throughout our history in hydraulic controls. There’s a lot of things that you can do that move towards fuel savings. Something as simple as — when you are raising a dump body on a bed, there’s an optimum speed that you should have the engine at, and anything over that you’re just wasting fuel. When you’re digging with an excavator and if you get to a point where you’re just over relief, why would you continue over relief?” he said. “It’s looking at those types of situations to optimize the load factor on the machine with what the hydraulic system is putting out,” Smith explained. “And if you look at the WA475 [the company’s new wheel loader] with the hydro-mechanical transmission, I think you’ll see where our technology is utilizing hydraulic in conjunction with more typical transmission technologies to give us significant improvements in productivity and fuel efficiency.” “I think the last aspect there is looking at doing something that we do with our HB365 hybrid, which hybrid technology and excavators used to be just to take the swing. You capture in an ultra-capacitor, then you would use that in the swing. We’re now taking some of that and moving that into the hydraulic system to also improve lift and dump speed. So, you can combine these technologies together to get the best effect for the customer,” he said. Some of Komatsu’s new equipment includes: The WA475-10 wheel-loader is newly designed with next-generation technology, developed from extensive customer feedback. Its engine has 22-hp more than the WA470-8 model, but with the Komatsu Hydraulic Mechanical Transmission, it achieves up to a 30% increase in fuel efficiency. KHMT dynamic braking also reduces brake wear. This PC130-11 conventional tail swing excavator on preview is built to be easily transported from job to job, so is a great choice for utility work or small construction jobs. Equipped with the Komatsu 4
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4 • 2020
closed-center hydraulic system, the 28,660 lb (13,000 kg) PC130-11 has fast loading cycles and high productivity. The D71PXi-24 is the industry’s newest and largest intelligent hydrostatic transmission dozer with advanced intelligent machine control. Its proactive dozing control can operate automatically 100% of the time, and its lift layer control automatically spreads fill from the existing terrain with the press of one button. The D155CX-8 pipelayer provides an alternative, stable pipelayer. Designed in conjunction with pipeline companies, the D155CX-8 received high marks from pipeline contractors during field evaluations. Easy to transport, the Tier 4 pipelayer has a 170,000-pound rated lift capacity and an oval track undercarriage that was designed for stability. Its front/rear and left/right weight distribution and long 12 ft 10 in. (3925 mm) track on ground, improve stability for pipeline work, especially when working on adverse grades. The WA800-8 wheel-loader has completely redesigned front and rear frame and loader linkages, with the most durable chassis in model history. Designed to load 60-100 ton haul trucks in quarry, aggregate, and mining applications, the WA800-8’s automatic dig, semi-automatic approach, and semi-automatic dump systems can be used together or separately to automate the work phases when v-cycle loading haul trucks.
www.fluidpowerworld.com
FPW
Paul J. Heney
VP, Editorial Director pheney@wtwhmedia.com
On Twitter @wtwh_paulheney
Water Removal Technology Remove particulate and water contamination improving system reliability and efficiency Dramatically extends oil and hydraulic component life Reduces the chance of catastrophic failure Reduces replacement part costs, maintenance costs and associated downtime Lowers energy consumption Increases equipment performance and improves machine productivity Improves environmental impact with reduction in waste products
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PASSION TO PERFORM
APRIL 2020
C ontents |
vol 7 no 2
|
fluidpowerworld.com
•
4
•
2020
F E AT U R E S OFFSHORE FEATURE
Hydraulics harnesses offshore wind A new hydraulic powertrain may pave the way for reliable and economical mega wind turbines.
32
WASTE MANAGEMENT
Hydraulics bring reliability and strength to waste management Hydraulic cylinders and valves are common on refuse machinery, as they bring the rugged power for controlling, lifting, filling, compacting and dumping in the many types of refuse vehicles used.
PNEUMATICS
Pneumatics: the go-to for food and beverage processing IoT-enabled pneumatic technologies ensures clean and reliable food and beverage design.
38 42
D E PA R T M E N T S
02
FluidLines
04
From The Field
08
Korane’s Outlook
10
Association Watch
14
Design Notes
22
Fundamentals
26
Maintenance
28
Training
30
Energy Efficiency
48 Products 55
Component Focus
56
Ad Index
A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e
2019
ON THE COVER
The hydraulic Hydrautrans Drive Train overcomes many of the weight and cost issues associated with common offshore wind turbine installations. | courtesy of Adobe Stock
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SILVER SILVER NATIONAL NATIONAL AWARD AWARD 2018 asbpe.org
b
APRIL 2020 • vol 7 no 2 • www.fluidpowerworld.com
MAIN MANUFACTURING PRODUCTS, INC EDITORIAL
DIGITAL MARKETING
PRODUCTION SERVICES
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Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon
Digital Marketing Coordinator Josh Breuler jbreuler@wtwhmedia.com @wtwh_joshb
Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane
Webinar Coordinator Halle Kirsh hkirsh@wtwhmedia.com Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com EVENTS
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FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2020 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. SUBSCRIBER SERVICES: To order a subscription please visit our web site at www.fluidpowerworld.com FLUID POWER WORLD (ISSN 2375-3641) is published seven times a year: in February, April, June, July, August, October, and December by WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Fluid Power World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114
4 • 2020
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PRINT PRODUCTION
HYDRAULIC FLANGES AND COMPONENTS
7
www.MAINmfg.com/flg Phone: 800.521.7918 info@MAINmfg.com Grand Blanc, MI USA
KORANE’S OUTLOOK Ken Korane • Contributing Editor
Ingenuity in the face of a pandemic As COVID-19 spreads worldwide, there are critical concerns that hospital ICUs won’t have enough ventilators on hand to help the most seriously ill patients breathe. Medical-equipment manufacturers have ramped up production of these machines. Firms like Dyson, Ford and Tesla are stepping in to help. General Motors is retooling a plant to deliver 30,000 units by August. However, it’s not that easy. Ventilators used in the U.S. are sophisticated, highly engineered and cost from $5,000 to $50,000 each. And they are built with hundreds of specialized components from a wide range of suppliers — many of whom are offshore, short staffed or currently dealing with their own supply chain issues. In what may be a pragmatic alternative, students at Rice University’s Brown School of Engineering have created an economical device from off-the-shelf parts that supplies hospital-grade ventilation. The fundamentals of ventilators are pretty basic: they mechanically push air to open up the lungs and get more oxygen to the patient. Last year, a student team at Rice’s Oshman Engineering Design Kitchen (OEDK) crafted a machine to do just that by
automating the compression of simple bag valve masks. A BVM consists of a flexible bladder that’s attached to a face mask. Squeezing the bag forces air through a one-way valve and into the lungs of intubated patients. They are routinely carried by emergency medical personnel, and more than 100 million BVMs are manufactured around the world each year. But squeezing by hand is tiring in just a few minutes. The automated system can do it for hours. The unit’s “compressor” is a motor driven rack-and-pinion mechanism with attached paddles that cyclically squeeze the bag. The students thought the device might be useful in low-resource hospitals in developing countries. Fast forward a year and with COVID-19 raging, requests are pouring into the university seeking plans for the prototype. Staff at OEDK quickly upgraded it into the ApolloBVM, a more-robust unit that’s medical grade. Most of its components are readily obtainable through online retailers and hardware stores like Amazon, McMasterCarr, Mouser and Servo City. Total cost is less than $250, a price tag significantly lower than that of even entry-level commercial ventilators. Hundreds of clinicians and manufacturers from more than 50 countries have requested information about the project and opensource plans have been posted online. The Dept. of Defense is reported to have expressed interest. With ongoing spread of coronavirus and a looming shortage of ventilators, ApolloBVM could help patients who are less-critically ill while they await availability of a standard hospital ventilator. “The immediate goal is a device that works well enough to keep noncritical COVID-19 patients stable and free up larger ventilators for more critical patients,” said Amy Kavalewitz, executive director of OEDK. It’s been successfully tested with an artificial lung and clinical trials with human patients are imminent. OEDK is also working with manufacturers to ramp-up production. Deep down, everyone hopes these devices will never be needed. But these aren’t normal times, so planning for the worst-case scenario is warranted. Whether the ApolloBVM helps save lives or, in the end, just collects dust, the positive results can’t be overlooked. The student project has involved plenty of creativity and teamwork under pressure to meet critical deadlines, not to mention honing design-engineering and code-writing capabilities and mastering the latest manufacturing techniques. These are all highly sought-after skills any employer would embrace as we emerge from this crisis. FPW
The ApolloBVM is made from off-the-shelf parts and supplies hospital-grade ventilation. | Mike Williams, Rice University Public Affairs
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www.fluidpowerworld.com
www.DMIC.com
1-800-248-DMIC
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HBL - Hose Barb To Male Thread BSE - Hose Barb To Male Thread 90 Deg EBS - Hose Barb To Male Thread 45 Deg
BV3D Actuator
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BVALP - Low Profile Suction Ball Valve
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SWFH61 - Split Flg Head To Weld
SWBARB - Hose Barb To Weld
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BVH - High Pressure Ball Valve
FCHH - Flow Control
SSW - Swivel Socket Weld FSW - Fixed Socket Weld
BVLS - Stainless Steel Ball Valve
COMPANION FLANGES FMC - C.61To Male Thread SFC - C.61 To Male Thread 90 Deg ESC - C.61 To Male Thread 45 Deg
SWEL90 - Weld Elbow 90 Deg SWEL45 - Weld Elbow 45 Deg SWEL90SR - Short Radius Weld Elbow
330 Vansickle Road – Unit 4 St. Catharines, ON, L2S 0B4 1-800-320-DMIC (3642) Phone: 905-688-3642 Fax: 905-688-9993
ASSOCIATION WATCH Edited by Mike Santora • Associate Editor
NFPA’s Global Market Report Update NFPA’s Global Market Reports and Forecasts are a collection of monthly and quarterly global market reports that will allow readers to investigate
U.S. highlights •
every angle of the global marketplace. Prepared by Oxford Economics, these reports are an exclusive benefit for all NFPA members. Non-members are encouraged to join NFPA
•
to access the full reports. Highlights are below.
Global highlights •
•
•
The rapid spread of the coronavirus, and the associated isolation policies implemented to contain the outbreak, has led to a significant disruption in economic activity. Services activity has seen the brunt of the impact, but manufacturing has also been hit. Global manufacturing output is expected to remain weak in Q2 before a swift rebound is seen in the second half of this year as the spread of the virus slows and isolation restrictions are eased, leading to the release of pent-up demand as business confidence increases. The oil market is still reeling from a severe demand and supply shock. For now, we assume that oil prices remain low enough for long enough to force significant cutbacks in U.S. production.
•
•
•
•
•
Industrial production (manufacturing, extraction, and utilities) is forecast to lag economic growth in 2020, falling by 2.3%, picking up to 5.2% growth in 2021. Manufacturing output is expected to contract 2.7% in 2020, driven by a decline in the motor vehicles and parts sector. In 2021. Manufacturing output is forecast at 6.1% growth, again driven by growth in the motor vehicles & parts sector. Extraction output is expected to fall 1% in 2020, driven by a decline in the non-fuel extraction activities sector. Next year, extraction output is forecast at 1.1%, driven by the oil and natural gas extraction sector. Construction output is expected to increase by 0.5% in 2020 and 3.6% in 2021. The service sector is expected to expand 0.2% in 2020, driven by growth in the healthcare and social work sector. In 2021, service sector output growth is forecast at 3.9%, driven by growth in the other business services sector. The value of industrial production in 2019 was US$3,055.6bn at 2015 prices. Within this, the largest sectors were utilities (US$322.2bn), food (US$279.4bn) and chemicals excluding pharmaceuticals (US$231.7bn). Over the next decade industrial production is projected to remain broadly stable as a share of GDP, and fall as a share of global output, as growth in developed economies is forecast to lag that of the emerging markets. The fastest growing industrial sectors over the next decade are expected to be high-tech goods, pharmaceuticals and other transport equipment. The slowest growing sectors are expected to be wearing apparel and furs, leather goods and textiles. FPW
NFPA | nfpa.com
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www.fluidpowerworld.com
NAHAD, FPDA staying connected digitally Seven12 Management is a professional management firm that specializes in helping associations like NAHAD and FPDA run their organizations. Programs often include in-person meetings and events but recently, the global pandemic has also brought digital services to the forefront.
With associations’ need to stay connected to members from a distance, webinars now look to be more popular than ever. Seven12 Management has been providing these services for a while, and it looks like interest is only going to increase in the near future.
For example, NAHAD’s recent webinar, Take Advantage of Federal Resources to Help Your Business, covered new CARES Act requirements for employers. The webinar helped show companies how to handle paid sick and family leave, opportunities for federal forgivable loans, and changes to help with cash flow as the economy moves into a temporary slowdown. Additionally, programs like FPDA University offer two ways to train employees —Assessment Testing and Technical Training which cover specific industry content for hydraulic, pneumatic, electromechanical, automation or sales.
Both organizations are providing COVID-19 resources as well. Visit nahad. org and fpda.org for more details on both organizations’ many offerings. FPW
ASSOCIATION WATCH
IFPS offers update on available programs With social distancing measures and stay at home orders keeping everyone in place, IFPS Executive Director Donna Pollander suggests that now might be a great opportunity to hit the books. “By now, we should all be very aware to socially distance ourselves from others. To ‘embrace this new-norm,’ the IFPS is launching a number of new initiatives for industry professionals,” Pollander said. “This could be a perfect time to start preparing for a certification test or gathering recertification professional development points.” The following are some of the resources IFPS is making available. New – Free Online Certification Study Groups – Every Tuesday and Thursday, an IFPS Accredited Instructor will lead a one-hour, free, online study group in the Hydraulic Specialist and Pneumatic Specialist Certification Study Manuals. You’ll need a study manual (print or pdf) to participate properly. A list of many of these programs can be found on page 28. Members may download study manuals free on the IFPS website. Non-members may purchase a study manual flash drive (or a print copy) or become an IFPS Member and download a free copy. You can also register for a Specialist Certification Test with a “to be determined” test date and receive a free downloadable study manual. Certifications expiring in 2020? – The IFPS is granting all recertifications a six-month graced period.
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www.fluidpowerworld.com
Upcoming Web seminars – The IFPS is waiving the registration fee for all upcoming Web seminars. This could be a perfect time to get those recertification points you’ll need when it’s time for you to recertify. See page28 for more details. Certification test candidates – Pollander also stated that she has notified upcoming certification test candidates with instructions on how to reschedule their tests. The IFPS will waive all reschedule fees until December 31.
FPW
IFPS | ifps.org
QUALITY HYDRAULIC HOSE & ACCESSORIES
Equipment manufacturers call for national manufacturing strategy
Kuriyama Hydraulic Connections Catalog • Includes new Alfabiotech extra flexible and bio oil resistant hydraulic hoses. • New Flexor TR4XF extra flexible SAE 100 R4 oil return hose.
The Association of Equipment Manufacturers (AEM) is calling
Quick Release Couplings
on the federal government to develop and implement a comprehensive national strategy for manufacturing to strengthen the economy, create new jobs and opportunities, and ensure the United States is the best place in the world for equipment manufacturers to innovate, manufacture, and do business.
THE ASSOCIATION FOR HOSE AND ACCESSORIES DISTRIBUTION
EDITION 1017
To confront both the short-term and the long-term challenges facing the equipment manufacturing industry, AEM is urging the U.S. Congress and the Trump administration to develop and implement a national strategy to revitalize America’s manufacturing sector and ensure that the country remains the global manufacturing superpower. Specifically, AEM is urging the federal government to consider the following: •
•
•
Kuriyama Hydraulic Quick Couplers Catalog • For fast and easy connections of hydraulic hoses. • Made from high strength carbon steel with chrome-III zinc plating. • Ideal for agricultural machinery and industrial equipment.
The creation of a national institute that would serve as a hub for all federal manufacturing programs in the executive branch and coordinate federal manufacturing policy across agencies; The establishment of a Chief Manufacturing Officer reporting directly to the President of the United States and responsible for developing and carrying out the national manufacturing strategy. The formation of a National Manufacturing Council to provide non-partisan advice to the President on how to strengthen the manufacturing sector and ensure the future competitiveness of U.S. manufacturing in the global economy.
Piranhaflex™ Non-Conductive Hydraulic Hoses • Series PF267NC has improved flexural rigidity offering increased flexibility for medium pressure hydraulic oil and lubrication lines. • Series PFLT364 for medium pressure Hydraulic lines for fork trucks in cold storage applications. • New P400 Portable Service hose crimper.
FPW
AEM | aem.org
Phone: (847) 755-0360 | Fax: (847) 885-0996 360 E. State Parkway • Schaumburg, IL 60173 sales@kuriyama.com www.fluidpowerworld.com
4 • 2020
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DESIGN NOTES Mary C.byGannon • Editor• Associate Editor Edited Mike Santora
Varnish removal cleans up plastic injection molding Hydraulic fluid is one of the most important components in an injection molding machine, which is why contaminated fluid cannot be overlooked. 80% of all hydraulic failures are caused by contaminated fluid. The common types of contaminants are solid particles and water, but varnish is just as destructive for hydraulic systems. 14
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The constant pressure and temperature fluctuations of the hydraulic fluid can lead to mechanical and thermal stress of the fluid. This instability results in a breakdown of oil molecules leading to the creation of a sticky residue (varnish by-products). This residue, combined with other contaminants, can cause friction and wear, which can shorten component oil life and cause unnecessary downtime of the system. Additionally, the forming of varnish can be accelerated by a chemical reaction between metal solid particles and water. This reaction results in corrosion of the components, changes in fluid properties, and oil degradation.
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Using a RMF varnish removal system from Des-Case improved uptime in an appliance manufacturer’s plastic injection molding machine.
A large appliance manufacturer in the United States reached out to DesCase regarding an increase in unplanned maintenance, blocked line filters, and frequent oil changes on their Toshiba plastic injection molding machine. All of these symptoms were in line with severe varnish problems and was further confirmed by an oil lab analysis. The results of the test showed a Membrane Patch Colorimetry
(MPC) value at a critical level of 63.4 and an ISO cleanliness level of 25/20/14. To solve the varnish problem, Des-Case offered its RMF Varnish Removal System, which acts as a kidney loop, continuously pumping fluid through the high-efficiency varnish removal cartridges. The Varnish Removal System combines varnish removal with oil quality monitoring and prevents varnish from forming by www.fluidpowerworld.com
removing solid contaminants and water. The Long Fiber Cellulose/PP cartridges are specially designed for the removal of varnish by-products which are dissolved in the fluid. These cartridges adsorb polar acids through special compacted fibers, which create an intricate internal flow path. Unlike other technologies, the cartridges do not add water to the fluid. They remove water and other solid contaminants. 4 • 2020
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DESIGN NOTES
During the operation time of the system, samples were taken frequently and sent to a laboratory for analysis. Next to a standard fluid analysis, an MPC and gravimetric solids (MPC weight) test was done to measure the varnish potential. After three weeks of filtration, the varnish potential (MPC value) went from a critical level of 63.4 to 7.8, and the MPC weight decreased from 0.0182 to 0.0072 g. In the following five weeks, the MPC dropped even lower to 1.6 and weight down to 0.0038 g. The ISO cleanliness levels also dropped from 25/20/14 to 17/14/11 in three weeks. Five weeks after that, the ISO code dropped even further to the target level of 15/13/10. As the data shows, the cleanliness and health of the lubricant improved significantly in a short time and will improve the uptime of the machine.
Long fiber cellulose/PP cartridges in Des-Case’s Varnish Removal System are specially designed for the removal of varnish by-products which are dissolved in the fluid.
FPW
Des-Case | descase.com
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VALVE ASSEMBLY & TESTING
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DESIGN NOTES Edited by Ken Korane • Contributing Editor
New design overcomes piston-pump limitations Piston pumps and motors have been on the market for many years, and they are arguably one of the most important components in many a hydraulic circuit. The basic design behind a conventional piston pump usually has seven or nine pistons that convert mechanical torque into oil pressure. In a piston motor, the process is reversed. Every project engineer has, without a doubt, experienced the limitations of piston pumps and motors: high-pressure ripple, and less-than-desired mechanical
AX fixed displacement piston pumps and AXM motors are available in multiple sizes with displacements from 18 to 76 cc/rev.
and volumetric efficiency, according to officials at Bucher Hydraulics, Elgin, Ill. In addition, the growing demand for electrically powered machines has exposed additional drawbacks such as noisy operation and minimum shaft speeds that must be fairly moderate when working at high pressure. Applications that face the need for faster cycle rates, increased operating pressures, more-responsive dynamics and accurate flow and pressure control have already been handcuffed by the shortcomings of current piston pumps. Engineers normally compensate for these restrictions by using accumulators and valves with associated high energy losses and additional costs. For these reasons, Bucher Hydraulics is introducing a new series of pumps that overcomes the limitations of conventional piston technology. Company officials say it is not just a further evolution of existing pump concepts, but rather it is a revolutionary design that offers better efficiency, excellent dynamics, low noise, and low minimum speed at high output torque. The new AX piston pump and AXM piston motor work on the principle of
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DESIGN NOTES
Tests show an 80% reduction in pressure pulsations in an AX size-24 pump running over 1 rev and 400 bar, compared to a conventional bent-axis pump.
balancing internal forces by having two rotating barrel plates facing each other, and each having 12 pistons. Thus, the units achieve a high power density all while limiting the axial forces, which need only a light bearing to handle the loads. The models come in displacements from 18 to 76 cc/rev, and the company plans to extend the range up to 115 cc/ rev in the near future. Maximum operating speed for the units is 3,600 rpm.
Sights on electrification
The characteristics of the Bucher Hydraulics AX pump were developed with a particular focus on construction machines powered by electric motors. The high volumetric The large, non-compensated forces in typical bent-axis motors need to be absorbed by extra-large ball or roller bearings. This increases the space required and makes integration into a machine more difficult.
and mechanical efficiency, low noise, lowpressure ripple, and minimum permissible speed of only 2 to 3 rpm, together with the possibility of bidirectional operation, make the AX pump well-suited for electrical and hybrid machines of the future. For example, because as there is virtually no minimum speed limit, they are ideally suited for matching fixeddisplacement AX units with variable-speed electric drives. Further, this high level of efficiency in electric-drive mobile machines is essential, as low power losses mean valuable battery capacity can be conserved. Likewise the AX pump, with a balanced design and more pistons, produces a low pressure ripple and generates minimal noise over a wide range of speeds and pressures. In contrast, conventional axial-piston pumps produce considerable noise as alternating and widely fluctuating internal pump forces result in housing vibrations that ultimately transmit to the machine. When traditional hydraulic pumps are used with diesel engines, the problems of physical pulsation are barely
noticeable. In inherently quiet electric-drive applications, that’s no longer acceptable. The advantages offered by these models also come into play in winch applications. Winch operations, in general, are problematic because torque-ripple issues can hurt performance. Efficiency at start-up can be poor. And high-pressure performance can be poor at low rotary speeds. Standard AX pumps and motors can reach a working pressure of 450 bar. And with a low-speed range of just a few rpms, the AX motor has a starting efficiency of 99% versus the 60 to 65% of a conventional axial-piston unit. Performance can significantly increase thanks to precise and accurate crane movements. Crane slew drives can take advantages of these attributes, too. Other industry applications can also benefit from the Bucher AX hydraulic pumps and motors characteristics of excellent energy efficiency and performance when the unit must start and run slowly under high load and pressure. In wheel motors, for instance, high power density and working pressure coupled with low permissible speed make the AXM motor the perfect alternative to gear motors. The minimum speed of 2 rpm brings new possibilities to mobile machines. New software lets engineers conduct multiple iterations during the design phase, offering several options in different and lower gear ratios. For straight travel in vehicles such as crawler excavators, the volumetric efficiency of approximately 96% will permit an increase in ground speed. FPW
Bucher Hydraulics bucherhydraulics.com
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DESIGN NOTES Edited by Mike Santora • Associate Editor
Mechanical joining tools for secure, leak-proof joints Monaghan Tooling Group’s Mechanical Joining Tools join tubing to flanges and fittings to create secure, leak-proof joints that withstand up to 20,000 lb of hydrostatic pressure. Superior to welded, brazed, or crimped joints, mechanically joined parts will not leak, pull apart, or loosen from pressure, vibration, or temperature changes. This proven method allows joints to be rolled to a torque or diameter spec. Rolling to a torque ensures consistent results, regardless of tolerance and variations of the tube OD, wall thickness, and component ID. Rolling to a consistent diameter guarantees a consistent ID of the tube, which makes it possible to “iron out” and round up the ID of the tube. Any annealed or ductile product can be mechanically joined, including mild steel, stainless steel, aluminum, titanium, copper, cupronickel, Inconel, and more. Monaghan Mechanical Joining Tool (MJT) is suitable for applications where joints loosen due to changes in temperature, altitude changes, vibration, and where high pressure is present — including those common in the automotive, fluid power, and aerospace industries.
How it works
A tube is inserted into the flange; then, a mechanical joining tool is inserted into the tube. A generous chamfer or radius should be provided on the backside of the flange. The opposing end should include a shoulder that the tube can bottom out against The Monaghan Mechanical Joining to ensure proper position. Flange grooves with sharp Tool (MJT) is suitable for applications corners at the top edge and where joints loosen due to changes the bottom of the groove in temperature, altitude changes, are required. The width of vibration, and where high pressure is the groove can be 0.062 to present — including those common
0.375-in. (1.6 to 9.5mm), with depths from 0.005 to 0.0320-in. (0.13 to 0.81 mm) — both dimensions are dependent on flange width, thickness, and the hardness of the tube. When the tube has been rolled to about 25% of total MJT expansion required, it makes metal-to-metal contact with the flange. At approximately 50% MJT expansion, the tube metal begins to flow into the grooved serrations of the flange. When the Mechanical Joining Tool is completely expanded, grooved serrations are now filled to the predetermined groove fill percentage of the tool. (Groove fill percentages vary by industry as well as applications.) Once the correct joint has been completed, the rotation of the tool is reversed so that it can be extracted from the assembly and the cycle can be repeated with new components. Monaghan MJT is suitable for a variety of applications, including hydraulic fittings, fitting and block assemblies for hydraulic components, hydraulic lines, tube installation into transmissions, differentials on large equipment, and all types of fluid lines in aircraft. Monaghan engineers are available to assist with tooling selection and other aspects of the mechanical joining process. Monaghan Tooling Group provides the engineered tooling and services, including application-related consulting, to solve machining challenges. They have partnered with standard and custom tooling manufacturers including Elliott Tool Technologies, Diatool, UC Tools, RE-AL, MK-Tools, Reamtec, and Axis, to address the challenges of precision metal finishing and high-performance cutting. FPW
Monaghan Tooling Group | monaghantooling.com
in the automotive, fluid power, and aerospace industries.
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DESIGN NOTES Edited by Ken Korane • Contributing Editor
Vacuum lifting systems maximize safety Vacuworx, Tulsa, Okla., manufactures innovative heavy-duty material-handling systems based on hydraulic-powered vacuum lifting. The equipment is used in the oil and gas, water and sewer, highway and heavy construction, concrete construction, landscaping and manufacturing industries.
The adapter includes a flow-control block for easier adjustment of hydraulics.
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The company announced at Conexpo/IFPE that it has engineered significant updates to its line of RC series vacuum lifting systems. All changes are designed to maximize safety while minimizing down time on the job. In addition, the lifters are “smarter” than ever before by incorporating a CAN bus system to provide real-time diagnostics and enhanced safety features. Although the installation for RC series lifters is said to be quite simple, Vacuworx engineers have made several enhancements to the adapter (the part that connects the lifter to the host machine, such as an excavator) which improve the process. The adapter now features removable top caps, which lets an installer position and secure the adapter pin easily. Standard pin size is 110 mm, but the adapter will also accommodate pin sizes down to 50 mm using bushings. Vacuworx also offers an adapter for 120 mm pins and larger. A flow control block has been incorporated into the adapter to allow for safer and more convenient adjustment of the hydraulics. This puts the flow controls within easy reach, rather than higher up on the arm of the excavator. In addition, the part of the adapter that connects to the base plate on the lifter, referred to as the “tombstone,” is now a replaceable part of the assembly rather than being welded to the adapter. This is designed to minimize time and overall cost of repairs. In a similar vein, the traditional gear box has been replaced with a belt drive. This will provide longer service life and drastically reduce repairs, said company officials. The belt drive requires virtually no maintenance and is environmentally friendly with no oil to replace. In addition, the system design keeps engine bay temperatures cooler. Vacuworx has also implemented CAN bus technology for its vacuum lifting systems. Commonly used in passenger vehicles and other equipment, a Controller Area Network (CAN bus) lets internal www.fluidpowerworld.com
CAN bus gauge shows pressure levels and error codes.
devices communicate with each other without a host computer. Using a central logic controller, the system is designed to monitor for faults and quickly diagnose specific problems. The new dashboard gauge on one side of the lifter shows error codes, oil and fuel levels, pressure level, number of lifts and engine hours. The logic controller increases safety by ensuring that the electronic components are operating correctly. The simplified wiring design of the system has fewer components and no mechanical switches. The system incorporates pressure transducers instead of a vacuum switch for greater accuracy. All circuits can be monitored and diagnosed through the logic controller. There are no fuses to repair or replace — all faults are reset electronically. In addition, the design helps promote safety by identifying any incorrect repairs or environmental damage. FPW
Vacuworx | vacuworx.com
HYDRAULIC TEST POINT ADAPTERS • Safe and simple connection of pressure gauges • Bleed trapped air from the system • Draw fluid samples for analysis • Reduce system contamination
Contact us for more details: Toll Free 866 FLANGES | anchorfluidpower.com | sales@anchorfluidpower.com www.fluidpowerworld.com
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FUNDAMENTALS Josh Cosford • Contributing Editor
Hydraulic Symbology 203 — Pressure valves In Hydraulic Symbology 101, I covered the basic square used for pressure valves and also showed the most stripped-down versions of the two most commonly used pressure valve symbols, the relief valve and the pressure reducing valve. In this edition of Hydraulic Symbology, I’m going to cover the four primary pressure valves; the relief valve, motion control valve, sequence valve and reducing valve. Each is based on the same square symbol but are used quite differently in both circuits and real-life function.
valve closed with 3,000 psi of force, and in this circuit, it acts as the maximum limit pump pressure can achieve before being exhausted to tank.
Shown below are the quartet referenced from the same angle as each other. Each shows the basic square with a vertical arrow, abreast of a pilot line to the left and a spring to the right. The dashed line stands for a pilot signal, which is a fluid column of pressure energy used to push or act upon other components internal to the valve. The relief valve is normally closed (nonflowing). As pressure rises in the bottom port, energy pushes around to the pilot line to the left, but the valve is still closed. As the pressure continues to increase, the force pushing against the left side of the arrow starts to overcome the spring force applied from the right. When pilot pressure creates enough force, it can overcome spring pressure to slowly open the valve.
Springs are drawn to signify force being applied inwards and in the case of these symbols that force is to the left. The relief valve spring can be set as weak or strong within its allowable range by loosening or tightening its screw adjustment. The weaker the spring compression, the easier pilot pressure can force open the valve. As previously mentioned, the diagonal arrow depicts adjustability, and most pressure valves are adjustable. The example shows a circuit with all four types of pressure valves used. It looks like a lot going on, but I’m going to break them all down one by one so they make sense. The relief valve teed into the right after the pump is drawn just as the relief valve above, and it operates under the same principle. The spring is pushing the 22
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Sequence valves are not much different from relief valves, and this is at once obvious by their similar appearance. This sequence valve downstream of the pump is exactly the same as the relief save for the drain line and reduced pressure setting. A sequence valve is purposed to provide a secondary flow path which occurs in sequence to a parallel function. In other words, when the cylinder in this application extends to the end of stroke, pressure will rise immediately. When pressure hits 2,000 psi, our sequence valve opens, diverting all pump flow to rotate the motor while the cylinder remains stalled and as long as its directional valve remains energized. The sequence valve drain line is required to keep the valve’s performance consistent. Because the sequence valve experiences pressure on both ports, internal leakage allows pressure buildup inside the spring chamber which is additive to spring pressure.
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Without a drain, the pressure setting could rise or the valve could even lock up altogether. The key difference between a sequence valve and relief valve is the existence of this drain. A sequence valve makes an outstanding relief valve, in fact. The pressure reducing valve is plumbed in just past the directional valve in the B-port. You’ll notice immediately how different this valve is than the others, and the extra astute will have noticed two differences, actually. The pilot line is drawn differently, this time showing its pressure signal originating downstream of the valve. This important contrast allows the valve to reduce downstream pressure to protect the actuator or sub-circuit beyond. The reducing valve also differs in that it is normally flowing in its neutral state. Fluid is free to pass and allow the motor to spin, and not until downstream pressure from the motor rises to above the 1,700 psi setting of the valve does it start to close. The pilot line senses
downstream pressure and starts to move the arrow to the right, choking flow to the motor. This reduced flow also reduces pressure, but it does so smoothly and with little drop in velocity. The effect is that downstream pressure is simply reduced. You’ll notice in this example, there is also a check valve allowing flow to bypass the reducing valve altogether. This ensures the motor will experience little or no backpressure when it rotates in the opposite direction. Sometimes the reverse-flow check valve is not required, but it makes for good practice. The last pressure valve to be discussed today is the motion control valve, which in my example is broken down into the brake valve and the counterbalance valve. The brake valve is used in motor applications as seen above. The valve is also very similar to the relief valve in design, and in fact, could still be used as one (as is the case for all pressure valve aside from the reducing valve). The reverse flow check
valve allows free flow into the motor, allowing it to freely spin clockwise when the directional valve is left in its current detented position. When the directional valve is reversed, however, the check valve blocks free flow and oil must now flow through the brake valve. This valve, you’ll notice, has two separate pilot lines merging at the same point on the valve. It has the same direct acting pilot line that rounds the corner, but there is an additional pilot source drawn from the opposite port of the motor. These dual pilot sources add interesting functionality to the brake valve in that it is both internally and externally piloted. The internal, direct-acting signal will ensure the motor won’t move until a combination of load and pump pressure pushes through the motor to the tune of 3,000 psi. This allows the motor to stay “braked” while pump flow is nonexistent. However, a direct-acting brake control valve is an inefficient method to control motion. This valve has a trick up its sleeve — the
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FUNDAMENTALS
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surface area the external pilot works against is larger than the area of the direct acting side. The ratio of areas is often 4:1 but can be upwards of 8:1. The result is the pilot pressure needs to a quarter of work pressure, reducing energy lost to the brake valve. The brake valve is essentially braking to the tune of 3,000 psi, but opening to provide flow when the opposite port sees 375-750 psi. The valve uses pilot pressure as permission to open and allow flow, preventing unintended movement of the motor. Lastly, we arrive at the motion control valve labelled counterbalance valve. It’s typically one and the same as a brake valve but used in cylinder applications. This example shows a relief valve set to 2,800 psi and is plumbed to the cap port of the cylinder. The reverse flow check valve ensures the cylinder will extend with little pressure drop, but when the directional valve is placed back in neutral, the counterbalance valve remains closed so the cylinder will not accidentally retract. The counterbalance valve also has a pilot ratio enabling the valve to open once it senses pilot energy from the rod port, preventing accidental retraction. Counterbalance valves also work well on the rod port of a cylinder, which prevents overrunning loads as a cylinder moves “over center,” which is a condition of pulling forces on the rod. Both examples of these motion control valves could have been employed with spring chamber drain ports, just as with the sequence valve. The drain keeps the spring chamber free from additional pressure, but in the case of this circuit, the open line to the reservoir through directional valves is enough to prevent excessive pressure. It’s when both ports of the pressure valve are continuously pressurized that a drain or vent is absolutely required. There are many variations of pressure valves not covered here, but those will be discussed in a later article. In Hydraulic Symbology 204, I’ll cover the essentials of flow control valves, including how they’re drawn and where they’re used. FPW
Kawasaki Precision Machinery (U.S.A.) Inc. Grand Rapids, MI www.kpm-usa.com 616.975.3100 DISTRIBUTION OPPORTUNITIES AVAILABLE
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MAINTENANCE Mary C. Gannon • Editor
Tool ensures easy maintenance for hose and fitting changeovers Assembling Push-Lok style hose and fittings can
Weighing just 1.9 lb, the tool is portable and lightweight for easy field-service repairs but is rugged enough for repetitive be a tedious, time-consuming and sometimes even unsafe task. And if production applications. It is an ideal tool for many manufacturers the hose and fitting assemblies are not assembled correctly, their use that are currently retooling their plants to respond to critical could lead to potential dangerous applications down the road. COVID-19 needs by now manufacturing medical devices, face masks and more, said Karl Wagner, Founder of Barb-Tech Tools. Wagner said Push-Lok is used in many types of industries and A new tool, the Barb-Tech II, easily assembles Push-Lok style hose heavily in automation, medical device design and pharmaceutical and fittings from 1⁄4 to ¾ in. ID. It works with a variety of fittings and and lab testing. Common applications include plastics and compatible barbed fittings using a changeable mandrel system. injection molding. The tool is designed for low pressure The device uses a cleat-style hose grip on a lightweight applications — like pneumatics, water and low-pressure oil lines — hand operated system that produces up to 300 psi of fitting and is suited particularly well to applications where line changeinsertion force, which is ideal for pneumatic assemblies and hose outs are made frequently. assemblies for low-pressure designs. This force reduces the force The device features a mandrel at one end to hold the fittings required by the operator by one-third. The device also prevents and jaw-like clamps at the other end. Pushing a lever pushes the over-bent wrists, an injury common to Push-Lok hose assembly. fitting into the hose, while the jaw-clamps tightly hold the hose secure as the fitting is pushed into the hose. The idea for Barb-Tech Tools came to Wagner when he was working in a cold warehouse and with spools of hose and boxes of fittings. He was expected to assemble them all by hand. “And the other end of the hose may have already been hooked up to something. I needed something that I could just walk over, and push this fitting in,” he said. “I couldn’t take it off and go someplace warm. To have something really portable that you can just take to the job site was really key for making a product that worked for the industry. And I’ve actually had people call, ‘Well, I got a maintenance guy, he’s trying to repair hoses up on a ladder. This fits the bill for what they need in a situation like that.” Wagner designed mandrels for 90° and 45° fittings because they are especially difficult to assemble by hand without good leverage. “The key with the Push-Lok design is you have to Barb-Tech II tools feature a mandrel at one end to hold the fittings and be able to get a really straight push on the axes of jaw-like clamps at the other end to quickly push the fitting into the hose. | All images Barb-Tech Tools
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the barbs to be able to install the thing accurately. And it does need to get pushed clear up to the yellow washer line, which is pretty indicative of any of the Push-Lok,” Wagner said. Unlike similar bench-top tools, the portable Barb-Tech II comes in a case for easy carrying throughout plants for easy hose repair. It comes with two male and two female mandrels to accommodate a large range of straight fittings. Application-specific mandrel design services are available. The case features extra compartments for additional mandrels and/or fittings to take to the job. The portability of the tool is key, said Wagner. “In maintenance, it’s really difficult to disassemble the hoses away from machinery and move them to a workbench to have it done. So, that’s a competitive advantage,” he said. “This can really help them speed up updates and retooling because pushing these barbed fittings into the hose, especially if it’s cold, can be difficult. It’s like trying to push a rope. The hose wants to do anything but go over the fitting. Then the hose contracts, like a Chinese finger grip, so once you stop pushing, the hose contracts and it’s then impossible to get the fitting to push further in again. “So, that was part of the motivation for the tool, was being able to be have a pretty quick process, so that the hose doesn’t have time to take a set. When you use the tool, the jaws just grab the hose, and gives it a really good grip so you can get the fitting pushed in.” The mandrels are designed by Wagner and produced locally so it doesn’t take long for custom designs to be completed either, he said. Wagner reiterated the safety benefits of Barb-Tech Tools, as it helps to reduce injuries with its ergonomic design. He tested the device with S-shaped load cells to prove the ergonomic benefits of the design. “You’re able to keep your wrist straight. Your hand is actually operating in a normal position, and of course the reduction of, the amount of work that you have to do,” Wagner concluded. “The 3⁄8 mandrel takes about 85 lb to press that fitting into the hose. The ¼ in. material actually takes closer to 120 psi proportion. The amount of work you’re doing with your hands is not good, especially if you’re trying to do it repetitively. I can take those measurements to prove that this is a huge savings for people that are out there trying to do this.” FPW
Barb-Tech Tools | barbtechtools.com
Push-Lok fitting assembly can be time consuming and repetitive. The Barb-Tech II tool allows for quick and safe assembly of these fittings with low-pressure hose. | Barb-Tech Tools
FLUID CONDUCTING QUICK DISCONNECT COUPLINGS Working Pressures to 6,000 p.s.i. | 3/4” thru 3” Size Hydraulics, Inc. thread to connect couplings are designed to provide high flow and low energy loss in fluid power systems. All products are built for rugged use and are designed with a minimum 4:1 Safety Factor. Notable features include superior flow characteristics and resistance to extreme pressures and systems induced shock loads. The carbon steel couplings are offered with both poppet style (5TV and 6TV Series) or flat face valves (TVF Series). A variety of port options and pressure ratings up to 6,000 psi, and proven performance in the field make these products popular in the mining, oil and gas, construction, and other natural resource sectors.
Each use of the Barb-Tech Tool ensures proper assembly of low-pressure fluid, oil and air lines.
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P.O. Box 6479 · Fort Worth, TX 76115 · V. 817-923-1965 · hydraulicsinc.com
TRAINING Mary C. Gannon • Editor
Training goes online — and free Several fluid power training companies and organizations are offering their training programs free-of-charge during the COVID-19 crisis, where most employees, unless deemed essential, are either working remotely or not at all.
YouTube Live
First up, Fluid Power World has teamed up with the experts at LunchBoxSessions.com to bring you free YouTube Live training sessions at 2 p.m. EDT on Tuesdays, in which Carl Dyke uses operating cutaways and his popular Live Schematics to bring hydraulic valves to life. Tuesday April 14: Proportional Directional Valves Part I — Dyke was live in-camera, where he used an operating cutaway of a single stage, electro-hydraulic proportional valve, a fully operational hydraulic circuit with all electronics, and some simulations to boot. He introduced some basic functions and a few troubleshooting tips as well. The archived video can be seen at https://bit.ly/3ekXPSU. Tuesday April 28: Pilot Pressure Control Valves and Systems — Dyke will have a working, manual pilot control stick and a fully operational, electrohydraulic pilot pressure system from a mining shovel. You’ll experience some intricate 3D simulations and learn some troubleshooting tips!
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Attendees can interact throughout the live video by logging into their Google or YouTube account. Questions and comments can be posed to Dyke this way. Visit fluidpowerworld.com or lunchboxsessions. com on the Monday before the live sessions to obtain the live video link. New topics will be launched each month.
Engineering Adventures across the pond
Engineering Adventures, a U.K.-based hydraulic training resource, is offering sessions to help businesses emerge stronger from this difficult time of remote working and social distancing. Much of the company’s basic fluid power training is now free and Gary Molton BSc, Owner of Engineering Adventures, said he has just released a new industrial power unit training project at www.e4training.com/ hydraulic_projects/tanksize1.php that will also be free until lockdown ends. “e4training.com includes virtual hydraulic test rigs, which let people experiment, in safety, by operating realistic simulations of actual components, circuits and hydraulic systems. The website provides a valuable training resource for all abilities from beginners to experts,” Molton said. “It includes a range of specialist ‘home working’ lesson plans for salespeople, managers, fitters or maintenance engineers. It also benefits from bite size tutorials, instructional videos, circuit builder software, visual calculators, reference information, troubleshooting and design guides.” Molton said discounts will be available for companies who sign up three or more people to the courses when the free promotion ends. Features of the training website besides the virtual hydraulic test rig include hydraulic circuit builder, hydraulic troubleshooting,
system checking calculators, design guides and part reference solutions, a phone app which doesn’t require WiFi, and more. Visit www.e4training.com for more information.
IFPS courses free of charge
The International Fluid Power Society (IFPS) is offering free resources to its membership to help with their learning requirements as they work towards certification. One new initiative is free online study groups, led by an accredited instructor, for anyone preparing to take the Hydraulic or Pneumatic Specialist Certification Test.
Upcoming free educational webinars include:
Upcoming study groups include:
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April 21 — Understand the difference between isothermal and adiabatic conditions April 21 — Understand the purposes of the accumulator April 23 — Calculate the kinetic energy required to stop a load with a shock absorber
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April 22 — High-Pressure Hydraulics, presented by Josh Cosford, Higginson Equipment Inc. June 17 — Selecting and Sizing Accumulators, presented by John Bibaeff, PE, CFPAI
Archived study groups and webinars are also available for members.
FPW
Visit ifps.org for more details and to register.
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ENERGY EFFICIENCY Ron Marshall • Contributing Editor
Compressed Air Fail: Compressor response
A
A food processing plant invited a compressor vendor in to conduct a compressed air assessment. The goal here was to determine the plant’s system efficiency for a possible compressed air improvement project. The vendor placed data loggers on the compressed air system to measure the plant pressure and power. The data logging showed a flat compressor loading profile that made sense — because the plant had a continuous process. The compressor power in the accompanying chart shows a reasonably flat and unchanging compressor power consumption. However, a closer look revealed a significant problem. The power consumption of
Compressor 2, a 100-hp screw compressor, was only about 51 kW, much lower than the 80 kW expected power at full load. And, when comparing the pressure profile with the compressor loading through the full period of operation, it appeared that Compressor 2 was not responding to changes to pressure. Typically, when pressure reduces, the running compressor starts to produce more compressed air to try to keep the pressure constant. This increases the flow until the compressor is at maximum output. In this case, Compressor 2 remained at low power, outputting only part of its capacity, which allowed the pressure to reduce to unacceptable levels. Something was wrong with this compressor. Further investigation revealed internal mechanical problems within the air compressor that prevented the compressor from producing more air when the pressure dropped. The plant had been suffering with transient low-pressure problems for many years, but never discovered the cause until someone measured their system. The study also revealed inefficient compressor and air dryer operation — the compressors are running in an inefficient modulation mode, and the desiccant air dryer in an inefficient fixed cycle mode. Significant potential savings were identified that will save this factory significant operating costs when improved. Placing data loggers on a compressed air system is often a fruitful exercise that can reveal all sorts of problems, including: • • • • • • •
transient low-pressure problems compressor control issues air dryer failures pressure drops system inefficiencies high leakage levels compressors running when unnecessary
Consider having your system measured by a competent compressed air service professional. This could reveal some significant system problems of your own and show a path to big improvements. FPW
At first glance, this chart shows constant compressor loading — but a closer look shows a problem with compressor control. 30
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Hydraulics
harnesses
offshore wind Ken Korane • Contributing Editor
A new hydraulic powertrain may pave the way for reliable and economical mega wind turbines.
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O F F S H O R E
Offshore wind electricity generation has seen annual growth above 25% in recent years, as global consumers increasingly embrace renewable energy. The U.S. National Renewable Energy Laboratory predicts accelerated market growth in the next decade, with cumulative capacity rising to nearly 200 GW by 2030 and over 500 GW by 2050. To help reach these ambitious goals, wind-turbine specialist Hydrautrans BV, based in Utrecht, The Netherlands, is looking to tap the proven benefits of hydraulics. It is developing a 12+ MW mechanical-hydraulic drive train that is said to be ideally suited for next-generation offshore windfarms. Size matters
The rapidly expanding offshore wind market has spurred demand for larger and more powerful turbines. Ocean-based wind platforms tend to be more efficient as they get bigger, making offshore wind a more cost-effective and competitive source of clean energy. As size increases, however, it puts traditional mechanical and direct-drive electrical transmissions under serious pressure, said Hydrautrans CEO Ernst van Zuijlen. There are major shortcomings in offshore turbines that exceed 10 MW, he explained. At these power levels conventional mechanical gearboxes are prone to breakdowns and have high maintenance requirements. That’s why the offshore industry increasingly opts for direct-drive generators. These units slowly rotate at the same speed as the rotor. But as direct-driven generators get bigger, they also bring with it an exponential increase in weight.
T E C H N O L O G Y
That makes deployment increasingly difficult. At a rated power of 12 MW, for example, the generator itself weighs around 450 tons and, with ancillary connected systems, the entire unit tops the scale at about 600 tons. In addition, the rotor and blades also weigh over 200 tons. A package this heavy complicates transport logistics and installation. It requires a ship with the crane capacity to lift the entire 600-ton drive to a height of 140 m or more — all while being subjected to waves and wind forces. Successful installation is only possible with an extremely large and expensive jack-up vessel that costs about $500,000 per day. Alternative approach
The hybrid Hydrautrans Drive Train (HDT) overcomes these challenges, said van Zuijlen. The HDT will have a capacity that exceeds 12 MW and which can be increased by adding modular units. Yet with a higher power-to-weight ratio and comparable cost per kg, it is designed to be significantly smaller, lighter and more reliable compared to mechanical and direct-drive options. In the HDT transmission, the turbine rotor turns at about 8 rpm on the main shaft. Producing electricity efficiently means the rotational speed has to be increased to more than 1,200 rpm, he said. To accomplish this, the rotor directly drives a large ring gear that meshes with 16 planetary gearboxes. Every gearbox drives a hydraulic pump. Four pumps supply high-pressure fluid to one hydraulic motor of identical design; hence, the speed ratio is 1:4. These four motors are directly coupled to two 6+ MW generators that produce electricity. Thus, the Hydrautrans Drive Train consists of mechanical power-split and modular hydraulic systems that drive lighter, high-speed generators, compared to those in direct-drive electrical systems.
Conventional mechanical and electrical direct-drive transmissions are plagued by serious shortcomings in large wind turbines. A new hydraulic transmission offers a smaller, lighter and more-reliable alternative. | Adobe Stock
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O F F S H O R E
T E C H N O L O G Y
Innovative hydraulics
While hydraulics has long been renowned for its high power density, the technology hasn’t previously been used successfully in large wind turbines because traditional hydraulic pumps and motors are inefficient, said van Zuijlen. Also, metalto-metal contact between moving parts causes friction, resistance and wear that limit performance and life. Now, in a breakthrough for economical renewable power generation, the Hydrautrans Drive Train takes advantage of patented Floating Cup Technology (FCT) developed by INNAS BV, Breda, The Netherlands. The FCT transmits power through hydraulic forces without metalto-metal contact. This virtually eliminates friction and wear and enables an efficiency of over 98% per pump and motor. FCT technology is proven in smaller systems. The hydraulic pumps and motors Hydrautrans plans to use in the HDT are approximately 100 times larger in terms of volume/displacement per rotation. “That should result in even higher efficiency than FCT pumps already on the market,” said van Zuijlen. According to Peter Achten of INNAS, the HDT’s pumps and motors have a displacement of 4,920 cc per revolution, and they are designed for a peak pressure of 350 bar. In the wind turbine application the load is mainly around 270 bar. Pumps
The Hydrautrans Drive Train includes eight planetary gearboxes on either side of the ring gear. Each planetary drives a hydraulic pump, and four pumps supply one hydraulic motor.
Cutaway view of the nacelle shows gearing, pumps and hydraulic motors connected to the electric generators on the right. 34
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have a nominal rotational speed of 375 rpm, which results in a peak power level of 1.1 MW. The motors run four times faster (1,500 rpm) and have a peak power of 4.3 MW. Four pumps will supply each motor, and two motors will mount in series to drive one generator. Each has two parallel low-pressure ports and two high-pressure ports. The hydraulic units are designed with 28 pistons (2 x 14). Pistons on the left side of the rotor are positioned in line with pistons on the right side. There is no phase shift like in INNAS’s current pumps and motors. “This has a disadvantage for the noise of the units, which is not the biggest concern for large offshore wind turbines. The most important advantage is that it completely eliminates the axial load on the bearing, which makes it possible to increase the lifetime of the roller bearings to a few decades,” said Achten. System benefits
“The high-efficiency mechanical-hydraulic system is a serious alternative to typical direct drives,” said van Zuijlen. “First of all, there’s the weight saving and related lower cost. Because of the high power density we can suffice with a lighter design. We have calculated that this can save up to 40% on weight.” Maximum hoisting weight, including the generators, is now in the 200 to 240 ton range. And the compact drive train reduces overall nacelle dimensions. “In addition, our drive train is modular. You can split the system in components that can be installed using cranes of 250 ton capacity. And as a result, the foundations do not have to be as large and heavy. The modular design makes installation with existing, smaller vessels feasible, saving millions,” he continued. “During maintenance, an even smaller crane can exchange parts if you have to replace a pump, motor or gearbox. All that saves on costs.”
“
“
Mounting a 600-ton direct-drive electrical transmission requires an extremely large jack-up vessel that costs about $500,000 per day. A new hydraulic transmission will cut weight by 40% and slash installation costs.
The HDT’s INNAS floating-cup pump supplies 4,920 cc per revolution of flow at a peak pressure of 350 bar.
The mechanical-hydraulic system is expected to be less complex and highly reliable. Because the HDT ring gear is directly coupled to the shaft, there is no introduction of bending moments in the ring gear due to external loads or misalignment between components. The hydraulic transmission is flexible as well, damping peak loads and limiting cascade effects of one pump influencing the others. No wear and tear is expected in the hydraulic components as there is no metal-to-
metal contact. Because radial loads are absorbed in the main bearings — not in a mechanical gear box or generator — and fluctuations in wind-loading are partly damped in the hydraulic system, maintenance requirements are expected to be extremely low. And properly engineered, the turbine would not need to shut down should a single pump or hose fail. “In principle, partial operation would be possible,” said van Zuijlen. The entire system is designed for a 30 year lifespan.
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O F F S H O R E
T E C H N O L O G Y
Future outlook
Heavy-lift engineering company Mammoet, in partnership with Hydrautrans, has developed a self-mounting crane system which can lift a load of 250 tons. It permits mounting of the 12 MW HDT without the need for a large and extremely expensive jack-up installation vessel.
The pumps, motors and complete HDT drive train have been designed and conceptually engineered. To prove out the approach, Hydrautrans and INNAS have conducted tests in collaboration with TNO, the Netherlands Organization for Applied Scientific Research; and VDL ETG Precision Technology, a specialized manufacturer of ultraprecision parts and prototypes. The goals were to ensure the manufacturability of key components and validate performance and efficiency of the Floating Cup Technology in the HDT, which has already been demonstrated for smaller pumps operating on the same principle. Bench tests with six sets of cups and pistons in an assembled housing running at 350 bar indicated negligible friction losses and absence of component wear and confirmed volumetric efficiency of about 99%. Further improvements are possible with additional optimization, said van Zuijlen. Testing also validated the high-precision manufacturing process. Now that the Proof of Principle phase has been completed, VDL ETG will begin producing complete pumps and motors for prototype building and certification. “We hope to be able to have a first prototype of around 12 MW to be available in 2023,” he said. Hydrautrans officials are currently discussing the potential implementation of HDT technology with wind-energy OEMs. The hurdle is to not only convince offshore wind turbine manufacturers of the viability of the HDT and the underlying economic benefits. Turbine builders are also reluctant to abandon their multi-million dollar investments in current direct-drive technology. “They are interested but also hesitant, because it means a major change in the approach of their design,” said van Zuijlen. He expects similar to lower costs compared to traditional gearboxes as serial production begins, although no comparable gearboxes are available on the market. But taking into account all aspects of manufacturing, installation and maintenance, he predicts lifetime costs per kWh (LCoE) can be reduced by 4%. “At the end of the day our system can push the boundaries of what is technically possible. The hybrid drive train has a modular design and can be scaled up relatively easily up to 15 to 20 MW. Then the drive train is not the limiting factor but, rather, other components like the rotor blades,” he said. FPW
Hydrautrans | hydrautrans.nl INNAS | innas.com
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making a difference
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HYDRAULICS B R I N G R E L I A B I L I TY A N D ST R E N G T H TO
WASTE MANAGEMENT Hydraulic cylinders and valves are common on refuse machinery, as they bring the rugged power for controlling, lifting, filling, compacting and dumping in the many types of refuse vehicles used. Josh Cosford • Contributing Editor
Waste management is an industry considered best operating in the wings, leaving the main stage orderly and immaculate. Sure, everyone sees a garbage truck occasionally, and you may even leave your city workers a Christmas present every winter. But few of us understand the path trash takes from our curb to either its place of reincarnation or place of final rest. And unless you’re the type of fluid power aficionado to be reading this article anyway, fewer people know how prolific hydraulics are in the waste management process. Have you ever visited another state, province or country and seen a local piece of machinery seemingly designed on another planet? Dump trucks, concrete mixers and snowplows are often designed for and from regional preferences. Garbage trucks follow the regional recipe, so depending on municipal preferences, recycling requirements and the www.fluidpowerworld.com
efforts of the salespersons offering products into that region, each locale may use a different machine. The most common garbage truck (sometimes called a refuse truck), and the one most people think of, is the rear loader. The garbage is tossed into the gaping rear end and periodically compacted with what looks like a giant Hungry Hippo. It goes without saying these machines are heavily hydraulic powered, and these trucks indeed take advantage of hydraulic power density. The sweep blade and compactor action both use hydraulic cylinders. Older trucks required an operator’s thoughtful lever-operated directional control valve actuation to sweep and compact the trash. However, newer machines use either sequence valves or electronics to complete the action with one push of a lever or button. Hydraulics provide maximum productivity for garbage trucks, not only regarding cycle time, but the quantity and compaction rate of the garbage itself. Compaction rate refers to the density of trash per cubic yard of capacity after the material is compacted. Compaction rate is a measurement of mass per volume of space, rather than a time component. It is dictated by a combination of body strength, hydraulic cylinder force and the surface area of the compactor. A higher compaction rate 4 • 2020
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W A S T E
M A N A G E M E N T
Front loader refuse bodies
provides more compacted material per cubic yard, improving productivity. With more powerful compaction from heavy-duty hydraulics, a garbage truck reduces the frequency in which it exits its route to dump the load. An economically priced garbage truck may offer a capacity of only about eight cubic yards. With lighter-duty hydraulics, these smaller machines may only compact those eight cubic yards to a density of 800 lb each. With just a 6,400 lb load capacity, a smaller truck needs to dump more frequently. Larger, more expensive trucks employ larger sweep and compactor actuators, sometimes up to dual 6-in. bore cylinders. At a nominal working pressure of 3,000 psi, those two 6 in. bore cylinders can achieve maximum force over 80 tons combined. A capacity over 30 cubic yards in these larger trucks combined with more compaction force enables each one of those cubic yards to hold more raw waste. Instead of 800 lb per cubic yard, think more like 1,300 lb per cube. The large truck crams more garbage more effectively, now carrying over 39,000 lb each haul, vastly reducing dump frequency and thereby increasing productivity. 40
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Although the body capacity and compaction rate vary, so too does the method of filling the body. Front-load trucks primarily service commercial customers, looking much like mastodons as their giant “tusks” lift dumpsters over their back to empty them into their open hopper. Front-load garbage trucks are often larger than some of the rear load counterparts, and with so much material to compress, they experience reduced compaction rate. Also, commercial waste tends to be filled with dense, mixedmedia trash such as metal or wood, where residential garbage collected is primarily soft household waste. The front and rear load trucks each operate using roughly the same number of actuators. The rear loader is equipped with sweep cylinders pulling the hopper trash up into the body where it’s compacted. In contrast, the front load truck uses two sets of cylinders each to operate the forks and arms. The arm cylinders are equipped with counterbalance valves, since the mass of the dumpster goes over-center, turning the tension load into a compression load. The most recent truck to the game is
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Illustration shows the many cylinder designs required to operate and control refuse vehicles. | Parker Hannifin
the side loader garbage truck. This truck uses multiple cylinders to dump a standardissue garbage bin into the truck’s side hopper. Hydraulic actuation extends the grapple mechanism (a surprising distance, sometimes), the grapple arms clamp the bin and drag it in flush to the truck where cylinders lift and dump the bin contents into the hopper. The hydraulic system works in reverse to lower and replace the bin to the curb. Electric valves operate the many cylinders used for the bin handling functions, and some modern machines employ automatic or semi-automatic bin dumping operation, vastly improving productivity. We have all seen garbage trucks collecting trash, but so few of us have seen where they unload their less-than-precious cargo. Trash has to go somewhere, and that first somewhere is a transfer station. What nearly all garbage trucks share in operation is their method of dumping trash at the transfer station, where they operate as dump trucks. After unlocking their hydraulic tailgate latch cylinders, their large tailgates open using two hydraulic cylinders, looking much like a giant clamshell. Once the tailgate is high in
the air, a telescopic cylinder tilts the body and dumps the trash into a pit where it is processed. Some trucks, however, use their compactors to push trash out the body and into the pit, although this method is less common. The most advanced garbage trucks now take advantage of hydraulic hybrid technology. Rather than relying on the brute force from its diesel engine, a hydraulic pump/motor mounted to the transmission PTO both delivers and accepts hydraulic energy. When the vehicle slows for loading, the pump circuit sends fluid into a hydropneumatic accumulator to store energy. As the truck once again accelerates toward the next home, the pump switches to motor mode. The accumulator feeds its stored energy back to the system to supplement the diesel motor with a massive burst of torque. The hydraulic hybrid concept is ideally suited to the garbage truck’s repeated stop/start cycles in city waste collection. Hydraulic machinery continues to play a part in the postcollection processing of trash, but how handling occurs depends on the municipal and local regulations. The transfer station likely puts sizeable front end loaders into action to process the unyielding inflow of garbage. The front end loader is a workhorse — quickly transitioning between forward and reverse movement, lifting and dumping trash as required. New loaders are optioned with electric hybridization, turning the wheel motors into regenerative brakes, similar to how the garbage trucks recoup energy, but this time storing them in batteries. The two final destinations most common for waste are either incineration or landfill. For incinerated waste, a transfer station makes sense when built near the incinerator. Front end loaders fill staging area with waste fuel (garbage), where a giant crane equipped with a hydraulic grapple takes fistfuls of waste and dumps them into a gaping hopper. This hopper funnels the waste down below where hydraulic pushers send the waste into the burning inferno. Some incinerators power steam turbines to create electricity, while others burn the waste into dust. For landfill waste, instead of fueling incinerators, large 53-ft trailers are filled for transportation to landfill sites. You’d correctly assume that landfill sites also count on hydraulic machinery. If the 53-ft trailer isn’t already capable of dumping with a humungous telescopic cylinder, then some trailers are parked upon platforms which themselves lift to dump the trailer while the semi-truck is still attached! Thousands of tons of waste are processed at landfills every day, where a combination of loaders and dozers lift, push and spread the incoming garbage. Hydraulic equipment aids waste management every step of the way to take waste from your curb to its final resting place out of sight and out of mind. The power density, controllability and all-weather capability of fluid power perfectly suits the needs of the waste management industry. FPW
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Telescopic cylinders, like this 3-stage design from RAM Industries, are commonly used in the waste management industry, particularly for pushing or dumping waste out.
Rugged cylinders are used throughout waste management, such as these series RDH industrial grade, heavy-duty roundline hydraulic cylinders from Parker Hannifin, which provide extremely long cycle life and are field-repairable.
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P N E U M A T I C S
Pneumatics: the go-to for food and beverage processing IoT-enabled pneumatic technologies ensures clean and reliable food and beverage design. By Amit Patel • Product Marketing Manager, Food & Beverage, Emerson
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Pneumatics has always been a go-to technology in food and beverage applications, and for good reason. Pneumatics technology is clean and reliable, and it’s safe and easy to maintain. It also has design features that improve performance and potentially lower cost. And now, with the advent of the Industrial Internet of Things (IIoT), pneumatics is an even better choice for food and beverage applications. With IIoT connectivity, processing equipment can be safer to operate and predictive maintenance can be enhanced. Plus, energy use can be monitored and controlled more closely. IIoT connectivity
Pneumatics equipment can now be equipped with sensors that measure key operating parameters, like temperature,
pressure, flow rates, cycle times, valve response rate and more. Using this information, designers can monitor machine performance more closely than ever before. Original Equipment Manufacturers (OEMs) can now include pneumatic monitoring capabilities that can detect a pneumatic system’s operating state, analyze the data and forward alerts to the right people in an organization. They can provide reliable information on the condition of actuators, valves and other devices. These new capabilities are being enabled as part of the IIoT functionality. Edge devices to crunch the data
With all that new data, it would be easy to overwhelm users who are just beginning their IIoT journey or for facilities where now greater demand is placed on the central control device such as a PLC. However, a number of manufacturers like Emerson have created edge gateways
designed to capture data from machine components and analyze it at the local factory level, comparing the performance to design parameters. That happens without sending the information to the machine control or the cloud. When the sensor data indicates a machine is operating outside the target ranges, the edge device sends alerts to the appropriate people. And only the outlier data is forwarded to the central control or the cloud. These edge devices can be deployed anywhere throughout the plant, handling up to 250 inputs. That probably may not be enough for an entire plant. But it could certainly monitor the mission-critical functions needed for one processing line or area of the plant. Connecting sensors on pneumatics components to an edge gateway sets the stage for major improvements in maintenance and safety as well as energy use. | Adobe Stock
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P N E U M A T I C S
Enhanced maintenance
Because wear and tear are such a fact of life in any industrial setting, maintenance is where IIoT capabilities become so helpful. Plant operators can implement a whole new level of predictive maintenance, using IIoT-enhanced pneumatics. By comparing a machine’s performance to established set points, the IIoT edge device can notify the appropriate manager if the system isn’t meeting the established standards. For instance, maintenance technicians could determine that a shock absorber on the end of an actuator is deteriorating, just by sensing an increase in cycle speed, even by a few milliseconds. Or machine builders could take advantage of the diagnostic features of IIoT-enhanced pneumatics to measure critical parameters like cylinder velocity. In either case, knowing which equipment needs maintenance allows plant engineers to potentially avoid unplanned downtime, replacing components with shorter and fewer planned machine stops. A safer workplace
Pneumatics technology is already highly regarded for its contribution to worker
safety, incorporating several safety features and components that protect operators and equipment, prevent downtime, improve reliability and extend operational life. The IIoT enhances pneumatics technology even further, providing new tracking and measurement capabilities. These new features give operators even greater insight into the performance of a machine and its components and subsystems. A good example would be a machine with a safety light curtain controlling a valve. If the valve response time changed from 30 to 50 msec, or even 70 msec, an operator would be able to get much further into the dangerous motion area of a machine before a safety response event could be triggered. Normally, that kind of situation would not have been noticed or addressed before the device reached its mission time replacement cycle. However, with IIoT capability, that decline in the valve response time (and the corresponding alert response time) would be captured, analyzed and reported in time for corrective action — before any deterioration in functionality that would put the machine operator at risk.
An edge device like Emerson’s AVENTICS Smart Pneumatics Monitor module provides the user with reliable information on the state of wear of pneumatic actuators, valves and other devices as well as the energy efficiency of pneumatics systems.
Energy efficiency - detecting leakages
Increase in consumption only when valve is actuated » anomaly/leakage on or downstream of valve
• •
Overall increase in consumption » anomaly/leakage in supply or upstream of valve Flow 44
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Energy efficiency is a key economic factor. The SPM gives a clear indication of where and how compressed air consumption changes. This allows users to determine location of possible leakages.
In addition, Emerson’s new, integrated, scalable, zoned safety approach requires fewer connections and saves valuable real estate within the machine and manifold, reducing the number of safety system components by up to 35%. It helps design engineers satisfy regulations by allowing up to three safety zones to be isolated on a machine from a single pneumatics assembly. A valve manifold can be configured to shut down pilot air and power only to the equipment that will come in contact with the operator, leaving the rest of the machine in operation. Energy use
Fluid leaks can cause huge energy losses in mechanical systems and it’s often difficult to pinpoint the cause or the source of the problem. By monitoring the pressure and flow of these systems, plant operators can track their energy usage and identify potential problems before they occur. With the data gathered from the sensors on pneumatics components, IIoT edge devices identify leaks and monitor energy usage and air consumption. Examples where this can be valuable is for the actuation of critical components such as automated hygienic valves which are used throughout a facility moving vital process/consumable media. Once again, alarms or alerts can be sent to the appropriate managers.
It’s not a web page, it’s an industry information site So much happens between issues of R&D World that even another issue would not be enough to keep up. That’s why it makes sense to visit rdworldonline.com and stay on Twitter, Facebook and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community.
rdworldonline.com
The Emerson ASCO 8290 Series angle-body multipurpose pneumatically operated valve is a two-way, direct-acting valve where the internal wetted components comply to Food Safe (EC-1935/2004) and FDA (CFR 21) making it highly suitable for auxiliary fluids such as steam or water.
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Other advantages of pneumatics
Beyond IIoT connectivity, pneumatics technology offers a wide range of other benefits for food and beverage producers, including: Cleanliness. Pneumatics equipment is ideal for work where frequent washdowns are required. There are even pneumatics valves for sanitary conditions, withstanding aggressive detergents and chemicals. Reliability. Pneumatics equipment is less complex than other power technologies and, as a result, is known for dependable operation with less downtime. Pneumatics valves are engineered for high actuation rates and can handle high-speed production or high-speed motion sequences for packaging or for safe, rapid and reliable control of process valves and auxiliary valves for processing such as the Emerson ASCO 8290 series. Cost. On a component-by-component comparison, pneumatics devices generally have a lower initial cost than electronics. And in operation, pneumatics technology is extremely cost-effective, becoming most efficient when the total demand nears the capacity of the compressor. Plus, there is little added cost to add more devices, since compressed air is already being used throughout most food and beverage plants. Training. As food and beverage processors deploy pneumatics throughout their plants, they’re finding their teams need less ramp-up and training time with the introduction of new equipment. 46
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Pneumatics technology: a good fit for food and beverage
Always a strong contender for any food and beverage application, pneumatics technology has been enhanced with the addition of Industrial Internet of Things capability. It’s clean and reliable, cost-effective and easy to maintain. And now it has enhanced capabilities for preventive maintenance, worker safety and energy savings. Best of all, it’s not only scalable, it actually becomes more efficient as plant operators add more equipment — not simply as the total demand for pneumatics nears the capacity of the air compressors, but as plant workers become more familiar and comfortable with the technology. FPW
Emerson | emerson.com
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Mechanical flow meters ProSense FG1 series mechanical variable area ďŹ&#x201A;ow meters provide a visual indication of ďŹ&#x201A;ow rate for water or petroleum-based ďŹ&#x201A;uids. These meters oďŹ&#x20AC;er Âą5% full-scale accuracy and a repeatability of Âą1% â&#x20AC;&#x201D; important for cyclical applications requiring consistent readings. Two adjustable ďŹ&#x201A;ow limit pointers are available to provide preset indication of high, low or normal ďŹ&#x201A;ow rates. The ďŹ&#x201A;ow meters are constructed of high-impact polysulfone plastic (body, piston, cone) with brass ďŹ ttings (1â &#x201E;2 and 3â &#x201E;4 NPT models). FG1 series ďŹ&#x201A;ow meters are available with 1â &#x201E;2, 3â &#x201E;4, or 1-in. NPT process connections and have easy-to-read ďŹ&#x201A;ow scales in both gallons per minute (gpm) and liters per minute (lpm). Measurement ranges are from 0.25 - 2.5 gpm (1 to 10 lpm) to 4 - 28 gpm (20 to 100 lpm).
Oil-free scroll compressors The W-series of oil-free scroll rotary air compressors generates Class 0 oil-free air quality and oďŹ&#x20AC;ers quiet operation. Scroll compressors meet a broad spectrum of oil-free needs for commercial applications that require contamination-free air, low maintenance, and a smaller footprint. The W-series scroll compressors use an orbital wheel singlestage technology. Two interlacing spiral scrolls pump, compress, and pressurize the air. One scroll remains in a ďŹ xed position, while the other scroll orbits around it without rotating. The motion traps the air in the pockets between the two scrolls and pushes the air towards the center. As the air moves closer to the center, the pockets shrink, and the air compresses. This unique design creates air completely free of oil â&#x20AC;&#x201D; there is no oil in the compressor, air, or condensate at all. The scroll compressors have a simple tip seal design with no metal-to-metal contact eliminating metal friction and the need for lubrication while maintaining sealing performance and saving energy.
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Open-loop variable-displacement pump The XD5 hydraulic pump is the ďŹ rst model of the XD series designed speciďŹ cally to meet the demands of mobile markets. The XD5 is applicable in on and oďŹ&#x20AC;-highway equipment such as mining trucks, haulers and dozers, excavators, and trenchers. It can also be used in on-highway vehicles such as refuge trucks, snowplows, and any Class 8 service truck. The XD5 is an open-loop axial-piston hydraulic pump with almost instantaneous response to system commands through a high-response, three-way, direct-acting control. The new pump is signiďŹ cantly smaller and lighter than its comparable pump line, the PVG series. The heart of all Oilgear pumps, including the XD5, is its proprietary Hard-OnHard Technology. This process enables Oilgear pumps to withstand continuous use in medium to heavy duty cycles mitigating contamination risks which can lead to premature or increased maintenance and costly equipment downtime. The XD5 is the ďŹ rst of what will be ďŹ ve models in the XD series, ranging from 45 to 130 cm3.
Miniature valve controls ventilator flow The Parker LM-Pro miniature proportional valve uses a linear motor actuation technology to enable ďŹ&#x201A;ow up to 540 slpm in a very compact and energy-eďŹ&#x192;cient package. A critical feature of the LM-Pro valve is the valveâ&#x20AC;&#x2122;s linear motor actuation technology that provides exceptional resolution over a longer stroke and lower power consumption than traditional solenoid or voice coil actuation designs. With a linear controllable ďŹ&#x201A;ow range from 0.5 to 540 slpm, pressure capability up to 100 psi (6.9 bar) and typical power consumption of less than 2 W, the LM-Pro valve enables precise ďŹ&#x201A;ow control throughout the full performance range of the valve. The LM-Pro valve allows for simple, closed-loop feedback, giving the customer precise pressure or ďŹ&#x201A;ow control. This ensures accurate and safe delivery of precise gases to patients, from neonates to adults. Typical applications will require less than 2 W of power, giving users longer battery life or the ability to take advantage of a smaller battery to save size and weight. Typical hysteresis of <10% (full scale), coupled with a fast response time of <20 msec (full cycle), provides excellent low and high ďŹ&#x201A;ow rate and precision control proportional valve performance.
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HARSH Applications
Signal-operated air pressure relay ControlAir controlair.com The Type 7150 Precision Air Relay is a highprecision, multi-stage, pressure relay offering fine adjustment and maximum stability under variable operating conditions. High-resolution output control combined with high relief capacity makes the Type 7150 the choice for pneumatic counterbalance applications like articulating arms and balancers. The Type 7150 combines the technology of the ControlAir Type 200 Precision Air Relay with the high forward and reverse flow of the Type 6100, 1:1 Relay Volume Booster. A highly sensitive capsule controls the pilot pressure, which offers crisp and accurate adjustment. The Type 7150 Precision Air Relay is designed for applications where precise control, superior relief, and airflow sensitivity is needed. It is typically used when increased flow capacity or remote pressure control is required. Applications include volume boosting, roll loading, tension control, cylinder control, pressure control, counterbalance, and industrial clutch and brake control.
PENINSULAR CYLINDER CO. ®
Let’s Talk Cylinders
800-526-7968 www.peninsularcylinders.com
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Load sensing valves Bosch Rexroth boschrexroth-us.com
Fail-operational steer-by-wire valve for off-highway machinery Eaton eaton.com The SBX advanced steering valve is a fail-operational steer-by-wire valve for off-highway machinery. The compact, modular SBX valve increases machine flexibility and intelligence by enabling machine designers to tailor steering performance to the operator’s preferences and operating conditions. The SBX advanced steering valve was designed for use in a fully electronically controlled steer-by-wire system. Fail-operational functionality is achieved by mounting the SBX valve to a secondary electrohydraulic valve or manifold. Because there’s no hydraulic connection to the cab, the valve can be remotely mounted, allowing for more flexible machine design and reduced cab noise. The valve can be paired with the OEM’s machine control system or with an Eaton controller, further increasing design flexibility. The SBX advanced steering valve is SIL 2 and PLd capable, which enables OEMs to develop machinery that complies with international standards. Designed for equipment in the construction, agriculture, material handling, and forestry industries, the valve is suitable for use with systems incorporating multiple steering wheels or alternative devices, such as a joystick or lever.
The RM10 and RM15 load sensing valve platform is easy to apply for today’s functional demands. The product is readily integrated into modern, energy-efficient systems and features flexible assembly with no transition plate needed between the two distinct sizes. The new RM10 and RM15, with flow rates of 90 and 150 lpm, respectively, are cost-effective, compact, general-purpose, multiapplication load sense directional control valves. They are designed for mobile application markets. The product is based around an easy-to-configure, flexible assembly technique that allows for the quick, off-the-shelf configuration demanded in today’s fast-paced mobile machine design, prototype, and manufacturing environment. With no transition plate needed between the RM10 and RM15 or the current M4-12 portfolio, the valve line is a suitable fit providing flexibility for machines that demand varying flow rates and functions but have limited space due to industry regulations. The valves come equipped with common industry work ports and load sense relief cartridges. Rexroth’s RM10 and RM15 are easily integrated into today’s energy-efficient systems, working with low leakage demands at pump pressures of 280 bar and working port pressures at 320 bar.
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Hose cutting machines UNIFLEX uniflex.de The cutting machine EM 1 makes cutting of smaller hoses up to a diameter of 1¼-in. easy. The EM 1 has been re-engineered with some crucial details, along with the variant EM 1S. The mobile cutting machines which are, in comparison with the traditional circular cutters, just slightly bigger and negligibly heavier, are fixed at the workplace, i.e., the “cutting table,” using just two screws fast and safely. Both “small” cutting machines from UNIFLEX, the EM 1 for hoses up to 5⁄8-in. and the EM 1S for hoses up to 1¼ in. in diameter, are available in two motor versions (230 and 110 V, 50/60 Hz 1 Phase) for trouble-free use worldwide. Both devices are easily operated and are supplied with a manufacturer’s warranty of two years and are EC compliant.
Valve option for CAN bus HAWE North America hawe.com
PSL series of directional spool valves have a modular design that combines all actuation functions in one control block, making it individually adaptable to specific needs. The capabilities of these proportionaldirectional valves have now been extended, thanks to the new actuation option: CAN Lite. By switching from a valve controlled by pulse width modulation to CAN bus, the valves can be addressed precisely and functional parameters easily adjusted. The start and end position of the spool valve are already preset on delivery for easy commissioning. The hysteresis typical for spool valves during operation is very low with PSL-CAN Lite. The entire valve bank connects to the machine’s bus system with only one connector plug. This minimizes cabling effort and shortens commissioning time. Type PSL directional spool valves generally have operating pressures up to 420 bar (6,091 psi) and a flow rate range from 1 to 1000 lpm (0.26 to 264 gpm) available in four sizes. The different sizes can be combined in a valve bank. If only the size required for the respective individual function is used in the valve bank, weight is reduced and fine control is further improved.
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IO-Link-ready vacuum generator platform Piab piab.com piCOMPACT 23 SMART all-in-one ejector is an IO-Link-ready vacuum generator platform. It offers operation with either standard 24 V IO or IO-Link. Previously offered as an optional added feature, IO-Link is now included as a standard option. A generic input/output (IO) communication technology, IO-Link provides point-to-point links between sensors and actuators. It can be used with any fieldbus, enabling users to link together different systems within a plant. With casings and electrical enclosures fulfilling the IP65 standard, providing complete protection against dust, and excellent ability to withstand water, the new standard version of the popular piCOMPACT 23 vacuum generator is also more robust than the previous generation. This allows it to be installed closer to the usage point with no need for extra protective measures, making installation easier. The user-friendly ejector platform is also equipped with a new gyro-based display function that simplifies readings, reducing the number of errors and increasing productivity. The use of optocouplers to achieve separation between valve and sensor lines in the vacuum generator system also adds another level of security, further limiting the risk of accidental equipment damage or personal injury.
Piston pumps have higher ratings Continental Hydraulics continentalhydraulics.com HPVR piston pumps now have pressure ratings to 4,000 psi. These pumps feature medium-high working pressure capabilities that meet a range of applications. They feature simple construction for long, dependable service; and they are more contamination-tolerant than competitive pumps to improve dependability and reduce maintenance costs. The efficient, energy-saving design is also economical, with low overall cost for a high-performance variable volume pump. And quiet operation helps ensure hydraulic systems meet sound level standards. The HPVR series of inline axial piston variable-displacement pumps are available in three compact frame sizes and five displacements from 0.88 to and 3.97 in3./rev. For example, the HPVR-29 model offers 3.97 in.3/rev displacement with pump delivery of 29 gpm at 1,750 rpm. Its operating pressure is 4,000 psi (276 bar) continuous with intermittent excursions permissible to 4,500 psi (310 bar). Output flow and pressure are managed by a variety of control options and can work in conjunction with external control components, making them an excellent choice for almost any application. The HPVR series pumps are available in both SAE flange and ISO mounting 2-bolt patterns. Porting is available in rear and side locations as well as thru-drive configurations.
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COMPONENT FOCUS By: Josh Cosford • Contributing Editor
How does hydrolysis affect seals? Literally, every fluid power system counts on soft-sealing technology to contain high-pressure liquid, allowing hydraulic energy to transmit useful work. The most common rubber technology in today’s fluid power system is synthetic, such as Buna nitrile or urethane. Each type of polymer has its advantages, but they also differ in their disadvantages.
The hardness of polyurethane makes it excellent in high-pressure applications requiring resistance to extrusion. However, urethane isn’t the single source rubber compound to be used in all hydraulic systems. As good as urethane is, it doesn’t play well with water. When water exists in your hydraulic system, either intentionally with high water-based fluids or accidentally with contamination, those H2O molecules make life tough for urethane. The reaction that occurs between urethane and water is called hydrolysis. As water saturation level increases, and especially in the presence of heat, the seal material will break down as a chemical reaction occurs between the rubber and water. The physical result of the seal breakdown results in a seal that physically
cracks and breaks apart as the polymer bonds can no longer hold tight. With more water or more heat, the hydrolysis effect accelerates, and seal breakdown occurs within days or weeks. Although occasionally engineers will select the incorrect material for their application, such as urethane for a water-glycol application designed to be fire-resistant, it’s more common that water contamination infects traditional hydraulic oil. Contamination doesn’t have to exist as free water, as even increased oil humidity will accelerate hydrolysis in the presence of heat. The solution to the problem of hydrolysis is first to choose the correct seal polymer for your application. For high water-based fluids such as emulsions or glycols, using Buna nitrile, thermoplastic or other suitable synthetic rubber is your first step in the fight. The second step is to ensure water contamination is controlled and kept minimal. If you have free water in your hydraulic system, you have problems more significant than just hydrolysis. It’s essential to monitor oil for clarity and color, and if you don’t electronically monitor oil humidity, taking part in an oil analysis program will help. Regular samples taken
Thermoplastic elastomer seal in the late stages of hydrolysis. | System Seals and analyzed tell you more about the health of your hydraulic machine than just water contamination alone. On a side note to oil and humidity, be aware that the type of oil you use may affect its tendency to attract and hold water. Bio fluids made from vegetable oil are an excellent choice for use in areas subject to environmental awareness. Still, these fluids often have increased hygroscopic tendencies, meaning they absorb water at a higher rate, even from the air. Be sure your bio fluid is free from humidity, especially in damp environments. That being said, modern urethanes have evolved to resist the damaging effects of hydrolysis. Special thermoplastic polymers of urethane provide a highpressure, extrusion resistant seal with none of the side effects. If you have a particular application where water exists in conjunction with high pressure, reach out to your sealing technology partner to help you choose the best seal for your purpose. FPW
Fluorocarbon (FPM) seal showing early signs of hydrolysis. | System Seals
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