Pressure gauges - unsung heroes p. 34
Safe and fast vacuum systems p. 44
Pneumatic cylinder innovations p. 54
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August 2020
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FLUIDLINES Mary C. Gannon • Editor
We’re shut down — not broken — and that’s a good thing As he does every year, Alan Beaulieau, President of ITR Economics kicked off The NFPA Industry & Economic Outlook Conference on August 11 — a little differently than his usual dry humor from the stage, but still with his similar upbeat attitude. The key takeaway from this year’s opening keynote, is that the U.S. industrial market is simply shut down — we’re not broken, Beaulieau said. He emphasized that there is an important distinction between the two. And although he said it’s challenging to prepare economic forecasts in a global pandemic that no one has seen in our lifetime before, looking at other past shut downs such as 9/11 offers some insight as to where we’re going from here. To prepare their forecasts, the experts at ITR must decide if we’re in the second wave of COVID-19 or if it’s still coming — will it be worse than what we see now? From looking at the numbers, he said doesn’t think so. As he said to NFPA members — things are starting to turn positive and they need to plan for the future. If we’re in the second wave, Beaulieau said, there is no incentive for governors to shut down again. Looking at the number of cases and deaths, both globally and stateside, things seem to be leveling off, even in those large states like Florida, California and Texas were numbers spiked dramatically last month. “I think the trends are encouraging, the number of cases and deaths are coming down — the mortality rate is being managed and … they’re dealing with it appropriately.” Additionally, the stimulus measures and unemployment insurance benefits have made a difference and will continue to make a difference — the Fed chairman has even said there is no limit to what the Fed can do. With interest-free loans and money in consumers’ pockets, we’re rebounding. And yes, there will be inflation, but it won’t be for several years. Finally, while some leading indicators are down (defaulting on rents, for example) almost all are on the rise — real estate sales are above year ago levels, the stock market is all but recovered (though we’ll have a correction in the near future), retail sales for June 2020 came in 2.3% above June 2019, indicating consumers who don’t live paycheck to paycheck 2
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have disposable income and are ready to spend. “You don’t see disposable income when you’re in a recession,” he said, and that has made all the difference in the world. These indicators should get fluid power manufacturers and OEMs enthused, Beaulieau said. “This is telling you need to get busy and motivate,” he said. What does this all mean? Look for a healthy V-shaped recovery, Beauleau said, highlighting ITR’s macro forecast that shows the negative pressure will continue through 2020 and fluid power shipments will continue to decline through the first quarter of 2021 but things will pick up after that. The global economy will bounce back late this year and through early 2021. Export business is going to do well — the world G7 indicator shows it’s moving in the right direction, and good things are happening around the world. His best advice: “Separate near-term events from fundamental economics and determine which will likely prevail in your markets,” he said. “The world is healing and it’s a good thing as we move forward. Grow and go. Plan to be ready for an expansion.”
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Robotics poised for more growth, jobs The knock against robots has always been that they “take away jobs.” The counter argument that’s offered is that robots create new jobs, and those are generally better jobs than the ones that vanish. Interviewing the great Dean Kamen a handful of years ago, I thought he put it better than anyone. He said: “There’s no job shortage, there are skill shortages — and kids that don’t have the skills to do tech are going to see less and less and less exciting career options available to them. The boring careers, the physical labor careers, the dangerous careers are going away.” And in the post-COVID-19 world (which I hope we’ll be in sooner than later!), realize that robots will be even more of a reality than ever, their use being fast-tracked in many industries where social distancing would be difficult. Fluid power has a definite role to play here, with pneumatic grippers and soft robotics getting a lot of attention the last few years. The International Federation of Robotics has estimated that by 2022, almost 4 million industrial robots are expected to be operating in factories worldwide. These robots will play a vital role in automating production to speed up the post-COVID-19 economy. At the same time, robots are driving demand for skilled workers. Educational systems must effectively adjust to this demand, the group said. “Governments and companies around the globe now need to focus on providing the right skills necessary to work with robots and intelligent automation systems,” said Milton Guerry, IFR President. “This is important to take maximum advantage of the opportunities that these technologies offer. The post-Corona recovery will further accelerate the deployment of robotics. Policies and strategies are important to help workforces make the transition to a more automated economy.” What’s clear is that changing hiring strategies may be necessary for a lot of companies. “If you can’t find the experienced people, you have to break down your hiring practices to skill sets and not titles,” said Dr. Byron Clayton, CEO of Advanced Robotics for Manufacturing. “You have to hire more for potential. If you can’t find the person who is experienced, then you have to find a person that has potential to learn that job.” Find more from the International Federation of Robotics at ifr.org and Advanced Robotics for Manufacturing at arminstitute.org. FPW
Paul J. Heney
VP, Editorial Director pheney@wtwhmedia.com
On Twitter @wtwh_paulheney 4
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AUGUST 2020
C ontents |
vol 7 no 5
|
fluidpowerworld.com
•
8
•
2020
F E AT U R E S PRESSURE GAUGES
Pressure gauges: unsung heroes Knowing which style of pressure gauge is right for your fluid power system is critical in ensuring consistent, efficient operation.
MOBILE HYDRAULICS
Hydraulics in mining: safe and reliable Eliminating downtime and ensuring safety in mining — two benefits hydraulics provides consistently.
PACKAGING
Vacuum handling systems stress safety and speed Ergonomic and versatile vacuum lifters address today’s logistic bottlenecks.
34 40 44
D E PA R T M E N T S
02
FluidLines
04
From The Field
10
Korane’s Outlook
12
Association Watch
16
Design Notes
24
Fundamentals
28
Training
30
R&D
32
Energy Efficiency
50
Products
54
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
Mining machinery relies heavily on hydraulic technologies for safe and reliable operations. | courtesy of istockphoto.com
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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. Noncommissioned 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
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KORANE’S OUTLOOK Ken Korane • Contributing Editor
The democratization of IoT Most advocates for fluid power technology are well aware of the Industrial Internet of Things (IIoT), where factory floor and mobile equipment are fitted with sensors, connected to wireless networks and send vast volumes of data to the cloud. Analyzing the data in real time gives manufacturers a better idea of how their production lines are operating, predicts when machines need servicing, improves efficiency and safety, and even opens up new revenue streams.
data-centric business strategy. Data, in the hands of many, creates competitive advantages,” said Kraemer, because knowledge that is widely accessible ensures more stakeholders embrace, support and benefit from IIoT. In this set-up, a company’s own sensors, devices and machines connect to a preconfigured IoT platform, in this case Software AG’s Cumulocity IoT, which accesses data using common fieldbus protocols. The platform provides out-of-the-box applications, such as for building plug-and-play dashboards, so users can define workflows, manage devices, analyze anomalies and view statistics. It can also remotely The devil, unfortunately, is in the details. While large organizations connect to HMIs and seamlessly integrate with order-management have made progress, many potential users of IIoT — especially small and ERP systems. to mid-size firms — are still on the sidelines when it comes to mass “There is no need for coding to get started with IoT projects,” adoption due to the cost, complexity and risk. Kraemer emphasized. “Algorithms are easily created using a dragJuergen Kraemer, General Manager, IoT and Analytics at and-drop GUI without any programming knowledge.” Companies can Software AG, says there’s a better option. In a presentation, “The start with just 5 or 10 sensors and the tools needed to connect and democratization of IIoT,” at last month’s Hannover Fair Digital Days, he explained how hands-on experts like machine operators, engineers manage devices, and implement functions like remote monitoring in a matter of days. Then they can scale up as practical and evolve toward and plant managers can be equipped with self-service software tools condition monitoring and more-advanced analytics. to readily access, analyze and act on IIoT data. “These tools can be This approach holds several advantages. Manufacturers can focus used by everyone, not just software developers and data scientists,” on their core expertise and build on top of a proven software base, he said, and leveraging them has a powerful effect. which also brings enterprise-grade features like multitenancy, high “In our interconnected world, companies that implement a digital strategy will be better positioned to innovate and differentiate. availability, scalability and security. It can even be offered as a managed solution with usage-based pricing to minimize investment risk. But success is not just about technology, it’s about establishing a In contrast, constructing a complete, custom IoT solution — relying on hyperscalers and a sizeable development team that must select and network many devices and platform services — can take months or years to complete and realize return on investment. Numerous businesses have gotten on board. Pneumatics manufacturer SMC Corp., for example, has partnered with Software AG to help adapt customers’ machines for smart networking and decentralized intelligence. As most air cylinders are already fitted with sensors, integrating them on the Cumulocity IoT platform permits real-time monitoring, reports on latency times and impending faults, and generates reliable analytics tailored to each machine. It’s evolved to include leakage detection services and energy efficiency tracking. “While today’s organizations are realizing that IoT has the power to completely transform any business, it is abundantly clear that the majority of these organizations experience significant barriers to effective IoT implementation,” said Kraemer. The democratization of IoT provides an efficient and agile path to widespread adoption and success. IIoT permits wireless monitoring and analysis of machine systems. FPW
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ASSOCIATION WATCH Edited by Mike Santora • Associate Editor
2020 NFPA Robotics Challenge scholarship winner announced The National Fluid Power Association recently announced that Matthew Morley of Sunnyvale, Calif., is the winner of the 2020 NFPA Robotics Challenge Scholarship. Despite several FIRST Robotics and National Robotics League event cancellations this year, the scholarship program received 87 applications from students who built their robots using pneumatics. This scholarship program helps build awareness of fluid power benefits and careers among high school students. The scholarship awards $40,000 ($10,000 per year for four years) to a high school senior who participates in a FIRST Robotics or National Robotics League Competition Team and uses fluid power in the competition robot. The money awarded may be used to study engineering at any accredited technical college or university in the United States. Morley will be using the scholarship to pursue a degree at Northeastern University in Boston. Morley already has a background in a number of engineering-related activities. “I was born and raised in Sunnyvale, Calif. and graduated from Design Tech High School in Redwood City this June. Design Tech’s personalized curriculum and focus on design thinking gave me the opportunity to develop my passions and hobbies. In my spare time, I enjoy working with and fixing my homemade 3D printers, playing video games with friends, sailing on our high school varsity team, and contributing my knowledge of modern control theory to the open-source FIRST Robotics Competition robot code library. “Participating in my school’s FIRST Robotics team, 5940 BREAD, opened my eyes to the possibilities of engineering. I joined the team in my freshman year when
Matthew Morley of Sunnyvale, Calif., is the winner of the 2020 NFPA Robotics Challenge Scholarship.
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it was in just its second year and relished the open-ended, real-world engineering problems that we had to solve to succeed as I rose to Technical Captain my junior year. My participation in the team gave me an outlet for my engineering passions as I developed my mechanical design, fabrication, programming, and leadership skills. “This fall, I’m excited to be studying mechanical engineering at Northeastern University. Northeastern is known for its strong co-op program, where undergraduate students participate in six-month industrysponsored co-ops. From my FIRST experience, I know that I love to dive into technically challenging engineering problems, learning what I have to in order to be successful along the way, and these co-ops are the perfect opportunity for me to do so. “The honor of this scholarship award will help give me the financial means to pursue my education at Northeastern and help me focus my interests on the design challenges that can be found in the member companies of the NFPA.” The NFPA judges who interviewed Matthew were impressed by his knowledge of pneumatics and his sincere interest in the experiences that they had in college. The judges were: Bob Hammond of Deltrol Fluid Products, Frank Langro of Festo, Bill Haley of FORCE America, Tom Peterson of HUSCO, Olia Mladenova of HYDAC, Travis Schmidt of HydraForce, Jim Kaas of Iowa Fluid Power, Bradlee Dittmer and Charles Werdehoff of IMI Precision, Tom Blansett of the International Fluid Power Society, Jeff McCarthy of SunSource and Andrew Kleitsch. If you would like to be a judge for next year’s Robotics Challenge Scholarship applications, contact Lynn Beyer at lbeyer@ nfpa.com or (414) 778-3364. FPW
ESA announces 2020 Scholarship winners The Equipment Service Association (ESA) awarded three $2,000 scholarships through ESA’s Board of Directors call on June 25. Winners were picked at random, and all excitedly accepted.
“ESA is proud of all the applicants who met the criteria and would like to extend best wishes to all who submitted as they further their education. It’s a great pleasure to provide education and educational opportunity to ESA members, and their families,” said Rick Lindemann, President of ESA and Dakota Fluid Power. “We thank our generous supporters and are very excited to announce the 2020 winners.” The Equipment Service Association Scholarships Foundation began in 1994 and has awarded over $50,000 in scholarships. The 501(c)3 charitable foundation is 100% donation-supported, and all applicants must meet certain criteria to be eligible. ESA is pleased to announce that the 2020 scholarship winners are Sami Hoffman, Bret Malone, and Erin Johnson. “I am going into my senior year of studying Motorsports Engineering at IUPUI. I could not be more grateful to receive the 2020 ESA Scholarship. This is an early and great start to the final year of my degree. This scholarship will help me push through my final year and achieve my goals post-graduation of working in the highperformance automotive industry. I would also like to add that I could not do it without the support of my family and all their hard work to give me the opportunities to succeed. I am so grateful to receive this scholarship and look forward to the year ahead,” wrote Bret Malone. “I graduated this spring from St. Francis High School in Minnesota. While in High School, I was a member of the National Honors Society. I competed in Choir and Show Choir and was on the yearbook committee. I also have done various volunteer work through church and in the community. I will be attending North Dakota State University this fall pursuing a Bachelor of Science degree majoring in Radiology. I want to thank you, the Equipment Service Association, and the Scholarship Committee for the opportunity to apply and ultimately receive a scholarship this year. What a wonderful surprise! This will help with financial challenges for my freshman year of college,” submitted Erin Johnson. “Thank you very much for this opportunity. This scholarship will help me as I go into my freshman year at the University of Cincinnati to study Pre-Physical Therapy. I have danced competitively since I was
two years old doing all styles of dance. I have also completed high school with high honors for three years and graduated in the top 20% of my class at Oak Hills High School,” emailed Samantha Hoffman. “Helping to support the education of a member furthers our goal of surrounding ourselves with smart, experienced leaders,” said ESA Executive Director Amy Luckado. “We look forward to continuing this tradition for many years to come. The Equipment Service Association has great members and a community dedicated to service.” To learn more about ESA’s Scholarship Fund and how you can apply to be a potential candidate, offer a donation to continue the support of education in the industry or to learn more about The Equipment Service Association, visit www.2esa.org. FPW
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.
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ASSOCIATION WATCH
Full agenda for upcoming NFPA/FPIC Regional Conference now available September 2020 Virtual NFPA/FPIC Regional Conference September 3 | 8:00 AM – 11:30 AM (Central Time) A full agenda for the September 3 NFPA/FPIC Regional Conference on contamination and its effects on fluid power systems is now available. The conference, which will take place online via Zoom, will feature the following presentations: Varnish: The Forgotten Contaminant | Mark Barnes, Ph.D. CMRP, Senior Vice President Global Business Development, Des-Case Corporation
Fluid Conditioning Tools to Improve Hydraulic System Performance | Bhavbhuti Pandya, Group Product Manager, Hydraulic and Lube Filters, HYDAC Technologies and Kristine Mikulan, Group Product Manager, Filter Systems, HYDAC Technologies Dynamic Filter Testing Reveals Need for More Robust Filter Elements | Jeffrey Mothersbaugh, Applications Engineer – Filtration, Bekaert Corporation All NFPA members can attend the conference for free, but nonmembers will be invoiced for $100 after registering. Registration for the event closes September 1. Visit nfpa.com for more details. FPW
IFPS announces 2020 Fluid Power Hall of Fame Inductees A special award was established to acknowledge individuals who have dedicated their careers and have made significant contributions to Fluid Power technology. This year’s host, the International Fluid Power Society (IFPS), is excited to announce the 2020 Class of Inductees.
Those inducted to the Fluid Power Hall of Fame are George Beniek, Henry (Bud) Haver, Alan Hitchcox, Peter Nachtwey, and John G. Slater. “The Fluid Power Hall of Fame recognizes the lifelong contributions of individuals whose innovative ideas, entrepreneurial spirit, and hard work have significantly contributed to the continuing success of the fluid power industry,” said Rance Herren, CFPSD, CFPECS, CFPAI, CFPMT, Hall of Fame Committee Chair. “The inductees for the 2020 Class were selected from a slate of outstanding candidates and I am, along with the selection committee, truly thrilled to honor these visionary and influential leaders.” 14
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George Beniek
To say George Beniek has participated in the widest, most unusual fluid power applications for his over 60 years in the industry is an understatement. From being the first employee of 1961’s brand new Char-Lynn Test Lab, to hydraulically controlling and rotating a 24-foot theater stage, to coordinating the combined development efforts of the University of Minnesota with Eaton Corp. to create an energy-efficient fluid power-operated Plymouth Valore, Beniek has certainly traversed beyond the normal breadth of the field. He holds the patent for improving the performance of Eaton’s Low-Speed-High-Torque Hydraulic Motor. An army veteran of Korea, Beniek serves the Chanhassen American Legion Post Honor Guard and volunteers on its annual Fishing For Life summer veteran-family outings on Lake Minnetonka. But perhaps the accomplishment of which he is most proud of is his role as co-founder and overseer of the Minneapolis-St. Paul IFPS Chapter 5’s Past President’s Scholarship Fund. This one-year, full scholarship, awarded to a second-year fluid power student at one of four Minnesota colleges, has been given annually for 20 years and accounts thus far for cumulative awards totaling nearly $100,000.
Bud Haver
Winner of 2019’s “Coolest Thing Made in Michigan” Award, Henry (Bud) Haver culminates his 25-year tenure with Peninsular Cylinder of Roseville, Mich. as its President of seven years. Peninsular’s custom booster cylinder won the second annual “Coolest” Award, sponsored by the Michigan Manufacturers Association, from a field of 10 extremely diverse contest finalists of “Michigan Things.” He is largely responsible for Peninsular Cylinder’s expansion over the past three decades as well as its solid internal training www.fluidpowerworld.com
program. Haver, with 42 years in fluid power, earned Certified Fluid Power Specialist Certification in 1994, and subsequently earned Certified Solid Works Associate. He recently joined the NFPA’s Cylinder Standards Committee. He has served on Macomb Community College’s Business Advisory Council, contributed to the publication Basic Hydraulics – Component and Circuit Design, Operation, & Analysis, and authored numerous fluid power periodical articles. Haver also directed development of Peninsular’s strong engineering and manufacturing team and led the company’s development and implementation of an ISO-9001:2015 quality system.
Alan Hitchcox
After 33 years as author and editor at Hydraulics & Pneumatics magazine, Alan Hitchcox noted “the most indelible aspect of my career: all the great people I’ve met and with whom I’ve worked.” His leadership at the periodical has promoted fluid power in industry and advanced the cause of hydraulic and pneumatic power transmission and emerging technologies across a broad range of industries. Hitchcox has served as the committee chair for NFPA’s Electronic Sensors Committee and edited NFPA’s Recommended Practices for both pressure and lineardisplacement transducers. Not content with merely “industry” impact, he edited and appeared in Episode 15, Season 10 “Hydraulics” of the popular television program Modern Marvels. Having started his career in publishing as assistant editor for Power Transmission Design magazine in 1981, Hitchcox also organized technical seminars on fluid power technology and presented technical papers at IFPE. He notably quoted, “I did not seek a career in fluid power. Rather, after I fell into it, I developed a passion for learning as much as I could and have always found the wide variety of applications astounding.”
Peter Nachtwey
In a class by himself, Peter Nachtwey has well over 35 years laserfocused on the application of microelectronics to control theory, particularly in its application to fluid power industrial machinery. With Bachelor’s Degrees in both Electrical Engineering and Computer Engineering, Nachtwey began working with controls theory by writing software to synchronize wood-carrying, hydraulically powered conveyors, as well as servo-hydraulic controls to be utilized by sawmill OEMs. In 1985, he joined the fledgling Delta Computer Systems and began developing hydraulic servo controllers for programmable logic controllers (PLC’s). Nachtwey became president of Delta in 1992 and has continued to be the nationally recognized, leading proponent and expert on advanced control algorithms and simulation programs to enable less cumbersome methods for testing and developing machinery. He has made numerous presentations at technical conferences worldwide, including at IFPE, NFPA, and FPDA. He has published technical papers for metals industries, food processing, dam control systems, forest products, complex testing systems, and press applications — to name but a few. In his own words, Nachtway said, “My main contribution has been in control theory for hydraulic
systems and making automation using hydraulics simpler, more precise, faster and cheaper.”
John Slater
Retired from an illustrious career in fluid power engineering, which began in WWII as a naval Seabee, John G. (Jack) Slater has earned credentials as both a Wisconsin Professional Engineer and an IFPS Certified Fluid Power Engineer. Jack attained his Ph.D. in Fluid Flow from the University of Wisconsin and presented his doctoral thesis, “Energy Loss in Liquid Flow in Straight Pipes under High Pressure” to the 1953 American Society of Civil Engineering (ASCE) Meeting in Minneapolis. Of his thesis and presentation, Jack noted that “2,000 psi was high pressure at that time.” Since then, Slater has been employed both in industry and academia, having worked for A.O. Smith, Industrial Hydraulics Company, and Broome Inc. all in Wisconsin, before moving on to a successful 27-year tenure at Milwaukee School of Engineering (MSOE). At MSOE, he began as Program Director for Fluid Power Engineering Technology Degrees and subsequently became the Chairman of MSOE’s Mechanical Engineering Department. Slater won the Karl O. Werwath Distinguished Research Award in 1983 for the design and installation of hydraulics to move a sailboat’s keel to the right or left to facilitate tacking. Nominations were open January 1 – April 15, to any individual, living or deceased, who demonstrated excellence within their 25-plus year fluid power career. A six-member selection committee, from diverse segments of the industry, chose these inductees based on their contributions to the fluid power industry using a subjective and objective evaluation system. IFPS | ifps.org
www.fluidpowerworld.com
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DESIGN NOTES Edited by Mike Santora • Associate Editor
Auto-Dock Systems: The future is now
Center Auto-Dock
Advances in hydraulic connection technology are again evolving within mobile machinery and tool attachment design while positively impacting professional use. The increased demands of worksite productivity and efficiency by the expert user have challenged manufacturers of machines, attachments, and component suppliers with technological improvements. After all, “time is money.” This article focuses on the advances of the autodock system — What is it, what is causing this demand, and how is it impacting manufacturers and professionals? To better understand how auto-dock systems provide much-needed support, let’s review the evolution of hydraulic quick connects.
ISO A/B “poppet” quick connect coupling
Often termed the general-purpose quick connect, its basic design was only to offer an economical means to connect and disconnect hydraulic lines between machines and tools and attachments. This basic quick connect coupling has been in use for more than 50 years. 16
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www.fluidpowerworld.com
ISO 16028 “flat Face” quick connect coupling
Demand required the introduction of a no-spill/ non-drip quick disconnect and easier “one-handed” connection — to eliminate oil loss and reduce contamination to the hydraulic system. Eventually, a residual pressure elimination nipple was introduced to ease concerns with difficulty in connecting attachments from thermal expansion.
Screw-to-connect coupling
The development of heavier duty machines increased concerns with vibration damage and surge flow issues. A screw-to-connect coupling allowed a quick break for heavier duty equipment while withstanding the difficult application effects of vibration and surge flows
(helping to reduce and eliminate failures when using previous quick-connect designs).
Hand-operated multi-connector system
As multiple hydraulic functions were incorporated into machinery, this increased the amount of hose routing connections. Challenges were made to reduce overall envelope size, eliminate cross-connection, residual pressure issues, and save overall connection and disconnection time. Handoperated multi-connectors achieved all of these goals and opened up acceptance towards auto-connectors.
Fast forward to 2020 — today’s auto-dock system
This latest technological advance, an auto-dock system, allows a professional machine operator to change tools and attachments without leaving their cab. This is achieved by incorporating fit plates and blocks, using hydraulic cylinders and locking mechanisms, guide assistance, and electrical cab controls into a single
configuration at the point between machinery and tools and attachments. During connection or disconnection, an auto-dock system completely connects or disconnects all hydraulic lines, all electrical connections, any water lines, air lines, etc., simultaneously. Using this type of system greatly reduces downtime between tool/attachment changes to about 10-20 sec overall when compared to the more traditional 5-10 min. An autodock system also helps eliminate issues related to cross-connection (user error of connecting/disconnecting all lines) and also helps eliminate “hanging components” that may be damaged in tight workplaces (like snagging a hose in close quarters on rebar or rubbing hoses against concrete). Over the last 10-plus years, a couple of familiar companies have offered aftermarket auto-dock systems for small and medium-sized machinery, mainly geared for small business implementation. As mobile machinery and tool/attachment manufacturers have realized the values of an auto-dock system
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(by customer demand for improved overall savings), they are beginning to include them with new model introductions. Several larger OEMs have also begun offering auto-dock systems bundled with standard tools/attachments. This provides professional users with a multi-function machine with greater capabilities and uses at each job site. Auto-dock systems are currently finding greater popularity in demolition and recycling industries (any site where cleanup is involved, and many tools/attachments are used). Still, the values can be gained in many mobile applications and industries. As each manufacturer continues to develop capabilities using auto-dock systems, it will continue to revolutionize other mobile industries, similar to the influences caused by previous quick connect technologies. There are two common systems presently in use: horizontal and vertical connection. Thus far, the vertical connection system has been better received. It offers greater protection and improvements with the general lifespan on all auto-dock connections from dirt, debris, and other environmental conditions. A key consideration for auto-dock systems is the frequency of tool/attachment changeouts. Suppose a professional machine operator has to frequently change out a specific group of tools/attachments each workday. In that case, this is a suitable target that should be evaluated for time loss reductions with implementation of an auto-dock system. An important question often asked by fleet and site managers (for each job site) is how much equipment and personnel are required to get each job done. If a machine typically uses the same 4-5 attachments or several machines share a group of tools/ attachments (depending on the size of the job), it’s possible to increase the overall productively with an auto-dock system. It can free up valuable inventory and personnel for additional work sites.
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DESIGN NOTES
Another element to auto-dock systems is the consistency of design and usage. This is especially important when it comes to wear and tear on components used in mobile machinery. Logically, an auto-dock system allows operators more consistent conditions between connection and disconnection change out needs. Removing unnecessary variables (including user-inconsistencies), helps improve the overall life of components in this connection point system. The addition of sensors and other safety aspects also helps redirect from reactive towards proactive maintenance, including a desired predictive maintenance schedule. This technology shift is quickly bringing value to the mobile machinery industries. Once the investment is made, the professional fleet can quickly identify their return on investment. It allows professional machine operators to work more effectively at each job site while allowing fleet or site managers to
better plan and accommodate more jobs. From a manufacturing standpoint, OEMs can capitalize on advancing technology while meeting customer demands for improved productivity and efficiency. As auto-dock systems are used more often in mobile machinery industries, this technology should provide additional business opportunities compared to companies reluctant to adopt new ideas and principles.
Should you consider an auto-dock system?
1. Does your team or your customers have machines that frequently change out tool/attachments during each workday? 2. Has your team or your customers experienced issues related to a forgotten connection (i.e., hydraulic, electrical, water, air, etc.) during tool/attachment change outs? 3. Does your team or your customers often deal with damaged hose assemblies
4.
5.
6.
7.
from hanging hoses in more confined work areas? Has your fleet or site manager or your customers complained about effectively sharing machinery between job sites? Does your team or your customers often dedicate specific tools/attachments to specific machines? Would your team or your customers be interested in reducing maintenance costs between machines and tool/attachments? Is your team or your customers weighing additional machines and tool/ attachments purchases versus trying to find ways to maximize usage with their existing fleet?
If you answered “yes” to one or more of these questions, it’s time to learn more about auto-dock system technology. FPW
CEJN | cejn.com
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FLUID SYSTEMS FLUID SYSTEMS
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KRAFT KRAFT FLUID SYSTEMS FLUID SYSTEMS
DESIGN NOTES Edited by Mary Gannon • Editor
Sugar beet harvesters from Homer Maschinenbau require precise data collection, provided by Rheintacho speed sensors.
Rotational speed sensors allow highly sensitive mobile machine control Holmer Maschinenbau GmbH, a German-based agricultural company, developed the first self-propelled six-row sugar-beet harvester in 1974. Since that time, the Holmer machines have been in successful operation by customers in over 40 countries world-wide. On its sugar beet harvesters, it requires a precise collection of actual values directly at the place of consumption (propulsion, toppers, and sugar beet transport systems). These data points are an absolute requirement for the optimum balancing of performance requirements of its high-performance harvesters for various consumers. The entire system must react precisely and quickly to the changing demands of the decentralized consumer. For example, harvesting when the soil is looser requires less power for the harvesting module and driving through deep soil requires more propulsion power. These parameters can change during a harvesting process, making constant adjustments necessary. Decentralized collection of the actual, current performance needs allows a precise adjustment to the power production. Rotational speed sensors from Rheintacho are used to record one
of the most important performance indicators, namely the rotational speed of the hydraulicallydriven operations, in a cost-effective way and without construction restrictions. The sensor electronics of the fitted FC-series with asymmetric, one-eyed flange is constructed as a two-channel hall differential sensor.
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Rheintacho’s FC-series rotational speed sensor
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DESIGN NOTES
This sensor range complies with the standard DIN/EN 13309 (construction machines, agricultural technology). It is designed to withstand especially high temperatures (up to 160 °C) and pressures thanks to its special brass alloy. The brass sensor complies with protection type IP69K thanks to its intelligently designed sealing system. The sensors of the FC-series have two frequency outputs. The extremely narrow tolerated phase shift of 20° in identifying the direction of rotation means that the sensor provides a highly precise signal and enables highly sensitive controlling. The prompt, contact-free measurement of shaft speed in these modern mobile hydraulic control circuits from Rheintacho has become an essential part of the Holmer system to guarantee the best harvesting results with minimal influence from the soil environment. FPW
Rheintacho | rheintacho.de
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FC-series sensors withstand especially high temperatures (up to 160 °C) and pressures thanks to their special brass alloy.
Zero compressed air consumption in standby mode Monitors the system for leaks Ensures maintenance in the event of leaks Enables effective real-time monitoring of relevant process data www.festo.us
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DESIGN NOTES Edited by Mike Santora • Associate Editor
Mini factories in containers help reduce mask shortages Disposable protective nasal-and-mouth masks are in short supply, but a manufacturing system from Swiss company Mikron could put masks within everyone’s reach. This scalable system produces 50-100 face masks per minute, depending on the version. With engineering support from Festo, Mikron developed the system in just six weeks.
Mini factories in containers
The beauty of Mikron’s system is that it fits in a 20-ft shipping container, which can also act as a cleanroom. The factory in a box could be located in front of a hospital, next to a shopping center, or near a school. The
integrated air-conditioning system with air purification filters makes production possible even in places with a high risk of viral contamination. With adequate raw materials, the system can operate autonomously for more than two hours. “This reduces the number of people required to operate the system, and as a result, lowers the risk of infection,” explains Nils Rödel, General Manager of Mikron Berlin. “The mini factory can produce protective masks in remote areas or even in crisis zones where meeting hygiene standards is most challenging.” It would be possible to produce two million protective mouth-nose masks each month with just one system. The masks are based on meltblown, nonwoven fabric, which consists of many layers of fine fibers and thus filters out even the smallest particles such as bacteria and viruses from the air. “Using official statistics, we calculated that medical personnel in Germany alone need at least 50 million disposable protective mouth-nose masks per month,” reports Rödel. “We could meet this demand with 25 containers.” Eliminating the need for transport makes the end product less costly. Depending on how it’s configured, the system can make packs of ten masks or individual ones, shrink-wrapped for cleanliness, and packaged in printed bags and boxes if required. “Packaging masks involves docking an automated station developed by pi4_robotics GmbH, Berlin, a project partner,” says Rödel.
Reliable supply of system components Fits in a 20-ft shipping container: Mikron’s system for producing 50100 protective masks a minute.
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Electric and pneumatic components from Festo ensure the transport, clamping, unwinding, shaping, and folding for the non-woven fabric. An ultrasonic sealing station seals the edges. The servo drives CMMT from Festo are used for controlling the electric
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How You Want Them, When You Want Them DESIGN NOTES
Short lead times for custom or off-the-shelf cylinders
FABCO-AIR A member of Festo Group
Earloops added and done: Mikron’s scalable system produces 50-100 masks a minute, depending on the version.
F Series • Highly configurable general purpose air cylinder • Twelve bore sizes (5/16 to 3”) and standard strokes to 32” • Options include adjustable air cushions, Viton® seals, rod wipers and more • Support for food packaging or washdown environments
Pancake II • Robust compact actuator • Eight bore sizes (1/2 to 4”) and up to 9” stroke standard • Composite body enables impact resistant, self-lubricating operation • Composite rod bearing for reduced wear and increased load capacity
drives, EMMT are also used in the application because they can be easily connected to PLCs from major manufacturers, including Beckhoff, Siemens, and Rockwell. The pneumatic components from the Festo core product range installed in the system — such as the compact cylinder ADN, the guided drive DFM, and the round cylinder DSNU —are in stock worldwide and available for shipment within 24 hours. Global availability enables quick and reliable manufacture of systems for producing masks within a condensed time frame. The pneumatic drives are actuated by MPA valves. The safety valve MS6-SV-E ensures that safetycritical system components are exhausted and de-energized as quickly as possible in the event of a sudden emergency stop. Thanks to its international production and sales network, products from Festo are quickly available in 176 countries and enable systems to be built at locations worldwide. This is entirely in keeping with the global open-source approach of Project CAROLA, which provided the impetus for designing the mask production system in a shipping container.
Independent, decentralized, and virtual
“The current travel restrictions make it extremely difficult for commissioning technicians to go where the systems are to be built,” says Rödel. “Mikron came up with a digitized solution. We use Microsoft HoloLens, which enables commissioning to be done virtually using an interactive 3D projection.”
OEM NFPA
FPW
• Cost-optimized NFPA interchangeable pneumatic cylinder • Five bore sizes (1-1/2 to 4”) and strokes up to 48” standard • Adjustable air cushions and magnet for position sensing standard • Variety of NFPA mounting options
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FESTO | festo.us
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FUNDAMENTALS Josh Cosford • Contributing Editor
Hydraulic symbology 205 – pumps The base symbol for the hydraulic pump (Figure 1) is actually quite simple. It starts with the standard circle and a directional arrow pointing out one end from within that circle. The solid-filled triangle makes this a hydraulic pump while pneumatic pumps (and most pneumatic symbols) are outlines only. There exist no other options for this particular pump symbol, which can be accurately described as a fixed displacement, unidirectional hydraulic pump.
The third symbol in Figure 1 illustrates the very simplified version of the variable displacement, pressure compensated, unidirectional hydraulic pump. It includes the variable arrow across the entire symbol, explaining that the pump displacement can be modified. To the left is a smaller arrow, and as you may have picked up on from earlier symbol articles, it tells us the pump displacement varies automatically with pressure compensation. As a fan of ISO 1219 symbology, I don’t find this symbol visually pleasing, concise as it is.
It’s rare to see a pump in any orientation but North when reading schematics, and they are often paired below to a line terminating into the reservoir symbol, which I show just once. If multiple components such as filters, ball valves, accessories or even other pumps are used, the tank line can be widened as needed. Other designers prefer to show every tank line terminate into the same small symbol, while others will place a tank symbol right at every component requiring it, just is done in electrics with the ground symbol. Unfortunately, and except for rare circumstances, there are no symbology differences between the type of pumps available. The symbols for a gear pump, a vane pump, a piston pump or any other type of physical configuration does not carry with it any symbolic difference, nor does it matter as you’ll find out by the end of this. The second pump is not much different from the first, with the exception of the second black directional triangle, which informs us this pump can expel fluid from what would otherwise be the suction port. This is the symbol for a bi-rotational pump, which is rare outside of advanced mobile machinery, especially in the fixed displacement version as shown. Although a series of check valves could allow both ports to become either the tank or pressure lines, depending upon the direction of rotation, this is still a rare concept. Figure 2. Pressure compensated pump
Figure 1. Hydraulic pumps 24
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My favorite symbol to express the pressure compensated pump is the smaller of the two symbols in Figure 2. This is a slightly more detailed example of the symbol I depicted in Hydraulic Symbology 101, and I’ve added color to help with the explanation. Don’t worry about the scary looking object to the right, we’ll get to that shortly. For this particular symbol of the pressure compensated pump, the shaft sticks out to the right, which can be attached to the square of a combustion engine prime mover symbol or the circular symbol of an www.fluidpowerworld.com
SECURE Metal-To-Metal electric motor. The semicircular arrow shows us the shaft rotates clockwise, or to the right since rotation direction is always observed from the vantage point of the shaft end. The variable arrow bisects the pump symbol and of course tells us the pump is adjustable displacement. The method of displacement control is defined by the compound symbol attached to the pump’s left. Under the long rectangle is a spring with a variability arrow, which represents the pressure compensator spring, itself semienclosed and attached to the bottom of the pump’s variable arrow. Opposite the spring is a triangular input for pilot pressure, and this juxtaposition is intentional. The orange pilot signal is taken directly from the red system pressure line exiting the pump, with the dashed orange line confirming it is indeed pilot energy. The spring setting fights with pilot pressure to infinitely and smoothly adjust the flow rate to match downstream pressure drop equal to the compensator setting. For example, if the setting is 3,000 psi, any downstream combination of load and flow-related pressure below 3,000 psi will see the spring maintain full displacement of the swashplate, producing full pump flow. As downstream pressure rises, pilot energy acts upon the (undepicted) control piston, reducing flow until downstream load and flowrelated pressure equalizes to 3,000 psi. Should downstream pressure continue to rise, the control piston being pushed on by orange pilot energy can reduce the swashplate angle to near zero, where the only flow is that which is being absorbed through lubrication and leakage. The leakage is lost through the blue dashed line going to tank, which may or may not be drawn together with the green suction line which obviously initiates at the reservoir. Moving along to the scary looking thing on the right, we have here the detailed breakdown of the variable displacement, pressure compensated, load-sensing, unidirectional hydraulic pump. You’ve likely seen this symbol before because the manufacturers prefer to show this level of detail, especially to differentiate advanced controls options like remoted compensation or horsepower control. This “load-sensing pump” www.fluidpowerworld.com
will make sense to you shortly. I’ll warn that it will take some time and effort to understand this symbol as you methodically work through the rest of this article. Starting with the pump (a), it has the diagonal variability arrow bisecting the circle and is attached to the rod ends of two cylinders. Cylinder (b) is the bias piston meant to force the pump to full displacement whenever possible, a task made easier by a spring pushing the piston forward. Some pumps make do with only a strong spring, but this example is balanced with pilot energy. Affixed on the right is a tiny object with a variable arrow, which can be adjusted to move left or right within the cylinder. Not all pumps have this additional component, which is the minimum volume stop, preventing the bias piston from retracting fully, which subsequently prevents fully standby of the pump. If you’re familiar with cylinder symbols, you’ll see that (c) also looks like a single acting cylinder with a stroke adjustor at the cap side. This is the control piston, which will always be a larger bore diameter than the bias piston. The control piston’s stroke adjustment is called the maximum volume stop and is used to modify the maximum displacement of the pump, convenient when you need a displacement between the two sizes available for the chosen pump. The two “cylinders” are attached by their rods to each other, and as one extends the other must retract and vice versa, and I’ll explain shortly why and how their battle develops. Because all load sensing pumps must be pressure compensated, I’ll start with (d), which is the pressure compensator. Although it looks different, it is essentially a relief valve governing the control piston (c). It’s shown in its neutral condition, where it bleeds the chamber of the control piston (c) through orifice (e), orifice (f), and also through the other compensator (g) where it can choose any flow path directly to tank. Regardless of its flow path, pilot energy inside the control piston (c) is zero, so it loses the battle with the bias piston (b) and the pump is on full displacement pump at its highest rate. The load sense compensator (g) looks much the same as the pressure compensator (d) and is similar in function except where 8 • 2020
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FUNDAMENTALS
it takes pilot energy and what it does with it afterward. As with the pressure compensator symbol (d), it is a 3-way, 2-position valve that is spring-offset with adjustable pressure settings for both. Each is supplemented with the parallel lines above and below both positional envelopes, and these lines tell us the valve is infinitely variable between the two positions. The variable orifice at (j) could be any flow control, lever valve or proportional valve used to adjust flow (which creates backpressure when reduced) in the red system pressure line starting at the pump. You can see the node just after the pump outlet that combines system pressure with pilot lines supplying the bias piston and both compensators. Let’s first take the load sense compensator (g) out of the picture and describe the pressure compensator (d) and what occurs during operation. When the pump fires up, and assuming all downstream directional valves are closed, the spring inside the bias piston (b) fully strokes the pump to max displacement. This immediately creates pressure in the work and pilot lines as fluid fills the plumbing with no exit strategy, and this rise in pressure at the pilot line at (d) forces the pressure compensator to shift to the right. The second pilot line attached to
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the top of compensator (d) allows pilot energy to enter through line (i) where it fills the control piston (c) rapidly. Because the control piston is larger bore than the bias piston, it wins the fight and moves the pump’s variable arrow to reduce displacement until the only flow is what is required to overcome leakage. The pump is on “standby.” Now when a downstream directional valve is opened, a flow path is created that drops system pressure to below the setting of the (d) compensator, and it immediately succumbs to spring pressure and snaps back to near its neutral setting, opening the drain lines once again to tank. The orifices (e) and (f) dampen the motion of the compensator, preventing rapid oscillations, but the orifice also prevents pressure spikes into the pump’s case. They also ensure that pressure doesn’t decay from the control piston (c) when system pressure degrades rapidly for fractions of a second. Flow from the pump will be balanced by the opposing bias and control pistons to match downstream pressure drop at exactly the pressure compensator setting. Finally, we look at the operation of the load sense compensator (g) shown on top. It also receives a pilot signal directly from the pump outlet, but you’ll see that it also gets a competing signal from the work line after the metering orifice. The pressure signal at (g) compares the combined effort of the spring value and the load-sense pilot signal just before (h). The setting of the pressure compensator (d) is much higher than the setting of the load sense compensator (g), which is set to create reasonable pressure drop across (j). If the (d) compensator is set to 3,000 psi, it’ll only see this pressure on standby or max load pressure, while the (g) compensator might be set to 300 psi, where it measures pressure drop across (j) valve. Typically a load sense circuit will have multiple orifices in a load sense network all feeding back a pilot signal to the load sense compensator (g), where it picks the highest pressure signal and meters the pump’s flow to match that pressure differential and provides just enough flow to satisfy the desired flow rate at the desired work pressure plus the pressure of the load sense compensator’s spring value. For example, if load pressure is 1,000 psi, the pump will hold pressure at 1,300 psi, providing the extra 300 psi just to create flow across the metering valve (j). This symbol shows you that no matter the initial feeling of complexity, breaking down any schematic thoughtfully reveals its purpose of design. I fell in love with hydraulics when I learned about the load sensing concept. That just using columns of fluid pressure to create an efficient supply and demand scenario to satisfy many downstream actuators with essentially the exact flow and pressure they need for the job, and little more, I found exhilarating. FPW
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TRAINING Mary C. Gannon • Editor
ESA announces first Virtual Tech Event for September The Equipment Service Association (ESA) is hosting its Virtual Tech Event Thursday, September 10. ESA changed the format from in-person to virtual, condensing a few days into one impactful day, fulfilling ESA’s elite training standards by offering seven dynamic sessions filled with industry-rich content. For just $50, the Virtual Tech Event encapsulates exceptional training, time for networking and questions,
“ESA knew virtual was the only way to host this event, safely,” said Rick Lindemann, president of ESA and Dakota Fluid Power. “We had to do this the right way for our members so we concentrated on inviting the best fluid power experts in the field, while focusing on the elite training and educational know-how our members expect.” The agenda is as follows:
Morning sessions
9:30 ET – Welcome and Introductions 9:40 – 10:10 – Hydraulic Cylinder Cushions, Tony Casassa, Application Engineer, Aggressive Hydraulics 10:10 – 10:40 – Hydraulic Seal Failures – Some Common and Some Not So Common, Sonny Goldsmith, Training, Hercules Sealing Products 10:40 – 11:20 – Understanding ISO Codes, Curtis Hass, National Sales Manager, Donaldson Company 11:20 – 11:50 – STAMPED, Dave Miller, Vice President of Global Product Line Management, Gates 11:50 – Morning Wrap-Up/Afternoon Review 12:00 – 1:00 – Lunch Break FLUID POWER WORLD
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1:00 ET – Introduction of CFC Hosts 1:05 – 4:00 – Session Series Fluid Power Safety (55 Minutes) Basic Industrial Control Theory (55 Minutes) Predictive & Preventative Maintenance (55 Minutes)
Speakers include:
and allows for lunch and breaks.
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Afternoon sessions
Robert J. Sheaf Jr., CEO of CFC-Solar, Inc. — Sheaf founded Certified Fluid Consultants (CFC) in 1990 and is owner/CEO of CFC-Solar Inc. (Currently operating as CFC Industrial Training). He has been directly involved with fluid power for 45 years and has taught fluid power courses for 39 years throughout the United States, Canada and Mexico. He served two years on the Board of Directors for the Equipment Service Association and was a director of the ESA Scholarship Fund. Jon Rhodes, President of CFC Industrial Training — Rhodes is the president of CFC Industrial Training and has 31 years of Industrial Experience. As an instructor, he assisted in the development of custom fluid power training stands for the oil and gas industry as well as providing machine specific fluid power and electrohydraulic hands-on training for an entire maintenance and engineering staff at a new start-up steel mill. He has also designed and built custom hydraulic test rigs for variable torque loading and simulation for the US Military. Rhodes holds an A.S.E.E.T. in Electronics Engineering. He also holds U.S. Patent # 6,158,923 for Method and Apparatus for installing Pre-Assembled Silt Fence. Tony Casassa, Application Engineer at Aggressive Hydraulics — Casassa started his career out of Purdue University by working at Parker Hannifin in the Hydraulics Group in a combination of sales and engineering positions, involved in complete hydraulic systems for mobile equipment. He then moved to the OEM side working at Tadano Mantis as their Hydraulic Engineer for the mobile telescoping boom crawler cranes products — including working
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to improve the production roll off cleanliness of the hydraulic systems. Casassa joined Aggressive Hydraulics in 2014 as an Application Engineer working with customers on custom cylinder applications for a variety of mobile and industrial applications. Melvin “Sonny” Goldsmith, Hercules Sealing Products — Goldsmith was employed by Hercules Sealing Products for 39 years during which time he was a territory manager, regional distribution manager, sales manager and developed and presented customer product training seminars. He retired from full time work with Hercules about 6 years ago but continues to provide customer product training seminars as requested. Curtis Haas, Donaldson Company Inc. — Haas has been with Donaldson Company Inc. for 21 years and is currently U.S. National Sales Manager, Stationary Hydraulics & Lube Filtration Division. He was previously the District Manager, Industrial Hydraulics Upper Midwest Region supporting End User, OEM, and Distribution customers. Haas is experienced with current contamination control methods relative to particulate, water, and varnish mitigation. He holds a B.S. Degree in Industrial Technologies from Saint Cloud State University and is a U.S. Army Aviation Veteran. He was born and raised in the Twin Cities. Safety is the priority for ESA members and while factory tours are always the highlight of the in-person event, ESA’s Virtual Tech Event offers a viable advertising opportunity. There are commercial and social media options available, with various advertising packages, allowing companies to create a visual medium broadening the reach of their advertising funds. “We know the factory tours are very important to our members and we wanted to create a platform where ESA members could participate while also giving them the opportunity to network,” said ESA Executive Director Amy Luckado. “Virtual events are successful when you provide both exceptional training, and educational materials and we want our members to have every opportunity possible that will increase their business.” Visit www.2esa.org/training-events to register. Registration closes at 5pm (Eastern) Friday, September 4. FPW
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RESEARCH & DEVELOPMENT Edited by Mary C. Gannon • Editor
IFK 2020 goes digital from October 12-14 The 12th International Fluid Power Conference (12th IFK) will take place online as a virtual event from October 12 to 14. The IFK team headed by Prof. Jürgen Weber is thus taking up the challenge of providing an attractive platform to meet the needs of participants of one of the most important international conferences in the fluid power industry innovations and research and development.
of .J ür ge
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Right before the initial event date in March, the IFK team around Weber decided to postpone the 12th IFK to October 12- 14. Initially, the idea was to hold an on-site event with flexible hygiene concepts. The contact to speakers and exhibitors was maintained in this difficult time to ensure a program with more than 100 international expert contributions and an accompanying trade exhibition. Even though some coronavirus-related restrictions have now been lifted, the situation in autumn in particular is unpredictable and a “second wave” seems possible at any time. The organization team therefore decided to actively involve the previous participants in the decision-making process by means of a survey. In this survey, 49% of those questioned expressed concerns over a face-to-face event due to travel restrictions by authorities or companies and health risks. 75% of the respondents answered that they would consider attending an online meeting in principle. The organizers from the Chair of Fluid-Mechatronic Systems Engineering at the TU Dresden, together with the Fluid Power Association within the VDMA, took this as an opportunity to push for certainty about hosting the IFK and made the decision to hold the IFK as a digital event Pr this year. “Unfortunately, the hygiene concepts required for the original event 30
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The digital platform resembles an actual conference center. venue would not have given us an appropriate environment,” said Weber. “Therefore, we decided on a digital concept that seems much more attractive under these conditions. All in all, the participation and discussion culture in virtual events surprised me positively this year, so that I am looking forward to the virtual IFK with anticipation.“ While the conference program is still being finalized, topics could include system design and integration, additive manufacturing, component innovations in pumps, fluids and more, pneumatics technologies, intelligent control, mobile and industrial applications, novel displacement machines and systems architecture, electrohydraulic actuators, predictive maintenance and much more. A web tool that transports the conference feeling into the participant’s office will be used for the digital conference. In principle, the tool is structured like a real conference center and virtually reflects the typical conference day. At the beginning of the conference, participants check in and create an individual
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profile. Afterwards, they enter the foyer, which is the central hub of the conference and where moderators guide them through the program in live mode. Here you will find useful information such as the current program or the possibility to create your own individual conference calendar. The individual conference rooms can be reached from here. Speakers give their lectures live via video stream, while the audience can exchange information via group chat. Afterwards, participants have the opportunity to ask the speakers questions in the Speaker’s Corner. It is also possible to switch to the digital exhibition from the foyer. Companies can freely design their digital exhibition stands here and decorate them with videos, presentations or brochures, for example. A chat window allows participants and exhibitors to contact each other directly or make an appointment for a video chat. In general, personal exchanges will be encouraged at the digital conference. For example, there are group chat windows in the foyer, the conference rooms and the Speaker’s Corners, which allow interaction with a large community. On the other hand, there is the possibility of using private conference rooms for two or more discussion partners. As traditionally one of the most important meeting places in the field of fluid power, the IFK is a forum for users, manufacturers and researchers from all over the world. The organizers have to meet these standards for the transformation into a digital event and invite you to attend the conference, which is also accessible due to lower costs, and to help shape the drive systems of the future.
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Further information, details of the program and contact details for the organizers can be found at ifk2020.com. FPW
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ENERGY EFFICIENCY Ron Marshall • Contributing Editor
Compressed air fail: The spare dryer
A
A printing plant had two compressors — one main and one backup — each with refrigerated air dryers. A third air dryer was on site as a backup, should the main dryer go down for any reason. The spare compressor was too small for the plant but was used as emergency backup, in case the main compressor would fail. An air auditor viewed the installation with the goal of reducing the system’s energy consumption. The auditor typically would measure the kW of each component to ensure things were working as they should. When he measured the air dryer, he was surprised to see the unit was consuming power but was not even hooked up to the compressed air system. The dryer does not have an “off ” switch, so it must be deenergized at the disconnect switch. Air dryers consume much less power than air compressors. In this case, the consumption was only about 1.5 kW, but the operating costs can certainly add up over time. This useless dryer was consuming about $900 per year in electrical costs — while doing absolutely nothing! The same effect is often seen in other locations when non-cycling air dryers are used as spares or coupled with compressors that are not running (sometimes the offending dryer is inside the compressor enclosure). Non-cycling dryers usually consume near rated kW if left running, even when there is no compressed air flowing through them. The key to avoiding this kind of energy waste is to turn the spare dryer off when not being used — and to purchase cycling air dryers for any situation where the dryer will not be processing air full time or will be partially loaded. Save yourself some money by attending to your air dryers! FPW
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This spare refrigerated dryer was not even hooked up, yet its refrigeration circuit continues to consume power.
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Pressure gauges: unsung heroes
Knowing which style of pressure gauge is right for your fluid power system is critical in ensuring consistent, efficient operation. Carl Dyke • Contributing Editor • info@lunchboxsessions.com
Pressure gauges are unsung heroes in many hydraulic systems. They are neither directing flow nor controlling pressure. If the pressure gauge is damaged or goes missing, the machine may continue to operate as though the pressure gauge was never even required. Even though a good pressure gauge should have no effect on its hydraulic system, it should not be ignored. It’s a first line of diagnosis and detection, and invaluable in a well-executed preventative maintenance program. A pressure gauge is your glimpse inside of an otherwise opaque system. It provides quantitative information about how the system is operating, and whether that operation is within normal limits. The best gauge
Like nearly everything else in hydraulics, asking “what’s the best pressure gauge” is almost guaranteed to get you the unsatisfying answer, “it depends.” And indeed, this is a case of one size never fitting all. Gauges that excel at repeatable and accurate high-pressure measurements almost universally will be 34
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inaccurate in low pressure systems. A bourdon tube type of gauge might be perfect for your needs, until you take into account the coarse and corrosive media you need it to measure. And a diaphragm gauge might seem like the right answer, until you learn that pressure spikes are not well tolerated, and temperature swings make the readings less accurate. To make a good choice for your system, you’ll need to know a bit about the different kinds of gauges available and understand their specific mechanics and limitations. Then you’ll be in a much better position to make a smart decision. A typical pressure gauge
The typical analog pressure gauge features an indicator needle that rests at approximately a 7 o’clock position and sweeps around to a 5 o’clock
position. Throughout the range of the sweep the needle points to the current pressure value on a printed scale with units as desired. This is all that is visible and evident from the outside. Behind the dial and inside the case is where the clever action takes place. Like an analog wristwatch the typical pressure gauge features a movement. This precision mechanism of gears and springs amplifies the small total travel of the primary sensing element and transfers this motion to the large sweep of the gauge needle.
The Bourdon tube with gear movement is popular and capable for a broad range of fluid power pressure measurements.
Bourdon tube
Typical sensing range: 600 mbar up to 6,000 bar (10 to 87,000 psi) The primary sensing element for so many fluid power pressure gauges is a Bourdon tube. Named after Eugene Bourdon’s 19th century www.fluidpowerworld.com
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invention, a Bourdon tube is a ‘C’ shaped or helical shaped tube that tends to straighten as the fluid is pressurized. While this straightening may be minor and in fact very subtle if viewed by the eye, the motion can be linked to a geared movement to create the full sweep of the needle, around the dial. The Bourdon tube tends to be a simple ‘C’ shape and made of a copper alloy for pressures below 60 bar (870 psi) where a stronger stainless-steel helical tube with a few complete wraps is necessary for the higher pressure ranges. The Bourdon tube is typically crimped, soldered or brazed to the socket which is the entry point for the pressurized fluid and also the fitting where the gauge is physically connected to the pneumatic or hydraulic system. While the Bourdon tube is not the only type of sensing element for pressure gauges, it is economical and effective for many applications.
A tiny motion from the sensing element is translated to a full dial sweep by a gear movement.
Diaphragm gauge
The diaphragm gauge is well suited for low pressure ranges.
Try out this gauge simulation on LunchBoxSessions.com.
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Typical sensing range: 0 to 40 bar (0 to 580 psi) From the outside, a diaphragm pressure gauge looks the same as a bourdon tube gauge, with the typical circular housing and an indicator needle that sweeps along a dial. The difference is found in the sensing element. Instead of a Bourdon tube deforming according to pressure, the membrane in a diaphragm gauge flexes against spring resistance. This deflection drives the indicator needle around the gauge face, via mechanical linkage. The large surface area of the diaphragm lends itself well to low pressure measurements. Small pressure changes are picked up easily. However, the diaphragm is vulnerable to high pressure. Exposure to a pressure spike beyond its rating may rupture the membrane. You’ll know if this has happened — the indicator needle will sit at the bottom of the scale and never move again. Diaphragm gauges are also adaptable to different media mixtures. The diaphragm can be coated with one of several materials to resist abrasion or corrosion from unusual www.fluidpowerworld.com
media. And unlike a winding Bourdon tube, the diaphragm has a large surface area, which provides lots of clearance. Challenging media full of particulate is less likely to clog this gauge. You can even purchase flange-fit gauges, which locate the diaphragm right at the interface point, making it nearly impossible to clog. Bellows
Typical sensing range: 0.03 to 5 bar (0.5 to 75 psi). A bellows-type gauge is typically used in low pressure applications, but it can be specially constructed to tolerate higher pressure instead. Some bellows gauges measure through the expansion of the bellows. The measured liquid is channeled into the bellows element, and as pressure increases, it pushes the bellows to expand. Alternately, a bellows gauge might direct the measurement liquid into the cavern around the bellows element to compress it. In either arrangement, it is the movement of the bellows that slides the mechanical linkage driving the indicator needle. Like the diaphragm and bourdon tube gauges, the needle is mechanically linked to the sensing element. Housing
ABS plastic is generally the standard housing material for all three of these gauge types. This plastic is light and inexpensive, but it won’t survive much rough treatment. Consider the installation conditions. Will this gauge be permanently mounted in a relatively protected location? Or will it be carried around by millwrights, or located where an object may fall on it? The housing can generally be upgraded to stainless steel, which will fare better in adversity than the ABS plastic. Liquid fill
Gauges might be referred to as “dry,” or they can be liquid-filled. The liquid fill option provides dampening against environmental vibration. It can also provide lubrication for the movement mechanism. Many liquid gauges are hermetically sealed,
but some have a small valve at the top. Glycerin and silicon are two popular liquidfill options for hydraulic pressure gauges. Glycerin is typically used for indoor installations. It offers good dampening within a temperature range of –4° and 140°F (-20° and 60°C). Silicone maintains a low viscosity even at colder temperatures and is often preferred for colder climate applications. Look for good dampening between -40° to 140°F (-40° to 60°C). Maintenance and care
There aren’t really any serviceable parts in a typical gauge, but there are some requirements for long life and reliable accuracy. Often a pressure gauge is installed in a system with an on/off valve in place at the entry fitting. This valve allows the gauge to rest on the pin at zero until a reading is needed. The gauge stays calibrated longer when left in this state. The viewer of the gauge opens the valve when a reading is needed. Later when the system is shut down and the needle rests at zero, the valve is closed once again. Some liquid filled gauges used as portable diagnostic instruments may include a small on/off venting valve at
the top of the case. This valve may need to be open to the atmosphere for an accurate reading, but it will allow the liquid to leak out if not closed once again before the valve is tilted. If the fluid leaks out, the life of the gauge may be shortened.
The gauge with two connections is used to measure the difference in pressure between two zones.
Temperature vulnerability
All three analog gauge types we’ve looked at — Bourdon tube, diaphragm and bellows — will demonstrate some inaccuracy with temperature changes, whether they are changes within the measured fluid, or the ambient temperature around the gauge. This is due to fluid expansion, as well as the properties of the metals and materials used in the gauges and sensing elements themselves. To limit inaccuracy, try to take readings at roughly the same system temperature and ambient temperature. When that’s not practical, at least note the temperatures so that they can be considered when evaluating the reading. Impact shock
If your gauge is not going to be permanently mounted to one location, consider adding a protective boot to cushion against accidental impact. In our own classroom environment, we’ve found that unprotected bourdon tube gauges can lose calibration after only one or two drops. Needless to say, all of our gauges are now covered with protective boots.
The ‘C’ shaped Bourdon tube straightens as pressure increases, with linked motion to the gear movement.
Pressure shock
Pressure spikes can ruin calibration, or even destroy the delicate sensing mechanism of bourdon tube, diaphragm, and bellows gauges. If your system suffers an overpressure event, make sure to examine the gauges for signs that they have lost calibration. If your gauge is the type with an on/off valve, this is another reason to leave the gauge shut off from the system unless you intend to take a reading. When the valve is off, it should isolate the gauge from pressure spikes. Losing calibration
If you are convinced that the hydraulic system is completely shut down and depressurized, but the indicator needle does not rest on the zero pin, the gauge has gone out of calibration. It may be able to be recalibrated if it has not been damaged, but it’s more likely that the gauge will need replacement. Differential piston gauge
Typical sensing range: Up to 680 bar (10,000 psi) Let’s finish up with a look at a slightly different style of gauge. A pressure gauge with two connection points is often required to determine the level of clogging in a full pressure filter element, or to measure the margin pressure in a load sense hydraulic system. Differential pressure gauges compare the pressure between two different
Try out this gauge simulation on LunchBoxSessions.com.
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Ordering your gauges with an optional rubber boot provides extra protection from shock damage.
fluid zones. All of the gauge styles we’ve seen so far — bourdon tube, diaphragm and bellows — can be adapted for differential measurements, but the piston gauge departs from these in a few significant ways. Bypass flow
Piston gauges can have a small amount of bypass flow from the highpressure side to the low-pressure side. (If your application cannot tolerate even a minimal amount of mixing between the two ports, a different style of differential gauge might be your best choice, or you may select a piston-type gauge with a separating diaphragm to prevent bypass flow.) The pressurized fluid on both sides of the gauge simply pushes on either side of the piston, with a spring working to hold the piston centered. Magnetic linkage
Instead of a mechanical linkage, a magnet on the piston carries the needle indicator along as it shifts. There is no delicate mechanism and no spring to become over-flexed or deformed by an extreme pressure spike, so expect a long and reliable life from your differential piston gauge. Conclusion
Accurate gauges take the guesswork out of your hydraulic system performance. Keep your readings accurate and reliable by selecting the best gauge for your system pressure and operating environment. Protect your gauges by installing them in safe locations, choosing the appropriate casing and fill options, and even outfitting them with a protective boot if needed. Understand the behavior and limitations of each gauge type, so that you are not fooled by a gauge that has lost calibration. FPW
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Hydraulics in mining: safe and reliable
Eliminating downtime and ensuring safety in mining — two benefits hydraulics provides consistently.
Josh Cosford • Contributing Editor More than almost any other industry appropriating fluid power, mining is where safety sits front and center from design to execution. Surface mining enjoys bragging rights to some of the most massive machines ever manufactured by humans. Vehicles of downright monstrous proportions possess the power to smatter a pickup truck as easily as a thumb smears a tiny red clover mite crawling up your patio furniture. Despite the destructive capacity of surface mining machinery, underground mining sits at the head of the boardroom table of jeopardy. 40
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| istockphoto.com
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Hydraulic clutch cylinders from Higginson Equipment, undergo a rigorous testing and manufacturing regimen to ensure they meet the safety requirements in mining hoists.
Hydraulics are critical to the safe operation of many machines in a mine.
High power density, inherent controllability, and mature technology make hydraulics a safe and reliable choice to control machinery.
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Hundreds of lost lives result from single, horrific accidents, especially related to underground explosions. For as long as we have been mining, we have been sacrificing lives to feed the world’s industrial and commercial machines. Miners are unsung heroes with next level bravery, and these heroes must never go unrecognized. With what we’ve learned in the past few hundred years, I’d like to say miners are now perfectly safe. Sadly, large scale disasters happen in mining, but that doesn’t mean we haven’t made huge strides in caring for our valuable human resources. Much of what the mining industry focuses on is indeed safety. Track record or not, the mining industry as a whole is committed to protecting important lives. If new technology, techniques and temperament combine to save even one life, that’s a step in the right direction. For generations, fluid power has been the top choice for underground mining machinery for various reasons. One of the most important has been its strictly hydro-mechanical operation, previous to the more recent electrical or electronic control. When fluid is transmitted under pressure to achieve work, no electrons are required to activate valves or actuators. No electrons mean no spark. No spark means no ignition source. Since the beginning of mine safety awareness, the potential has always been www.fluidpowerworld.com
there to create a spark that could ignite methane or subsequently, coal dust. Direct ignition of coal dust is rare, especially with our current mindfulness of safety, but when methane first ignites, the high energy provides the potential to ignite coal dust. A hydrostatically driven mine vehicle using only hand- and foot-operated valves to operate requires absolutely zero electricity. Buckets, conveyors, drills and other machinery need not require a single electrical component aside from the engine’s electric ignition and lighting. The old school hydraulic machines kept miners safe for many generations before electronic control was developed to resist and avoid any contribution to spark or explosions. These days, electronic control systems are prolific in mines, but the bulk of the work is still hydraulic in nature. Hydraulics are critical to the safe operation of many machines in a mine. High power density, inherent controllability, and mature technology make hydraulics a safe choice to control machinery. One category of machinery often overlooked for its need for hydraulics’ benefits is mine hoists tasked with hauling persons and machinery the vast depths underground. Mine hoists are advanced machines employing hydraulics on essential functions such as the brake and clutch. A hoist (or elevator) carries not only ore and machinery but also precious human cargo. In fact, some hoists lower and lift hundreds of persons more than two miles (three kilometers) into the dark depths. Although they travel at high velocity, hoists must move smoothly and safely. A sudden surge in either direction results in startled miners at best or various injuries at worst. So easily controlled is fluid power that proportional control over the pressure and velocity of braking systems is guaranteed. Multiple, redundantly controlled brakes ensure the hoist stops and starts smoothly, and the parallel nature of the valves provides many backup channels should one valve fail. Accumulators plumbed into the primary supply secure an emergency
supply of hydraulic energy should both of the pumps somehow fail simultaneously or if power unit electrical supply is lost altogether. The extensive quality control measures to manufacture mine-ready hydraulic components may be shocking to the average person. Valves, for example, must be produced to high standards meeting one of the various criteria set out by international bodies such as CSA, UL, and IEC, etc. Components must be explosion-proof, intrinsically safe, control reliable, and manufactured from high-quality raw materials. An explosion-proof component as defined in the National Electric Code dictates that “an enclosure must be able to contain any explosion originating within its housing and prevent sparks from within its housing from igniting vapors, gases, dust, or fibers in the air surrounding it. Therefore, explosion-proof, when referring to electrical enclosures, does not mean that it is able to withstand an exterior explosion. Instead, it is the enclosure’s ability to prevent an internal spark or explosion from causing a much larger blast.”1 UL or CSA rated control valves must be tested in the respective authority lab. Depending on the nature of the component being tested, it may need to operate reliably for a million cycles before it’s given the stamp of approval. Pressure tests may confirm the rated pressure, and if necessary, destructive testing may evaluate the burst pressure meets expectations. Accumulators are used frequently in mining, for example, so checking to see that burst pressure is indeed at least four times working pressure will prevent failure or injury down the road. It’s not good enough that mines only use high quality valves manufactured within the scope of various safety standards, but actuators must also represent the best of what’s available. Off-the-shelf hydraulic cylinders need not apply since their quality cannot be guaranteed without strict quality control measures implemented at every step of manufacture. Our team here at Higginson Equipment, where I work, can attest to the mining industry’s heightened prerequisite for quality. We manufacture hydraulic clutch cylinders for mine industry applications. Starting with high-quality alloys (such as 4140 for the heads and caps), we must send the raw material to third party firms for non-destructive testing before any chips fly in the machining process. Ultrasonic testing confirms the quality of the grain structure conforms to strict ASME and/or ASTM standards, and then the report is added to our quality package later provided to the customer. The strict quality control doesn’t stop at the raw
Accumulators are used in mining hoists to supply emergency hydraulic energy should both of the pumps somehow fail simultaneously or if power unit electrical supply is lost altogether. | courtesy of Roth Hydraulics
material. Critical components must be tested again after manufacturing. The machined piston rod pays a visit to the NDT lab once again to be examined via the magnetic particle test (or sometimes die penetrant test) to confirm the machining process left the material free from cracks, flaws, inclusions or lap-type defects. The threads must be perfect on both the piston and attachment end. Any such cracks or defects, however small, could be catastrophic when subjected to the extreme forces applied by pressurized oil. Upon assembly of machined parts, we perform dimensional checks on up to 20 critical surfaces, threads, and envelopes, all before we consider sending the quality control package to the customer. Upon approval of documents, our customer sends one of their senior quality inspectors to double-check the finished product. This is the final step in a long process to ensure valuable human lives and other capital are safe in the hands of a machine such as a mine hoist. FPW
Source: Specific Systems ( https://www.specificsystems.com/ common-questions/what-does-explosion-proof-mean)
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stress safety and speed Ergonomic and versatile vacuum lifters address today’s logistic bottlenecks.
Grant Welch • Manager, Handling Systems • Schmalz Inc. • Raleigh, N.C.
Online shopping has been growing at a rapid clip in recent years and, with the Covid-19 pandemic, that trend is further accelerating. Web sales are up significantly year over year as the widespread coronavirus keeps many shoppers at home and away from physical stores. Total U.S. online sales reached $73.2 billion in June, up 76.2% compared with $41.5 billion a year earlier, according to research from Adobe Analytics. Manufacturers, distribution centers and transporters are facing added pressure to move more goods quickly and safely. That holds for both the logistical flow of wares in fulfillment and distribution centers, as well as for producers that must handle, transfer and package products within individual plants. The often-manual tasks mostly involve lifting, rotating and carrying. For instance, products are typically loaded into cardboard boxes or crates, which
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are then picked up and moved from conveyor belts to a transport trolley or stacked on pallets. Companies therefore need to optimize their handling processes in terms of speed and efficiency, but at the same time protect the health and safety of their employees. Thus, there is a heightened interest in ergonomic lifting devices. Vacuum tube lifter
Schmalz, an experienced manufacturer in this field, designs individual handling systems
and crane systems that improve the pace of material flow and reduce costs — all while maintaining a keen focus on ergonomics. As one example, Schmalz has developed the JumboFlex vacuum tube lifter for dynamic handling of workpieces weighing up to 110 lb (50 kg). It consists of a vacuum generator, lifting unit, operating unit housed in the handle, and a vacuum gripper. The device attaches to a supporting bridge, gantry or jib crane. The JumboFlex is characterized by its lifting unit, essentially a flexible tube
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The JumboErgo vacuum lifter lets workers move large and unwieldy workpieces weighing up to 660 lb.
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that contracts and extends to raise and lower loads. To pick up and lift a product, a vacuum pump, blower or ejector generates a vacuum in the system by continually evacuating air. The resulting difference between negative pressure and ambient pressure draws the workpiece to the gripper. Once the item has been secured, a change in flow rate causes the lift tube to contract and lift the load. To lower and release, the control element feeds atmospheric air back into the system. Vacuum level reduces and causes the lift tube to expand and lower the load. Height is precisely controlled by metering the amount of atmospheric air that is fed into the system. Maximum venting via the operator handle completely eliminates the vacuum and releases the load. The control handle fits comfortably in one hand and lets the operator work for extended periods of time without fatigue.
Simple finger-tip control with the JumboFlex ensures safe handling of fragile products.
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Get a grip Engineers at Schmalz have collaborated with ergonomics
researchers at the Technical University of Munich to design three new operator handles for the JumboFlex vacuum tube lifter. Regardless of whether users are right or left-handed, the devices enable load movement with minimal effort and fingertip control over lifting, lowering and releasing of goods. The new control handles can increase safety, and simplify or accelerate the handling process. The JumboFlex Safety+ operator handle focuses on optimum safety. To release a workpiece from the vacuum tube lifter, workers must use both hands to operate a release lever and a control button at the same time. The two-hand concept controls release and protects particularly delicate items. Disabled users can also work safely with the Safety+. The option to adjust the lowering speed directly on the handle using a screw provides additional protection. The unit accommodates all JumboFlex lift capacities (44, 77 and 110 lb). The JumboFlex Easy-Release control system also has an additional release lever. However, its function and operation are entirely different. Pressing the control button and auxiliary lever immediately reduces residual vacuum. This makes it much easier to set down a load, especially when handling airtight objects or when using large suction cups or grippers with bellows cups. To prevent the release lever from unintentional actuation that prematurely reduces the residual vacuum, the lever remains locked until the control button is fully depressed. In contrast to the Safety+, the user can carry out the handling process with one hand — leaving the second hand free to align the vacuum-gripped load. Whereas the Flex Easy-Release is designed to be locked in place, the JumboFlex Quick-Release allows loads to be deliberately ejected during lifting. With this product, the aim is to
Operation is extremely intuitive with simple one- or two-finger control. The system is suited for machine loading, shipping and picking, and many other lifting applications. An extensive range of available grippers makes the lifter ideal for a wide variety of objects such as boxes, bags, barrels and wooden boards. These include simple, round vacuum cups for compact goods such as cardboard boxes and buckets, and cups with a skirt for optimal sealing on plastic bags and shrink-wrapped packages. Other versions include double- and four-head suction cups for open, clamped, glued or larger flat workpieces. And universal grippers with multiple cups are suited for boxes that vary in size and shape. Such devices can safely lift a load even when the suction area is not completely covered. Operators can swap out grippers quickly and easily without tools using an integrated quick-change adapter. And with a 90° slewing mechanism, workpieces can be gripped on the side and automatically swung into a horizontal position. Like the vacuum grippers, other system components can be
The JumboFlex Safety+ operator handle requires both hands to control release and protect delicate items. shorten cycle times when robust workpieces need to be moved quickly — for example when handling baggage at an airport. A second control element releases the goods immediately. Like on the Easy-Release, the release lever is attached to the operator handle but is not locked in position. Workers can actuate the lever at any lifting height. Both the Easy-Release and Quick-Release products are only designed to accommodate the largest JumboFlex configuration with a lift capacity of 110 lb. As always, different suction cups can be used for different workpieces.
The JumboFlex permits one-hand lifting of loads weighing up to 110 lb
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No Kinks No Hose Twisting
Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime cutting the overall cost of hydraulics.
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configured to meet individual customer specifications. That includes several types of vacuum generators. For instance, EVE electric vacuum pumps feature short evacuation times, low power consumption and are available in versions with 25, 40, 50 or 67 m³/hr suction capacity. Or users can opt for the SBPL, a basic ejector with low compressed-air consumption and a maximum suction rate of 52 m³/hr. An optional SRC remote control for vacuum generators lets workers switch the unit off and on during work breaks directly at the operating element. The SRC has an integrated induction generator and requires no external energy. It operates at the push of a button and saves up to 40% of the energy consumed versus systems that run continuously. The JumboFlex vacuum tube lifter provides a maximum lifting stroke of 5.9 ft (1.8 m) and maximum lifting speed is 3.28 ft/ sec (1 m/sec). The large effective suction area confers safe, secure and damage-free gripping by using vacuum. Only one person is needed for handling, productivity increases thanks to reduced loading times, and there’s minimal downtime due to employee injury.
Personnel using JumboFlex High-Stack devices can pick up boxes and bags off the floor and stack them up to 8.4 ft high, all while maintaining an upright posture. integrated rotary union for continuous swiveling of the device. An extended, ergonomic onehand control handle and guide bar controls up and down movements. A second guide bar lets the operator use the other hand to easily maneuver the vacuum tube lifter. Handle length and guide bars are adjustable. To prevent the unintentional release of workpieces from a sizeable height, the High-Stack is equipped with a special release mechanism that ensures the operator can only release an object using a second control button. Again, the standard quick-change system lets operators replace the extensive range of grippers without tools. Vacuum generation is by means of an electric-driven pump or ejector.
Aiming high
Schmalz also offers several other versions of vacuum tube lifters which differ in form and function, and are designed for specific applications. For example, the JumboFlex High-Stack helps ensure optimal use of vertical space in storage areas and transport equipment for workpieces weighing up to 110 lb (50 kg). With traditional lift systems, maximum stack height is usually 1.70 m, about 5.5 ft. To facilitate ergonomics, the company developed the JumboFlex HighStack that can pick up boxes and bags off the floor and stack them to a height of 8.4 ft (2.55 m), all while maintaining an upright posture. It includes a sturdy lifting tube and 48
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New JumboFlex Safety+, EasyRelease and Quick-Release handles are designed to increase safety or speed handling processes.
Heavy lifting
If jobs call for handling larger and heavier loads, Schmalz’s JumboErgo shares many characteristics of the JumboFlex but with a lift capacity of up to 660 lb (300 kg). One main difference between the two is the configuration of the operator handle. Instead of using just one hand, the user operates the JumboErgo with both hands, to always maintain full control over heavy objects regardless of size and shape. A twist grip on the JumboErgo is designed like a motorcycle throttle for lifting, lowering and releasing the workpiece. The length of the operator handle can be varied, which helps ensure that workers always maintain a safe distance from the load. Thus, outsized or hefty items like boards, boxes, sacks and rubber bales can be moved gently and precisely.
high flow rate compressed-air vacuum generator for workpieces weighing up to 187 lb (85 kg). Safe support
To complement the various handling devices, Schmalz makes an extensive range of crane systems with lift capacities to 2,204 lb (1,000 kg). Column-mount or wall-mount jib cranes made of aluminum are often recommended. They combine low-friction operation with lightweight components. This increases efficiency and working speed without impairing positioning accuracy or ergonomics. With a maximum jib length of 6 m and a swivel angle of 270° for the column-mounted jib crane or 180° for the wall-mounted jib crane, a vacuum tube lifter can cover a significant operating range. The crane system can be adapted to the existing infrastructure at a minimal cost while permitting a high degree of flexibility. FPW
An extensive range of available grippers makes the lifters ideal for a wide variety of objects, including boxes, bags, barrels and boards.
Schmalz | schmalz.com
WHAT DO YOU THINK? Connect with thousands of engineering design professionals online.
A modular system lets users easily configure multiple vacuum grippers that can be custom tailored to a specific application. And among the vacuum pumps offered is the SBV electric vacuum generator. This continuously variable, frequency controlled blower adjusts power consumption to match changing loads and thus operates with high efficiency. The SEM ejector, another option, is a compact, www.fluidpowerworld.com
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PRODUCT WORLD
Air dryers quadruple maintenance intervals in rail applications
Rugged digital hydraulic pressure gauge
This rugged digital pressure gauge GE2514A from BVA Hydraulics is extremely accurate and oďŹ&#x20AC;ers a thick rubber shell to protect against the toughest elements. More precise readings will ensure users get the job done right the ďŹ rst time. It has a 5-digit display that allows readings over 10,000 psi and zero reset feature. Connection is via a Âź-in. NPT 304 SS. It is rated for 1 million cycles and for operating temperatures of 14 to 122° F (â&#x20AC;&#x201C;10 to 50° C). The user-friendly design features a simple two-button operation that allows operators to change settings quickly and eďŹ&#x20AC;ortlessly. It also has a durable rubber exterior, continuous backlight feature. The interchangeable design allows easy swapping out of one design with the new digital gauge by simply unscrewing the old and screwing in the new. Press the Power button, and you are up and running. Batteries are included.
Rugged connectors for easy conversion from DIN to Deutsch connection Patented adsorbent drying material removes humidity from compressed air systems, reduces downtime, energy, and life-cycle costs by extending maintenance schedules. These two new compressed air dryers are designed to extend maintenance intervals, minimize downtime, and reduce energy costs in rail applications, including brakes and door control. Typically, air dryers have an average service interval of fewer than two years. The Aventics RDD (Roll-Up Dessicant Drying) and RDDmin air dryers, have a service interval of eight years or 25,000 operating hours. The new products have a proprietary adsorption medium that removes humidity from compressed air systems more eďŹ&#x192;ciently, reducing energy usage with a smaller envelope size and weight. The dryers´ shock- and vibration-resistant design further enhances their reliability in tough rail applications.
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The newest addition to the GatorMate line of products, the 2- and 3-pin GT Series of rugged, connectors are fully molded, eliminating the need to purchase expensive crimping tools and reducing the labor required to assemble former ďŹ eld-wire versions. With the addition of the 5JGT DIN to Deutsch adapter, any solenoid valve DIN connection can easily convert to Deutsch-style connection. The rugged GT Series is an all-in-one molded connector assembly proven to work in the harshest environments with an IP67 rating resistant to dust, vibration, shock, and moisture. The connectors are over molded to enhance connection performance and ensure that high stress or vibration will not cause unintentional disconnection.
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Inductive linear position transducers
Hose assembly tool for 1 to 2-in. barbed fittings
AutomationDirect automationdirect.com
KOUL TOOLS koultools.com KOUL TOOLS has released the EZ-ON Hose Press Model 454 hose assembly tool for 1-2-in. hose sizes. It has the same patented vise clamp and lead screw drive system found on the 409B model but scaled up for larger sizes. The new 454 model is compact, lightweight, and has the power to handle difficult hose assemblies. Like the 409B, it is operated with a small impact gun or ratchet, allowing users to do hose assembly in almost any location.
Linear Variable Inductance Transducers (LVITs) from Alliance Sensors Group convert the linear displacement of an object into a proportional electrical signal output of 0-10 V or 4-20 mA (depending on model). LVITs are contactless devices designed for dimension or position measuring applications where the sensing element cannot be attached to the object being measured. LVITs exhibit outstanding repeatability and are used when higher accuracy is required. The LVIT proprietary SenSet process can match the endpoints of the sensor’s analog output with the ends of the range of motion of a workpiece (such as a hydraulic cylinder ram) in which the sensor is installed. The SenSet feature permits the user to optimize the position measuring system resolution over the full range of motion. Configuration styles include spring-loaded with ball tip, 19 mm (0.75in.) cylinder with rod eye mounting, and 27 mm (1.05-in.) cylinder with rod eyes. Stroke lengths vary from 6.35 to 457.2 mm (0.25 to 18 in.).
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PRODUCT WORLD
Universal Tractor Hydraulic Fluids
Dual hydraulic reels
Dual hydraulic reels, designed for use with hydraulic tools and accessories, are oďŹ&#x20AC;ered in two conďŹ gurations; the MPD and the TDMP series. As with most Coxreels spring rewind reels, the dual hydraulic reels have single-sided access for both the spring and the swivel. The supply and return lines come in the same side of the reel and feed into an external ďŹ&#x201A;uid path via a removable, dual-port hydraulic swivel. This same inlet and swivel side of the reel also houses an easy-to-service spring cartridge motor. This design, unique to the industry, allows for service of the main components without removal of the reel when the reel is installed into truck body boxes, as is popular in the service truck industry. Because the reel can be installed with the back side of the drum right up against a wall without concern for incoming hose lines, space utilization is improved. For capacities up to 30-ft of dual hose, the MPD series features a dual axle support system with a solid steel 1-in. axle. The TDMP is robustly built for capacities up to 50-ft, with triple axel support, dual arm guides, and stainless-steel hose guide rollers.
Universal Tractor Hydraulic Fluids (UTHF) are commonly used in agriculture as well as in many types of mobile and oďŹ&#x20AC;-road equipment including excavators and loaders. They improve the productivity of farm tractors by protecting the tractor parts. UTHF provide eďŹ&#x192;cient braking, seal compatibility, oxidation stability, thermal resistance, protection against dust and corrosion, and anti-foam characteristics. Also, smoother operation and long-life span of tractors can be achieved using these ďŹ&#x201A;uids. Champion UTHF ďŹ&#x201A;uids meet or exceed several manufacturer requirements, such as John Deere, AGCO, Volvo, Allison, and Parker. They are available in 1, 2.5, 5 and 55 gal. An Ultra Full Synthetic ďŹ&#x201A;uid is also available in 55 gal.
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Some of the best companies in the USA use GRH Products in their machines. Why shouldn’t you?
The best American manufacturers buy only from the best.
ALA INDUSTRIES LIMITED 3410 Delta Drive • Portage, IN 46368 Tel. 877-419-8536 Fax. 219-762-2066
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Web. www.alaindustrieslimited.com
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COMPONENT FOCUS Edited by Paul J. Heney, VP • Editorial Director
of rtesy
| Cou
on
Emers
Pneumatic cylinders There’s a bit of a joke in some circles that there’s nothing much new in standard fluid power components — cylinders, valves, pumps. But although these products have been around for many decades, that doesn’t mean that there aren’t new aspects to these workhorses of the industry.
Take pneumatic cylinders. Two recent product releases show some creative updates to these actuators. Emerson’s new Aventics TM5 TaskMaster aluminum cylinder reduces cost, energy consumption, equipment wear and downtime. And Bimba’s Position Feedback Cylinder (PFC) provides continuous position sensing in a lightweight, small bore air cylinder.
It’s all in the cushioning
With its rugged aluminum body construction and a steel piston rod, the TM5 TaskMaster features Emerson’s state-of-the-art pneumatic cushioning technology. This allows an ideal cushion adjustment to slow down the piston to a stop by the time it reaches the endcap. Ideal cushioning reduces the time it takes the cylinder to complete a stroke, allowing an improvement in efficiency that significantly boosts machine speed and lowers endcap hammer. Ideal cushioning 54
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also reduces cycle time and enables these cylinders to carry higher loads without sacrificing performance. The cylinder incurs less stress and there is no end-of-stroke bounce or endcap slamming, which is a main source of cylinder wear, slowness and noise. Ideal cushioning thus lengthens cylinder operating life and reduces downtime related to cylinder failure. Additionally, it reduces machine noise and vibration while reducing energy consumption. “The all-new TM5 TaskMaster gives machine builders and end-user manufacturers the tools to make their machines faster and more reliable,” said James Ward, VP engineering, machine automation, Americas, at Emerson. “It’s the highest performing and most reliable TaskMaster cylinder ever produced, so it gives them an opportunity to build a competitive advantage.” The NPFA-compliant TM5 is the latest addition to the TaskMaster line of aluminum cylinders, an industry standard for 50 years. Emerson’s online configurator provides a product part number, pricing and 2D and 3D CAD drawings in one convenient place. In addition, all product information and spare parts can be found in the Aventics Pneumatics Shop. TaskMaster TM5 provides a high-quality and readily available interchange cylinder to meet OEM and machine requirements. In combination with the online tools, a fast-delivery program allows for quick turnaround of orders, reducing lead times for customers. From configuration to production, Emerson´s process is completely automated.
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Bimba Manufacturing’s PFC provides continuous position sensing in a lightweight, small bore air cylinder. The PFC contains an internal linear resistive transducer (LRT) mounted in the cylinder rear head. The LRT probe, which has a resistive element on one side and a collector strip on the other, sits inside the cylinder rod. A wiper assembly is installed in the piston. Moving the piston creates an electrical circuit www.fluidpowerworld.com
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wave travels back to a signal converter in the electronics and is used to determine position — all in a few µsec. It is calibrated to produce exactly 0 V fully retracted and 10 V fully extended. In practice, the unit senses position as the piston moves back and forth. And it provides absolute position information. Accuracy — the combined effects of non-linearity, repeatability and hysteresis — is ± 0.016 in. maximum anywhere along the stroke. Non-contact operation provides many advantages. The technology is suitable for applications that involve dirty or moist environments, rapid oscillation over a small increment of stroke, and vibration. In addition, it is relatively immune to airline contamination. Both of these cylinders can operate with controllers like Bimba’s Pneumatic Control System, Digital Panel Meter Model, or Electronic Controller, as well as similar units. And for rotating applications, Bimba’s Pneu-Turn rotary actuator with position feedback is a rotary rack-and-pinion actuator that has a rotary potentiometric feedback transducer attached to the output shaft. It provides continuous shaft position sensing within ±0.5°.
| Courtesy of Bimba
between the resistive element and collector strip. Resistance in the circuit is proportional to piston position, which is used to produce an analog signal that the controller uses to determine a precise position. Three factors — resolution, linearity and repeatability — determine the LRT’s accuracy. Resolution is stroke sensitive: the longer the stroke, the less the resolution. It’s typically around 0.002 to 0.003 in. Linearity, the maximum deviation of the output voltage to a straight line, is ±1% of stroke. And mechanical repeatability is ±0.001 in. Thus, overall accuracy is on the order of a few hundredths of an inch. The Position Feedback Cylinder Non-Contact (PFCN) is similar to the PFC, except it uses a magnetostrictive sensor instead of an LRT. In basic terms, magnetostriction involves a fixed sensing element, called a waveguide, made of ferromagnetic material that runs the length of the cylinder. A magnet mounted on the piston creates a magnetic field. Short current pulses generated by the sensor electronics travel along a conductor attached to the waveguide. When the magnetic fields induced by the current and magnet interact, it generates a torsional strain in the waveguide. This mechanical
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AD INDEX
ACE Controls ....................................31 ALA Industries ..................................53 AutomationDirect .............................. 1 Clippard ............................................BC Daman Products...............................46 DMIC ................................................27 Fabco-Air, Inc....................................22 Festo .................................................20 Flow Ezy Filters.................................29 FluiDyne Fluid Power .......................38 HYDAC International .......................... 3 Hydraulex Global ................................ 5 Hydraulics Inc ...................................13
J.W. Winco, Inc. ................................26 Kraft Fluid Power ..............................18 LunchBox Sessions ...........................39 Main Manufacturing .......................... 8 Motion Industries .............................. 9 MP Filtri USA ...................................IBC Polyconn ...........................................11 SFC Koenig ........................................25 Super Swivels ...................................48 Tompkins Industries Inc. ............. IFC, 8 Veljan Hydrair..................................... 7 Webtec .............................................55 Yuken ................................................23
LEADERSHIP TEAM Co-Founder, VP Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memic Co-Founder, Managing Partner Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson
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Hydraulic Contamination Solutions • Complete hydraulic health checks • Real-time contamination monitoring • Prevents unscheduled downtime • Protects machinery, enhances lifespans
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PASSION TO PERFORM
Precision Flow Control Designing efficient systems involves much more than simply understanding a few basic principles. There is a true art to balancing the specific requirements of an application in order to achieve the desired goals in the best possible way. Help us understand the unique needs of your application and together, we’ll develop something that surpasses what any of us could have done alone. Contact your distributor to learn more, or visit clippard.com to request a free catalog and capabilities brochure.
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