Tough hydraulics for Antartic temps p. 34
Tracking power in solar p. 38
Compact rodless linear actuators p. 42
www.fluidpowerworld.com
December 2020
Custom hydraulics
carries the opera to new heights PAGE 18
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2020 Leadership in Fluid Power Welcome to Fluid Power World ’s first Leadership in Fluid Power winners’ section, where we are profiling the winners in the Leadership Awards Program that we have been promoting throughout the year. The Fluid Power World user community has cast votes and we are pleased to celebrate the winners in this special section of Leadership in Fluid Power. The three companies noted in the following pages are solution providers and innovators of pneumatic and hydraulic technologies and key accessories used in system design. This first class of leadership companies reflect the vision, integrity and creativity of their design and manufacturing engineers via their outstanding products and services.
Mary C. Gannon • Editor mgannon@wtwhmedia.com On Twitter @DW_marygannon
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www.fluidpowerworld.com
2020
Leadership in Fluid Power — Fluid Power Accessories
Congratulations! Anchor Fluid Power Anchor Fluid Power started business in 1983 in Cincinnati, Ohio under the original name Anchor Flange Company. As hydraulic systems were being developed to become increasingly powerful and more efficient, reliable and leak- ee connections were in demand. Anchor responded with a broad offering of high-pressure hydraulic flanges. In addition to SAE J518 & ISO 6162 style flanges, they also offer custom designs for a range of applications in demanding industries such as mobile equipment, steel production, plastic injection, offshore, and even subsea. By developing a service team focused on technical understanding and superior customer support, they have grown to become a leading supplier to the fluid power industry.
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Since then, their product offering has grown to include high-pressure ball valves, stainless steel WOG ball valves, flow control/needle/check valves, weld couplings, suction and return line adapters, and most recently, test point adapters and hoses. In addition, Anchor Fluid Power is an exclusive US distributor of Walther-Präzision, a world-leading developer and manufacturer of high-quality quick coupling systems. This unique partnership has brought exceptional value and safe connections to the North American market. Anchor Fluid Power carries certifications for ISO 9001, ISO 45001, and AS9100D (aerospace) and remains dedicated to continuous improvement in all aspects of the company. Product quality assurance is documented throughout the supply chain, beginning with raw material certifications. Ongoing independent material test analysis and hydraulic fatigue testing are integral components to their ISO 9001 Quality Management System.
Fluid Power h ip W in n e r 2 0 2 0 L e a d e rs P R ESENTED BY
www.fluidpowerworld.com
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2020
Leadership in Fluid Power — Pneumatics
Congratulations! Clippard Clippard Precision Fluid Control Products & Solutions Clippard provides thousands of standard and special precision flow control products to design engineers and manufacturers around the world. Clippard’s expertise is not limited to providing over 6,000 standard products, but also offers a unique advantage by providing custom products and value-added assemblies for hundreds of applications. Products include Electronic Pressure Regulators & Flow Controllers Electronic Valves: High Flow, Analytical, Oxygen Clean & Proportional Isolation PTFE Media Isolation Valves Pneumatic & Electronic Pinch Valves Precision Flow Controls & Regulators 7, 8, 10 & 15 mm Electronic Valves Directional Control & Air Pilot Valves Value-Added Custom Assemblies Custom Components & Systems Designed for Customer’s OEM Solutions
877-245-6247 | clippard.com ISO 9001 Certified ®Minimatic is a registered trademark of Clippard Instrument Laboratory, Inc.
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www.fluidpowerworld.com
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For over 75 years Clippard has been manufacturing and providing products and solutions to design engineers and manufacturers in a wide, diverse variety of industries including drug dispensing, laboratory equipment, medical devices, material handling, analytical, chemical analysis, sampling, life science/biotech, genetic research, gas chromatography, spectrometry, DNA synthesizing, leak test equipment, blood analyzing, printing, diagnostic equipment, fermentation, semiconductor, packaging, water treatment and many more. The Clippard name has long been associated with high quality standards. True cra smanship used in the manufacturing of the Minimatic® line is not limited by a numbers standard. Customers have long recognized the partnership they have with the Clippard organization, and have grown to appreciate the high standards self-imposed in the manufacturer and testing of products. Excellence in design, materials and workmanship is the Clippard difference that assures your satisfaction.
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2020
Leadership in Fluid Power — Hydraulics
Congratulations! RAM Industries Inc. RAM Industries Inc. is proud to be a leader in hydraulic and pneumatic cylinder design and manufacturing. RAM’s ability to design and manufacture to a customer’s application is our specialty. We have the right hydraulic cylinders for your project, and designs that are engineered to optimize cylinder performance on your equipment. For almost 50 years, RAM has served OEMs in a wide range of applications with custom and innovative cylinder solutions. We have experience serving a diverse mix of industries: •
Agriculture
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Construction
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Forestry
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Industrial Manufacturing
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Marine
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Material Handling
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Mining
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Oil and Gas
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Transportation
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Waste Management
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Aerospace
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Attachments
RAM’s success is built on its engineering and technical expertise. RAM is wellversed in the latest technologies in cylinder componentry, cylinder design and manufacturing methods to ensure your cylinder functions exactly as required. Our team establishes a close technical rapport with the experts in your organization. Together we determine precise cylinder fit and function parameters critical to your equipment’s operation. RAM prides itself on building quality cylinders through an ISO 9001 registered system.
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RAM can supply cylinders om pre-engineered cylinder drawings; however, complete design services are o en the norm. Designs may evolve om a basic list of technical specifications or customer’s conceptual idea. A wide range of cylinder models, bore sizes, stroke lengths, materials, port arrangements, IN FLUID SH I P PO ER W integrated valve cartridges, seal configurations, position sensors and mounting D E EA options are available. RAM is synonymous with quality built, reliable cylinder solutions. Join the organizations that trust their reputation and equipment performance on the RAM name! Contact the RAM team of experts today!
Fluid Power h ip W in n e r 2 0 2 0 L e a d e rs PRESEN T ED BY
WWW.RAMINDUSTRIES.COM | ESTIMATING@RAMINDUSTRIES.COM
www.fluidpowerworld.com
12 • 2020
FLUID POWER WORLD
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FLUIDLINES Mary C. Gannon • Editor
Staying merry and bright It’s the holiday season of 2020, which can mean a lot of things. We could stay focused on the negatives, worry about COVID-19, potential lockdowns, missing family, bicker about postelection drama and more. Or, we could look on the bright side of things and see that things are starting to look up. In a recent webinar from the NFPA, Catherine Putney of ITR Trends said that while there are certainly some downsides, most of the leading indicators are on the rise — showing we’re all poised for a turnaround in industry and manufacturing. She said that we’re going to see a recovery trend pretty quickly (unless we see more mass lockdowns, as in Spring 2020). Many fluid power companies are indicating that business activity is mildly up or flat — much better than down in the scheme of things. As Paul Heney points out in his From the Field column on page 8, the hose industry is seeing signs of a rebound. And even Eli Lustgarten, President of ESL Consultants, revised his farm equipment outlook from his forecast during the NFPA IEOC in August, saying he’s observed a “dramatic change” to the farm sector outlook over the last few months. This, said Lustgarten, means the farm equipment recession is over and he projects a high probability of at least a double-digit gain in demand in 2021 rather than his previously projected modest improvement.
I could keep going with more news from associations and economists highlighting the positive news that the industrial sector is seeing. But just know this — things are finally looking up. And now that we know vaccines are coming, too, I expect we’ll see a return to in-person conferences, sales calls and trade shows, maybe more so in the second quarter of 2021 and beyond. We know it’s not perfect and we have a way to go before we’re back to normal in business and in our everyday personal lives. But I choose to stay merry and bright as we close 2020 — let’s continue to work hard to make this year one we’ll remember the rest of our lives for how so many of us were able to push on through. Let’s focus on the bright side. FPW
Mary C. Gannon Editor mgannon@wtwhmedia.com On Twitter @DW_marygannon
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FROM THE FIELD Paul J. Heney • VP, Editorial Director
Getting back to in-person? After nine months of Zoom events and virtual meetings, associations seem to be gearing up for a 2021 that may see a return to in-person conferences. With vaccines on the horizon for citizens in the United States, I’m hopeful that this can be accomplished safely. The value we receive from meeting in person, networking, and sharing ideas in a casual setting (like over a meal or during a cocktail hour) is hard to measure. NAHAD, which is moving forward with its annual convention for April 10-13, 2021 at the Marriott Marquis San Diego Marina, has really gone the extra step in ensuring that its members and attendees feel comfortable. Earlier this month, I sat in on a webinar that the association put on, specifically to address any concerns. Sam Petillo, President, NAHAD, expressed his optimism for the future of the hose industry. “The hose industry is climbing out of the economic slowdown,” said Petillo. “My company has seen — and I know others, even on the manufacturing side, have seen — the volume of orders improve substantially since June … we should expect to see a sustained recovery throughout 2021 and an even stronger rebound the year after that, as oil and gas rebounds.” Molly Alton Mullins, Executive Vice President, NAHAD, noted that: “Members really want this opportunity to get together.” NAHAD opened registration on November 17, and the group has seen a great response, according to Jessica Hauser Forte, Director of Conferences, NAHAD. They’ve already sold 45 exhibit booths, have 75 registrants confirmed and sponsorship money is coming in, as well. Seven hospitality events are booked in conjunction with the conference. The NAHAD office and the Marriott have worked hard to ensure the safety of attendees, and this came across clearly during the meeting. The group has a webpage at nahad.org/ aws/NAHAD/pt/sp/convention_covid with information from the hotel, different airlines, the city of San Diego, and local attractions — what each is doing in relation to Covid-19, what refund policies are, etc. All are live-linked, so they contain the most up-to-date information. According to Donna Lynn Chong, Resident Manager, Marriott Marquis San Diego Marina, the hotel is doing deeper, more frequent cleaning. Staff is focused on disinfecting high
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touch areas regularly and hand sanitation devices have been placed throughout the hotel. They’re using mobile technology to minimize physical contact, such as with mobile keys. Surface disinfecting wipes are available in all rooms. In-stay housekeeping is limited to reduce contact during each guest’s stay. And there are physical distancing signs all across the property. And Karlee Hartmann, Director of Event Planning, Marriott Marquis San Diego Marina, said food and beverage will look somewhat different — hotel associates will serve guests while wearing all the PPE that is expected and required. While we’re used to seeing 10 people at round tables at conferences, the Marriott is reducing chair count to four per table, to better social distance guests. Aisles in conference rooms now feature six feet of distance. There are dedicated entrances and exits into each conference room. Most of the hospitalities will be held outdoors. For the popular Showcase of Hose Solutions, aisles will be extra wide with pipe and drape between rows, and there will be plenty of ballroom space to spread out. Masks will be required in the hotel, except when a guest is eating or drinking. All hotel associates are also required to wear masks in the state of California. Mullins noted that cancellation policies will be extremely flexible, and if someone has to cancel, they will get all of their money back, or they can apply it to a future NAHAD Conference. No one wants people to travel to an event unless they’re comfortable going. It’s always best to make an informed decision — and I applaud NAHAD and its board for putting all the information out there, so each member can do what’s right for them. FPW
www.fluidpowerworld.com
Paul J. Heney
VP, Editorial Director pheney@wtwhmedia.com
On Twitter @wtwh_paulheney
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fluidpowerworld.com
HYDRAULICS
Rating the real performance of hydraulic pumps Low-and high-speed tests show that pump and motor performance can vary widely, depending on the speed and pressure. That’s critically important in electrohydraulic actuators and electric-motor drives.
INDUSTRIAL
Tracking the power in solar fields Fluid power technologies are abundant in solar polar panel use, as multi-axis control devices help follow the sun as it tracks through the sky.
PNEUMATICS
Rodless cylinder solutions for compact pneumatic linear motion Designers requiring linear motion should consider rodless cylinders to realize compact packaging and other benefits for pneumatic actuation, without the cost of electrically-driven options.
FLUID POWER WORLD
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F E AT U R E S
Rugged transporter handles Antarctic extremes An innovative design based on proven hydraulics and sophisticated controls ensured reliable and efficient performance.
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02
Leadership in Fluid Power Winners
06
FluidLines
08
From The Field
14
Korane’s Outlook
16
Association Watch
18
Design Notes
28
Fundamentals
30
Maintenance
32
Energy Efficiency
52
Products
59
Component Focus
60
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
ON THE COVER
The Met commissioned a custom hydraulic rotary union and hub design for power and data distribution for production of Mascagni’s “Cavalleria Rusticana.” | courtesy of Marty Sohl/Met Opera
12 • 2020
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EDITORIAL
MARKETING
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney
VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia
Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon
Digital Marketing Coordinator Josh Breuler jbreuler@wtwhmedia.com @wtwh_joshb
Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane Contributing Editor Josh Cosford @FluidPowerTips Contributing Editor Carl Dyke @carlindustry
PRODUCTION SERVICES
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2011- 2019
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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www.DMIC.com
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CSN - Downline Coupling CSN (P) - Downline Coupling Piloted HCSN - High Pressure Coupling HCSN (P) - High Pressure Coupling Piloted
HBL - Hose Barb To Male Thread BSE - Hose Barb To Male Thread 90 Deg EBS - Hose Barb To Male Thread 45 Deg
BV3D Actuator
SNS - Male Thread To Female Thread SNE - Male Thread To Female Thread 90 Deg ESN - Male Thread To Female Thread 45 Deg FL4SU - Flange
BVALP - Low Profile Suction Ball Valve
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BVLS - Stainless Steel Ball Valve
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KORANE’S OUTLOOK Ken Korane • Contributing Editor
Fluid power’s green evolution All indications are that mobile and industrial systems of the future will be more automated and more digitally connected. And many experts contend future systems will also increasingly be low-carbon and electrified. Some construction equipment OEMs, for example, are committed to autonomous control and cloud-based maintenance systems, and next-generation machines that reduce the environmental impact or run on batteries. But if that’s what the future holds, how best to get there? According to Niall Caldwell, Director of Danfoss Digital Displacement in Edinburgh, Scotland, “Some would say we’ve reached a fork in the road and we’ve got a choice to make as a society, and certainly as leaders of industrial companies.” One path is business as usual, where we continue to incrementally improve existing technologies, he said. But with mature technologies, particularly hydraulics, there are diminishing returns on further incremental improvements,
and which may never fully meet future performance requirements. Others contend that we need a green revolution and completely revamp our machines, perhaps with electromechanical drives and actuators, electrically powered by fuel cells. But these sorts of radical immature technologies come with a high cost and also a high risk, he cautioned. Many industries face a dilemma. Should they put their development money into conventional technology to keep pace with current market conditions, or put it into the green revolution and hope their investments eventually pay off? Caldwell suggests a better path. “It’s what I call a green evolution, a technology which gives us an evolutionary path towards a revolutionary result, but with manageable risk and cost.” Hydraulics is successful because it is compact and powerful, tolerant of harsh environments and shocks, and offers robust linear actuators, he continued. And lastly, it’s low cost, which often is the overriding consideration in many industries. But there are some fundamental limitations, including
Electric excavator with Digital Displacement technology is part of a green evolution in hydraulics. | Courtesy of Danfoss
poor energy efficiency and challenging control by computer. Together, these could handcuff conventional hydraulics when future applications demand more automation, efficiency and electrification. To address those shortcomings, Danfoss has introduced Digital Displacement Pump technology, what Caldwell calls “a fundamental reboot of hydraulic power for the 21st century.” At its heart is a software controlled, radial-format pump that enables and disables cylinders in real time, and results in extreme accuracy, quick response, multiple controllable outlets and dramatically improved efficiency, he said. Users can integrate custom control functions into the software to enable automation of future systems. And it attains over 90% efficiency over the vast majority of the operating range. “This is unprecedented in hydraulic machines,” said Caldwell. “For the first time, we’ve got a technology which can offer similar efficiency characteristics to electric machines.” Merely swapping a conventional analog pump with a DDP can cut excavator fuel consumption by 20% and with a 20% increase in productivity, he said. And next-generation system architectures will eliminate control valves and include regeneration to push fuel savings beyond 30%, or encourage electric prime movers. “This is a technology which makes a business case as well as an environmental case.” Through fuel savings and higher productivity, a DDP system can pay for itself in short order, which is dramatically different from other more-revolutionary technologies, said Caldwell. “This is a vision for the direction of the industry where we can incrementally improve and evolve towards that highly efficient, revolutionary impact that we all aspire to, but with manageable technical risks and with manageable cost.” FPW
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www.fluidpowerworld.com
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.
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GRH 2020_FPW_PEOPLE AD1_APPROVED.indd 1
Web. www.alaindustrieslimited.com
7/24/20 7:45 AM
ASSOCIATION WATCH Edited by Mary C. Gannon • Editor
NFPA Annual Conference registration is open for virtual attendance The NFPA is moving forward with a virtual presentation for its Annual Conference in 2021, which will take place February 24 – 26. The virtual event will bring presentations and networking right to attendees’ desks. Registration is now open. In addition to the virtual experience, pending confirmation of a safe and suitable hotel venue, NFPA will be offering in-person networking during a Power of Association event. The event will include the digital content of the virtual conference as well as offer in-person experiences. It will be managed in accordance with the latest
COVID-19 regulations. Details and registration for this option will be available soon. The virtual program will use an online platform, called Remo, to provide networking. The conference will include speakers in the morning, committee meetings into the afternoon and networking throughout the day.
In addition, attendees are invited to join a highly interactive virtual activity via Thriver. This year’s speaker lineup includes Peter Zeihan and Alan Beaulieu as well as Harry Kraemer and David Nour. Presentations will feature topics such as examining complex world and US events and leading during a volatile and ambiguous business climate.
The Remo platform offers features such as: • Face-to-face interaction in a virtual ballroom setting • Group and private video calls • Opportunities to connect with any event attendee
NFPA | nfpa.com
FPW
NFPA Fluid Power Scholarship application available January 1 The NFPA Education and Technology Foundation will begin accepting applications on January 1, 2021 for $2,000 scholarships available to students pursuing fluid power technology fields of study.
as NFPA Education and Technology Foundation and Pascal Society donors. Support these efforts by making a donation. For further information on the scholarship program, contact Amy Zignego, Workforce Program Manager, at azignego@nfpa.com.
Twelve of these scholarships are available this year. The deadline to apply is March 18, 2021. A minimum 3.0 GPA on a 4.0 scale, 500-word essay, and two letters of recommendation are required from each applicant. The Foundation’s goal is to help individuals enrolled in high schools, technical colleges, and universities pursue their interests in fluid power. Educators and students should visit nfpa.com to access the application once it becomes available. Programs like the Fluid Power Scholarships are made possible in part by the generous support of industry volunteers as well 16
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FPW
International Fluid Power Society encourages certifications The International Fluid Power Society is the only organization that provides comprehensive technical certification offerings for all professionals in the fluid power and motion control industry. IFPS certification tests provide an objective, third-party assessment of an individual’s skill level. Certifications are portable and recognized industry-wide. Individuals who successfully master a level of competency are issued a credential. To keep pace with changing fluid power and motion control technologies, certifications must be renewed every five years. Certification is a straightforward process — consider the steps below and register to attend training and testing now. Step 1: Select Your Certification. Determine which test you should take and what certifications are offered.
Step 2: Submit Your Application. Options include Specialist, Technician, Mechanic, Connector & Conductor, Engineer, and System Designer. Step 3: Be Prepared. IFPS study manuals are available in print, PDF, flash drives, and interactive online. Online Interactive Study Manuals for Hydraulic and Pneumatic Specialist Certifications are available. Once purchased, you’ll have access to IFPS’ learning management system for one-year. Online Pretests, as well as pretests in the back of the study manual, are highly recommended before you take your certification test. Certification Review Classroom Training – IFPS offers a 4-day, in-person training with one of its certified training instructors. This training is generally for groups of 5 or more. Animated Circuits – The schematics in study manuals are available in animation and are great for a better understanding of how hydraulic and pneumatic circuits operate. The
circuits are color-coded and are available as .mpf and .wmv files Webinars & Study Groups — These webinars and study groups, presented by accredited instructors, are a free resource offered to members. Members also have access to a library of previously recorded webinars. Consider an IFPS Membership Step 4: Take your test at your scheduled location. Step 5: Recertify in five years. FPW
IFPS | www.ifps.org/certifications
Fluid Power Reference Handbook available for discount The International Fluid Power Society is currently offering a special discount on its Fluid Power Reference Handbook for two weeks though the end of December. Purchases made between December 14 and 28 are reduced by $15. Members can purchase the Reference Handbook for $59.95, while non-members
troubleshooting algorithms, general safety guidelines and is ISO, ANSI and SAE Compliant. Topics cover safety, symbology, fluid power data, fluids, fluid conditioning, connectors and conductors, reservoirs, compressors, prime movers, valves, cylinders, motors, semi-rotary actuators, vacuum, accumulators, control theory, troubleshooting algorithms, pumps, and a glossary of terms. FPW
will pay $79.95. The Fluid Power Reference Handbook contains 378 pages of must have information. It comes in soft and hard-cover and contains full-color graphics,
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IFPS | www.ifps.org/training-resources-handbook
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DESIGN NOTES Mary C. Gannon • Editor
Custom hydraulics carries the opera to new heights
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www.fluidpowerworld.com
When New York City’s Metropolitan Opera (The Met) began its initial production development for a new double-bill program of Mascagni’s Cavalleria Rusticana and Leoncavallo’s Pagliacci, its team of engineers and set designers were stumped on how they could bring together a rotating hydraulic design with the power and data needs the show would require. One of the main keys to the performance was the use of the Met’s rear wagon turntable, which is essentially a motorized wagon used to preset scenery by driving it on and off stage and facilitate rapid transitions of very large-scale scenery, said Jeff Mace, Director of Production Operations for The Met. The rear wagon turntable is behind the main stage when viewed from the audience, and it has a built-in 58-ft diameter rotating turntable, originally commissioned in 1966. Over the years, new capacities have been introduced to this turntable, such as a 208-V, 3-phase rated power transmission slip ring for high-voltage electric transmissions, and a single data commutator to pass Ethernet data through the slip ring. This allows the Opera to have the turntable
spinning in front of the audience, but also to control equipment and effects, lighting, automation, video, and more. The Production, directed by David McVicar with set design by Rae Smith, required a 30-person banquet table on that turntable. At the time, Mace said, the team was not sure if the table would be raised up and down more than once or if the lowering and raising was going to happen while rotating, so they needed a solution that could fit all those needs. It became readily apparent a hydraulic solution was needed, because they needed the power density and lower noise afforded by hydraulic systems versus something actuated by electric motors. A standard hydraulic scissor lift seemed the most logical choice. “And then we had to confront the problem of how to get hydraulic fluid power distribution out to the cylinders at the time of this effect, when we had no idea if we were going to need to do this while it was rotating, or while it was fixed,” Mace said. The rotation possibility introduced complexity because finding an off-the-shelf rotary union that could fit the bill was impossible. Mace turned to his regular stage production experts but when they learned of another complex issue the design would require — the space required for the hydraulics and electromechanical components needed to fit a 12 in. envelope — they suggested Mace call Dan Turner of Turner Hydraulics/ TASCorp., of Carlisle, Pa.
A scene from Mascagni’s “Cavalleria Rusticana.” Turner Hydraulics/TASCorp. created a unique hub to control the hydraulics, Ethernet and power distribution for the opera’s rear wagon turntable. | Courtesy of Marty Sohl / Met Opera
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DESIGN NOTES
So Mace contacted Turner, asking him for help with rotary fluid power all while maintaining the slip ring and data functions in a compact space. Turner was intrigued by the custom need. He and his team surveyed the system. “And somehow, miraculously, Dan said, ‘No problem,’ and took it on board. Dan and his team worked collaboratively with our in-house engineers, kind of iteratively, sharing models and drawings back and forth, and talking about end user functionality and accessibility and basic ergonomics of using the system. One of the things that really impressed me in that interaction was Dan’s attention to detail with respect to the end user, with respect to this thing not just being schematically functional but utilitarian and useful and accommodating of the environment.” Turner Hydraulics and its subsidiary TASCorp. (Turner Automation Services Corp.) designed an apparatus that is comprised of a fixed frame that is bolted to the base of the wagon with a rotating frame that’s connected to the rotating part of the wagon. Between those two frames is the hydraulic rotary union in a 10.5-in. form factor with four ports of hydraulic fluid transmission — a pressure line, tank line, drain or pilot operating line, and pressure line or second tank line.
The team at TASCorp. and Turner made the custom hub which transfers all the utilities up to the house using the AutoDesk CAD program Inventor. “What we had to do was come up with a way to allow the stage to rotate infinitely in any direction while full electricity, hydraulics and computer operations were operating whatever was on the set.” So Turner’s team decided to have the Ethernet communications at the center, and were able to acquire an off-the-shelf commutator that would allow that to happen. Mace said that the data slip ring is double the bandwidth of the Met’s previous solutions. “We went from having the capacity to transmit one data stream on one single network, and we would previously have had to decide, are we going to use the data
Turner Hydraulics/TASCorp. met the size restrictions of the special design needed by The Met, as they designed and built a special hub 10.5 in. deep to incorporate hydraulics, data and power distribution in one compact design. | Courtesy of Turner Hydraulics/TASCorp.
transmission capability for the automation network or the video network or the lighting network? But Turner was able to facilitate two data connections, so we now have double the flexibility. And then in addition to the data, he packaged a power transmission slip ring that also doubled our amperage capacity. So we had a 280-V, 3-phase slip ring that was rated for around 200 A, and he increased in the same footprint to 400 A capacity. So in addition to getting the kind of hydraulic solution we were aiming at, we doubled our capacity on power and data as well, without making any material modifications in house. It was really remarkable.”
A scene from Mozart’s “Le Nozze di
Figaro.” Although not all Met productions use the hydraulics of the custom hub design by Turner/TASCorp., this production utilized the data and power distribution capabilities of the hub. | Courtesy of Chris Lee / Met Opera
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To manage this power level, Turner worked with an outside vendor to bend the power rails into a circle that could fulfill the 208 V need. This, said Turner, would allow the rails to always stay connected even as the stage turned. Junction boxes were included on the set and house side so they could feed power to the unit. To accommodate the hydraulics, they designed a compact swivel unit with quick disconnects for all the lines plugged into the base of the unit all while feeding through the center of the unit. It allowed for four channels of 50 gpm or three channels of 50 gpm and a drain line. “The beauty of it is that everything has disconnects, whether it’s the electrical or the hydraulics and the Ethernet, so they just pop cover plates off of the center of the stage. And they just plug in whatever it is, whatever utility they’re trying to use,” Turner said. “They don’t have to do any hard wiring or hard piping or anything like that. It’s all very convenient.” Once the hub unit was complete, Turner’s team and the Met’s engineers had two weeks to install it and ensure it functioned properly. “Dan’s team came in, and we wheeled it into place, picked it up with a hoist, lowered it into place, and bolted it in. It wasn’t quite as painless as I just made it sound, but it was pretty close. So within two days after taking delivery, we had the primary apparatus installed and tested. Frankly, it couldn’t have gone more smoothly.” In the end, the show only used one function of the hub Turner designed — “The table only raises and lowers in front of the audience, but the turntable is not rotating, so you can’t quite tell that there’s magic happening there from the audience’s perspective,” Mace said. “But this has introduced a new creative capacity into the opera house. We do use this hydraulic distribution quite regularly to set up production effects and production elements that are hydraulically powered,” Mace continued. “So the thing I’m getting at, Dan is solving our problems. He’s not trying to fit us into the mold of any kind of prepackaged solution. That
A scene from Mascagni’s “Cavalleria Rusticana.” | Courtesy of Cory Weaver / Met Opera
iterative and tailored process and that willingness to find solutions to problems, is incredibly compatible with what a creative company like the Metropolitan Opera House needs to interact with. It’s flexible in all the ways that we need. We’re trying to pull off these incredible one-time feats. And Dan is well-suited to participate in that universe. “When people come to me and they say, ‘I need a hydraulics guy,’ he’s the only person I recommend, because he’s got what it takes to keep up with our industry, which tends to be tight timeline, low budget, heavy lifts. And it’s not always easy to find reliable partners, and it’s certainly not easy to find them willing to keep coming back for more projects.” FPW
Turner Hydraulics/TASCorp. | turnerhydraulics.com | tascorp.us
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DESIGN NOTES Edited by Mary C. Gannon • Editor
Pneumatic valves sort diamonds quickly and gently Diamond cutting is a task for human beings. The cutting must be carried out by a perfectly trained specialist, because — no matter how flawless the gemstones may be — an incorrectly placed cut will ruin everything. Even with perfect color and purity, the wrong cut can significantly reduce the value, which is why good grinders are considered artists in the industry.
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The sorting of the stones according to size, however, is done by machines. Much depends on them, too: the sorting process has to be very fast, yet there must not be any scratches. A sorting system with fast-switching valves from Festo manages to sort up to 10,000 diamonds per hour according to size without scratches. Once the cutting of the precious stones is finished, much more speed is required. For sale, the stones must be quickly sorted according to size, traditionally using a sieve. Although the process is quick, it has some disadvantages: it is very imprecise and stones regularly get stuck in the sieve. There is also the danger of damaging the diamonds. A more gentle alternative is optical straining, where a camera determines the size of the stones. For this purpose, a vibrating spiral conveyor — a special
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A vibrating spiral conveyor transports diamonds to the optical sieve and aligns them on their flat side. In this way, the conveyor prevents the stones from being damaged during tipping.
conveying device for dusty to coarse-grained bulk materials — first transports the diamonds one after the other onto a rotating, round glass plate and carefully turns them onto their flat side. A vibrating spiral conveyor transports diamonds to the optical sieve and aligns them on their flat side. In this way, the conveyor prevents the stones from being damaged during tipping. A vision system with a camera is mounted above the glass plate. A photoelectric cell detects each new stone on the glass plate and triggers the camera. The vision system counts the pixels on the captured image to determine how large the gemstone is. For the actual sorting of the gemstones, pneumatic valves are arranged in a circle under the rotary disk on which the diamonds are placed. Containers for the different stone sizes are positioned around the glass plate. As soon as a diamond passes the container corresponding to its size, the valves emit a compressed-air pulse and push it into it. As soon as a stone has reached the ejection point corresponding to its size, a compressedair pulse pushes it out of the valve into the corresponding container.
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DESIGN NOTES
The fast-switching valves have a response time of less than 2 msec and a repetition accuracy of less than 0.2 msec. In this way, they sort the diamonds quickly and precisely.
To ensure that the compressed-air pulse is as fast and precise as possible, fast-switching valves are used. These valves contain a magnet, into which a relatively high current is introduced for a very short time. This builds up the magnetic forces very quickly that attract the valve body, and the valve opens. The current is then immediately turned down to a minimum and finally turned off, causing the valve to close again. Quickly reducing the current makes very high cycle rates possible — in other words a constant opening and closing of the valve, without the magnet overheating and the valve failing. In addition, it switches very smoothly in every cycle. In total, the time per cycle is no more than 3 msec and around three stones per second are pushed into the appropriate container. With such fast sorting, the grinder can take a little more time for a perfect result. FPW
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DESIGN NOTES Edited by Mary C. Gannon • Editor
Electrohydraulic actuators optimize seed depth
Farmers running multi-row seed planters (left) that incorporate Graham’s depth control system with Thomson electrohydraulic actuators (right) have been experiencing improved yields and returns on their investments in less than a year.
Designers for heavy duty motion control applications have traditionally specified hydraulic cylinders for their high speed, heavy load handling and resilience. However, recent advancements that embed hydraulic technology within electric linear actuators have been delivering the benefits of hydraulics without common drawbacks. A prime example of this conversion has been the optimization of seed depth control for multi-row agricultural planters. Graham Electric Planter developed a solution using electrohydraulic actuators from Thomson Industries Inc. that equips conventional seeders for real-time, interactive seed depth control. Farmers planting corn, soy and other row crops usually know how deep to plant their seeds for maximum yield, but achieving that depth consistently amidst soil conditions that change daily from field to field, row to row and even within rows is a challenge. Planting seeds too shallow could cause rooting too close to the surface, while planting too deep could delay crop emergence. Most tractor-pulled planting rigs are equipped with mechanical springs that apply downforce on seed applicators to keep furrows at the right depth but have no way to adjust to changing soil conditions. Graham Managing Partner Marty Graham set out to replace mechanical springs with actuators that would adjust quickly in near real time. Traditional hydraulic cylinders met the first two requirements, but Graham ruled these out. “We wanted to avoid hydraulic cylinders because they are messy, and there are lots of fittings, hoses and wiring all over the place,” he said, adding that cylinder support systems www.fluidpowerworld.com
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DESIGN NOTES
Customized per each farmer’s requirements, Graham Electric’s depth control system relies heavily on the Thomson H-Track actuator to maintain control of its seeders.
tax already overloaded hydraulic systems needed for handling other functions. They also require an elaborate fluid-delivery infrastructure, which has the potential to leak and create hazardous messes. Ruling out hydraulic cylinders led him to electric actuators, but they didn’t have the resilience he needed. “If you’re going through the field and hit a pack of dirt or a rock, the actuator needs to be able to give a little,” said Graham. “Normal ball-screw-based actuators could bend, and you’d be replacing actuators all the time.” Graham found that Thomson offered an electric actuator with an embedded hydraulic fluid chamber that delivered the durability and communications capabilities that his application required without the need for a complicated, high-maintenance external infrastructure. The Thomson H-Track electrohydraulic actuator has the smallest mounting envelope in its class and uses a patented valve and reservoir design within that footprint. An attached motor controls the direction of the fluid flow within the actuator, and split tanks linked by a shuttle valve provide the back-pressure relief that gives the system its resilience. The H-Track actuator itself takes up less space than a hydraulic cylinder but doesn’t require an external fluid reservoir for running fluid supply lines to each crop row. H-Track actuator housings are completely sealed, weatherproof, dust-tight, corrosive resistant, and tested for IP67 static rated for temporary submersion and IP69K high-pressure washdown. The actuator also provides hydraulic fluid options of up to 82°C
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(180°F). Units are lubricated during assembly, requiring no adjustments or maintenance after they leave the factory and ensuring consistent performance for the life of the actuator. “We couldn’t find any other product that does what the H-Track does,” said Graham. “The self-contained, hydraulic chamber is key. Other vendors are trying to accomplish what a relief valve in a hydraulic chamber does, but it is not nearly as good as what Thomson is providing to us today.” The Graham depth control system is paired with a vacuumdriven seeding disk that deposits the seeds in the soil. A typical planter seeds up to at least 24 rows per sweep with one depth control unit, and thus requires one actuator for each row. Graham customizes a depth control unit for each farmer’s application. In a typical configuration, gauge wheels ride in the seed trench behind the seeding disk. A load cell sensor monitors the gauge wheel depth and sends readings wirelessly to the control software. An algorithm determines whether the gauge wheels are riding too high or low and signals the actuator to expand or reduce the downforce accordingly. “If the H-Track electrohydraulic actuator gets a signal that there is too much pressure, it just releases, which signals our electronics to reset it, and it goes back to where it was,” said Graham. Two wires connect each actuator to a companion wireless circuit board mounted behind it. In addition to enabling the actuator to receive data from positioning sensors monitoring the depth, the circuit board enables the sharing of real-time status updates with the control dashboard, integrating it with a full picture of the seeding operation. “We’re usually ±25 mm (1 in.) off our set point, With Graham’s depth control varying actuator stroke systems, planter operators are able between 31.5 and 85 mm to monitor and adjust the pressure (1.24 and 3.25 in.),” said
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status of each actuator, which are represented by the yellow bars on the left.
The Thomson H-Track electrohydraulic linear actuator enabled Graham Electric to implement a compact, wireless electric seed depth management system that could pay for itself within the first year of operation.
Graham. “If farmers are planting on terraces or have very loose soil, then they might pull it up to zero stroke, or if it’s really hard ground, they might have to push it all the way, but very rarely will they have to use the full stroke capability of the actuator.” The most pressure the actuators ever need to apply is typically 25 to 45 kg (50 to 100 lb) above the 113 kg (250-lb) weight of the seeding unit itself. This is well below the H-Track’s load handling capability of 2,180 kg (4,800 lb). Graham installs the system with minimal disruption to legacy systems. It uses the 12-V battery already on the system and requires no additional fluid handling systems or wires. There are also fewer mechanical parts that might break, leak or require additional maintenance. Electric control provides clean, smooth linear motion without hydraulic plumbing or other expensive componentry. The H-Track’s power demands are significantly less than those of a full hydraulic system as the actuators require power only when in motion. “And the wireless communication eliminates the harnesses, cabling and wiring that would otherwise be necessary, further keeping to our commitment to simplicity,” Graham said. Graham estimated that changing from springs to electric seed depth control will improve yield by at least 5%. He calculated that a farmer that gets 200 bushels of corn per acre should expect a 5-6 bushel increase, which would bring in $18 an acre or $18,000 per thousand acres in the first year – far more than the cost of conversion. “The H-Track with the self-contained hydraulic chamber was the backbone of the entire product,” Graham added. “Without the benefits of an electrohydraulic actuator, the entire product would be dramatically different.” Graham and his team are now addressing other seeding automation issues, including some that involve electrohydraulic actuators, and others that employ traditional electric actuators — all of which are wireless. FPW
Thomson Industries Inc. thomsonlinear.com Graham Electric Planter grahamelectricplanter.com
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FUNDAMENTALS Josh Cosford • Contributing Editor
Symbology 303 – Compound Symbols I’ve explained other compound symbols in previous Symbology lessons, although not from the specific perspective of intentionally using two or more combined symbols to make one complete, functional component. The detailed version of the pressure compensated pump symbol combines tiny cylinders with 3-way, 2-position regulators and a smattering of other small symbols to make one giant symbol — that symbol closer to a full schematic. This article focuses on the compound components using two or more symbols to construct a more complicated form of the same part. In machines using a hydraulic motor, you must take care to prevent the inertia of the load from negatively affecting both the machine and the hydraulic system itself. A rotating mass has momentum that persists despite your desire to slow or stop it via the directional valve control. A high-speed winch, for example, would like nothing more than to carry on rotating after the directional valve is closed, or even worse if you reverse the valve. When a directional valve closes while an inertial load still moves, the nearly incompressible hydraulic fluid spikes in pressure while the machine jolts to a sudden stop. You risk both mechanical breakage and blown seals as the impeded energy finds the path of least resistance. A crossover relief valve (also known as a cross port relief valve) installed parallel with the motor work lines, protects your machine from damage caused by rapid stopping action. In Figure 1, I’ve drawn such a valve upstream of the hydraulic motor. Although you can create the desired effect using two separately plumbed individual relief valves, the single-block design of the crossover relief saves the cost of plumbing while reducing leak points.
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Ports a1 and b1 connect upstream to the directional valve. It’s essential to know the directional valve would have both work ports blocked in the neutral position. You don’t need a cross port relief when A and B are open to tank. The “float center” spool configuration (often called a motor spool) works because it combines the work ports in the center condition, allowing the motor to spin down under its inertia (or perhaps using a brake valve). Ports a2 and b2 connect downstream of the motor, which, as you’ll remember from the dual inward-facing arrows, tells us the motor is birotational. As the motor rotates, fluid happily travels through a1 to a2 under pressure and then back through b2 and b1 at low pressure, since the hydraulic energy gets consumed at the motor. Imagine now that the directional valve slams shut, with fluid blocked from exiting port b1 while fluid can no longer enter through a1. Without the crossover relief valve in place, the cavity between a1 and a2 would cavitate under negative pressure. The passageway between b2 and b1 would spike pressure dramatically because both fluid and motor inertia have nowhere to dissipate. With the crossover relief protecting the circuit, this time when the valve closes, any excess pressure in the line b2-b1 acts upon the port 1 of the relief valve. With the a1-a2 side still cavitating slightly, fluid from the high-pressure side is welcomed to fill the void. The crossover relief valve brakes the motor, turning the inertia of its mass into heat across the relief valve. The motor slows rapidly but in a damped motion that can be tuned by the pressure settings of the cross port relief valves. Because the system is symmetrical, it’s clear that when the motor direction reverses, the same damping effect slows the motor in a controlled fashion without shocking or damaging the machine or the system. You’ll note I’ve shown the blue drain lines, starting from the spring chamber and terminating at the low-pressure side of the relief. The drain ensures the spring chamber drains of pressure to prevent that pressure from adding to the spring value or even locking up the relief valve altogether. A drain is typical for any component exposed to pressure at both work ports. I covered the second component in Figure 1 in a previous Symbology article, but I thought it was important enough to mention again as a compound symbol. The pressure compensated flow control often gets drawn in its simplified form, but the one depicted does a much better job of showing how the valve balances for differences between upstream and downstream pressure that reduces pressure drop, and therefore, flow. The 2/2 component downstream of the needle valve is the compensator. In this case, the 90 psi spring offsets the valve, allowing relatively free flow from port 2 to port 3. The functional key to this symbol happens with ports b and a of the compensator. As flow is
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A high flow relief valve requiring pilot operation flows at least 30 gpm but can handle
thousands of gpm in some applications. I’ve shown two relief valves plumbed in parallel with common pressure and tank connections. The P port of the valve block feeds the Main Stage valve but not before a connection node branches off upward through the orifice at o. You’ll notice all lines on either side of the Main Stage valve are solid, yet most others are the dashed pilot lines, which accurately describes their size. The fixed orifice limits flow so as not to oversaturate the pilot stage relief, which likely flows less than a gallon per minute. The pilot line connects through a node to the pilot pressure line denoted as x, which is standard practice for all hydraulic pilot pressure sources (y is the denotation for pilot drain, by the way). Continuing downstream to the next node, you can see the pilot line feeds down to the spring chamber of the main stage relief valve. You may have also noticed there is no variable symbol atop the main stage spring. The pressure control occurs through the pilot stage, which is a tiny relief valve selected to control pressure in the x passage of the combination valve. The pilot valve remains closed until the pressure at port P rises above the pilot valve pressure setting, where the pilot valve starts to open to bleed off x passage flow. The pilot valve’s path to tank allows the main stage valve to overcome its own pressure setting (which is a combination of its fixed spring pressure and the pilot pressure of the pilot valve). The two valves work in tandem to allow high flow pressure relief with accurate control. The x port shows as being blocked. However, if the valve operates in a hydraulic system with a dedicated pilot supply, that source is plumbed to the x port. In this case, I show the orifice plugged to separate the primary hydraulic supply from the pilot network. The x port also allows a secondary pilot control option, which may use a solenoid valve to dump pilot pressure to tank, essentially turning the main stage valve into an unloading valve. Or the pilot supply could come from a proportional pressure reducing valve that can electronically change the pressure in the pilot supply, so long as its lower than the setting of the pilot stage valve. FPW
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directed from port 1 to port 2 at a reduced rate by the needle valve, back pressure rises at port 1 inversely proportional to the flow setting. The pilot line feeds port b of the compensator, where it pushes the compensator’s spool against the pressure of the spring. Port a connects directly downstream of the needle valve at 2, where it avoids the backpressure at 1. In fact, the whole point of the compensator is to compare ports 1 and 2 and maintain exactly 90 psi of pressure drop through the needle valve. With a standard needle valve, any load-induced pressure increased at port 2 causes a reduction in pressure drop across the needle valve. Flow potential is equally factored between pressure drop and the size of the orifice, so as downstream pressure increases, the flow rate decreases relative pressure differential. As load pressure increases, that increased pressure feeds to port a to open the compensator further, increasing the effective orifice size flowing from 1 to 3. Regardless of downstream load pressure, the compensator opens up further as required to maintain the 90 psi pressure drop it measures between port 1 and port 2. I’ve drawn a pilot-operated relief valve in Figure 2. As you’ve probably figured out by now, when it comes to high flow hydraulic components, it isn’t effortless to directly control high flow components with springs or solenoids. Pilot control takes advantage of the power density of hydraulics to turn some components into mini actuators, as it were.
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MAINTENANCE A staff report
Eliminating water’s impact on hydraulic fluids Most hydraulic fluid is oil-based, so we cannot forget the adage that oil and water do not mix well. However, when it comes to the hydraulic oil transferring energy around your hydraulic system, much more is at stake. Whether free or in saturation, the potential harm from water is more detrimental than merely pooling at the bottom of your reservoir. Nearly every beneficial property of hydraulic oil is reduced or compromised when water contaminates it. Water will contaminate hydraulic oil in two ways; as either free water or saturated water. Free water is what exists as pockets or bubbles of separate water droplets. Saturated water is the dissolved kind — sharing space within the oil itself. Hydraulic oil can be humid just like air, and it’s nearly impossible to remove all humidity from oil, but you do want to keep it to a minimum. Relative water humidity less than 99% will keep the water entirely dissolved, but temperature differences will result in free water “raining” out of the fluid. Even if you could maintain water saturation just shy of 100%, the excess water will give the oil a telltale milky appearance. Milky oil is terrible under any circumstance.
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Water-contaminated oil reduces the lubricity of the hydraulic oil. Oil’s viscosity and shear-resistance provides a film barrier between two wear surfaces. Water contamination reduces both the viscosity and shear resistance, allowing metal to metal contact to occur. Although water-saturated oil may still provide full film lubrication under pressure, it loses that protection in areas of little pressure. A lesser-known fact of “wet” oil is the accelerated oxidation rate. Oil oxidation rate increases with heat, which is a common occurrence of many hydraulic systems. The increased oxidation results in the fracturing of oil molecules, which in turn creates varnish as the severed atoms stick to each other and additives in the oil. (The oxidation being discussed here is of the oil itself, not the metal components exposed to it.) It’s easy to connect oxidation with metal components’ rusting, which also occurs inside water-contaminated hydraulic systems. Water-based hydraulic fluids employ rust-inhibiting additives, but because hydraulic oil is inherently rust preventive, highly saturated oil provides little such protection. The case is exacerbated when free water pools in steel or iron locations, especially during downtime. It goes without saying; you must avoid excessive water contamination at all costs.
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To prevent all these, several key maintenance tips should be taken. First, conduct regular oil sampling and testing. An oil sample test tells you the quality of your fluid conditioning program and if efforts to reduce particle and water contamination are effective. You can purchase basic kits to determine water contamination level, and you may be surprised at how much water is held in saturation without any visual signs. If you spring for the high-end tests, you are given a bigger picture to hydraulic fluid health. You will discover the composition of particles (to see if bronze wear particles are accelerating, for example), TAN (to check for oxidation) and even viscosity index (letting you know how well your oil performs over a wide temperature range). It’s also important to clean out your reservoir. This task not only removes sludge at the bottom of the tank, but also provides a diagnostic opportunity as well. Perhaps a normally unseen layer of water resides below the lighter oil above. Additionally, when a tank is empty, you have a chance to inspect the quality and quantity of the contamination settling throughout the year. Using a desiccant breather on the vent of your equipment will help mitigate both dirt and moisture ingression. Desiccant breathers, which can filter down to 0.3 micron in some models, are filled with a hygroscopic agent that traps and adsorbs moisture contained in the air entering the filter. It also removes moisture from within the reservoir as the unit breathes out. By controlling moisture both outside and inside the reservoir, many of the problems typically caused by water contamination are prevented. Desiccant breathers are available in a variety of different models to suit the needs of your application. For example, some breathers integrate check valves into the design to isolate the system from ambient conditions — great for high humidity environments or systems that run intermittently, while others incorporate metal bodies to protect against extremely harsh environments. Using breathers and silica-gel adsorber filters to adsorb water in hydraulic systems reduces maintenance requirements and simplifies inspection needs. These devices usually have a visual indicator to let maintenance staff know they have reached maximum capacity and need to be replaced. Because these devices are usually a simple retrofit or spin-on design, they also can be installed or replaced without major system interruption. If water still persists, you may want to consider renting a dehydrator system if you don’t have one on hand. Positive pressure dehydrators blow air through the operating fluid in a reaction chamber. Drying the air is achieved by increasing the temperature of the ambient air in a side channel blower
and by getting it into contact with warmer oil. The air is introduced into the reaction chamber by a blower. The dry air takes up the water from the oil and is pushed out of the reaction chamber by the incoming air. The operating fluid is cycled through the reaction chamber by a system of two pumps. In vacuum-based systems, a vacuum is created in a vacuum chamber by means of a vacuum pump. With the vacuum, ambient air is sucked into the vacuum chamber. The vacuum expands the ambient air and proportionately reduces the relative humidity of the air. The oil is distributing within the vacuum chamber over a large surface area, resulting in a large and thin fluid film. Water contamination is a continual issue even when using the tips above. How to find the best way to eliminate or at least reduce the risk to a workable solution, truly depends on your type of system and the fluids passing through it. But vigilance in filtration, testing and inspection are key in reducing the impact water may have on your hydraulic system. FPW
Vacuum dehydrators, such as this VUD model from Hy-Pro Filtration remove emulsified or dissolved water from hydraulic oil.
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ENERGY EFFICIENCY Ron Marshall • Contributing Editor
Compressor discharge pressure (top line) remained constant, yet pressure drop across dryers and filters was as high as 20 psi during system peaks.
Compressed air fail: Dryer freeze
A
A large home products manufacturer had its compressed air system pressure hooked up to the building management system. System pressure was continuously monitored, and alarms would be sent to facility management if the levels dropped below a set low pressure threshold. The facility was suffering an ongoing problem. Many times each day, low pressure alarms would be received, resulting in the compressor operators going to the compressor room to investigate — only to find the pressure at the compressors was at proper levels. Additional monitors were placed on the system and it was revealed that the pressure loss across the refrigerated air dryer and filters reached as high as 20 psi during system peaks. Initially, this system loss was blamed on the system filters, but measurement revealed that this loss was at low levels. The actual problem was pressure loss across the air dryer. The dew point display on the dryer was at high levels, which indicated a problem. Service personnel were called, and they found that the refrigerant level in the dryer had reached low levels. This caused the internal dryer temperatures to fall below zero, causing the dryer to ice up inside. This ice blockage restricted flow and caused a large pressure differential. The dryer was repaired and the pressure drop returned to normal. The alarm problem was solved. FPW
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Fluid Power Technology
2021
Conference
PRODUCED BY
SAVE THE DATE! The Fluid Power Technology Conference kicks off with the 2021 Opening Session on January 19th and continues every other week through June. Donâ&#x20AC;&#x2122;t miss out!
Visit fluidpowertechconference.com for current information and all 2020 ON DEMAND SESSIONS
Sponsorship opportunities are available for future Fluid Power Technology Conference programs. For more information, contact Mike Ference, 216.386.8903, mference@wtwhmedia.com
M O B I L E
H Y D R A U L I C S
RUGGED TRANSPORTER HANDLES
ANTARCTIC EXTREMES AN INNOVATIVE DESIGN BASED ON PROVEN HYDRAULICS AND SOPHISTICATED CONTROLS ENSURED RELIABLE AND EFFICIENT PERFORMANCE. KEN KORANE CONTRIBUTING EDITOR 34
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PRINOTH PANTHER
tracked vehicles are used on challenging worksites around
the world. The rubber-tracked crawler carriers minimize damage to the underlying terrain thanks to their low ground pressure and superior stability while carrying payloads of up to 23 tons. They’re typically used in mining, construction, oil and gas, and electric utility applications. The company’s engineers are now pushing the machine’s all-weather, high-performance capabilities to new limits. Recently, Prinoth unveiled a vehicle unlike any other in the world that serves as a vital supply link to the Norwegian Troll Research Station in Jutulsessen, Antarctica. The station, which houses several dozen researchers, is a base for biological and geological field work, and for long-term monitoring of atmospheric, environmental and seismic activity. It is located 235 km (146 miles) from the coast.
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Prinoth’s Troll Panther vehicle carries vital supplies to remote Antarctic researchers.
The special transport vehicle, nicknamed the Troll Panther, is designed to move larger loads with less impact on the environment, compared with previous options, and with safety as the paramount priority. The aim was to reduce overall operational costs through lower fuel consumption, reduced total transport time and fewer personnel dedicated to delivering fuel and supplies in the Antarctic region. “This project certainly challenged our teams to push boundaries and refine our know-how, and to come up with a cutting-edge machine to allow traveling in the harsh climate of the Antarctic while still providing high levels of productivity,” said Engineering Director Eric Steben, based in the company’s North American headquarters in Granby, Quebec.
“Our heritage at Prinoth is coming from snow groomers,” the types of machines widely used for prepping ski slopes and cross-country trails, he said. “So we understand how to engineer cold-weather machines. The Troll is used only in transport during the Antarctic summer, where the temperature is not so extremely low, perhaps down to around –25° C. Nonetheless, it is a unique vehicle in a unique setting, the only vehicle of its kind in the world — especially because it’s a four-track machine with highly sophisticated hydraulics to control all of the tracks.” Machine platform
The Troll is based on a modified Prinoth Panther T16, the company’s largest rubber-track
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vehicle. It is powered by a transverse-mounted Caterpillar C15 diesel engine — a turbocharged unit rated at a maximum 580 hp and maximum torque of 1,958 lb-ft at 1,400 rpm. It is actually a combination of two vehicles, a front T16 with the engine and cabin; and a hydraulically propelled trailer comprised of a second, nearly identical T16 chassis and undercarriage system with the same wheels, suspension, rollers and tracks. The engine couples to a gear box that drives four hydraulic pumps. Each pump supplies a separate circuit and dedicated hydraulic motor on each of the four tracks. “The pumps are the same style that we use on all our snow groomers — Bosch Rexroth closed-circuit, variable-displacement
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hydrostatic pumps matched to Rexroth variabledisplacement motors,” said Steben. Hydraulic drive
The key to the propulsion system lies in the controls and software, he explained, because it is a complex task to deftly manage the hydraulics to both steer and continuously maintain and equalize traction on the four track drives. While the exact details are proprietary, the Troll’s hydraulics are managed by a specialized microcontroller built by TTControl, a joint venture of HYDAC International and TTTech. TTControl specializes in robust and flexible control systems and intelligent displays that stand up to the harsh environments typical of off-highway vehicles and mobile machinery. The company’s ECUs, I/O modules and HMIs are used across Prinoth’s snow grooming line-up, comprising a standardized control platform that meets stringent requirements for quality, safety and performance. Its master electronic control unit handles various tasks on the Troll, including controlling proportional valves and managing analog and digital inputs and outputs. It communicates via a standard CAN network. A state-of-theart graphical HMI offers an operator interface that displays information relevant to machine processes as well as working and driving conditions. In operation, steering wheel and throttle pedal input signals are interpreted at the controller which, in turn, initiates output signals to adjust pump output, manage valve functions, and precisely direct flow to each drive motor — and ultimately command vehicle motion and direction. “Adjusting the speed of each individual track lets us control the steering direction of the 36
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front and also the traction on the trailer, and ensure just the right amount of power is sent to the four track system,” said Steben. Sensors on the pumps, motors and valves constantly read system pressure as well as the speed of each track, to monitor and compensate for any changes in the closed system. “When we bring all that information together at the machine computer, we can fine tune and precisely control every corner of the machine,” he said. System modifications
The special transport vehicle moves larger loads with fewer personnel and less impact on the environment, compared with previous options.
Additional sensors monitor the temperature of critical systems, which is especially important for cold-start conditions. The vehicle’s main task is to transport goods from a seaside port to the research station, a one-way trip that takes three to four days. Overnight a generator electrically heats the fuel, coolant, hydraulic fluid and other systems to avoid a brutal coldstart in the morning. Start-up includes a long period of idling when the operators watch systems’ temperatures as they warm up. Initial movements are quite slow, until components reach a reasonable temperature and the vehicle can accelerate to higher speeds. “The Norwegians are especially experienced with winter conditions and with working in Antarctica. They really know how to take care of the mechanical and electrical systems and use the machine gently,” said Steben. Another cold-climate accommodation by the Prinoth engineers involves the hydraulic fluid. “We use an old-school, ATF Type-F fluid that has been used for years in hydraulic transmissions. It has very good Prinoth Engineering Director Eric Steben properties at cold temperatures,” he said. www.fluidpowerworld.com
M O B I L E
It maintains a moderate viscosity that prevents restricted flow, controllability issues and sluggish operations. Yet at higher temperatures it still fully protects system components from wear and premature failure. The fluid filtration requirements match the stringent recommendations for a conventional Panther. However, the filtration system is heated. An element inside the housing preheats the filter to avoid backpressure or over-pressure during a cold start. Likewise, pump cavitation could be a concern. “It is normally an issue with cold weather. But with 60+ years designing snow groomers, we are very used to it. So the Troll, like all our cold-weather line-up, uses a pressurized oil tank,” said Steben. The tank always supplies fluid to the pumps with a positive pressure, to prevent suction at the pump inlet. “Cavitation is something we want to avoid, that’s for sure,” he said. Special seals aren’t needed on the Troll. Standard low-temperature elastomers proven on Prinoth’s snow groomer hydraulics have worked well here. “In this case, it was not cold enough to change to special materials such as silicone that might be required on an Antarctic winter machine.”
That said, leaks are totally unacceptable. “In Antarctica, everything is really, really strict, so spillage is not an option,” Steben emphasized. The entire continent is essentially considered a nature preserve, and an international environmental convention bans any discharge onto the ground or ice shelves. “We really take care that we have an essentially leak-free design. We do visual checks and regular inspections, and we also monitor for low fluid levels – to quickly spot any problems. All the hydraulic components are also designed for easy service.” Safety first
While no redundancy was built into the machine, design criteria were higher than normal because failure was simply out of the question, said Steben. “Because of that we had to over-engineer a couple of hairier areas where we can’t afford any cracks or leaks.” For example, because the terrain can be rough, the trailer has been structurally reinforced with higher safety factors. And like the snow groomers, the Troll uses extreme-temperature hoses rated to –40° C. However, the hoses are one size larger than normal because, particularly in long runs, back pressure could be an issue in
H Y D R A U L I C S
some cases. So the grade and size of the hoses have been slightly over designed. Because of the proven components and ample experience with snow groomers, and with T16s used in winter conditions, few concerns cropped up during prototyping and testing in cold conditions. One minor issue was ice build-up on certain components, where slight adjustments were necessary. Delivery and roll-out were problem free and, for the researchers, the Troll proved to be a welcome addition. Previously, the supply line involved several snow groomers dragging loaded sleds across the continent. Now, with more power, four tracks and better traction, the machine can carry heavy loads on the trailer and pull multiple sleds behind — up to 120 tons of cargo each trip. Travel speed is around 15 kph (9.3 mph), fully loaded. “With one machine, they can transport more material with less fuel per ton, and at a lower cost,” said Steben. The Troll is now in regular operation in Antarctica for the season that normally runs from midNovember to March. FPW
Prinoth | prinoth.com
Fully loaded, the Troll can transport up to 120 tons of cargo at speeds of nearly 10 mph.
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I N D U S T R I A L
F L U I D
P O W E R
Tracking the Power in Solar Fields
Fluid power technologies are abundant in solar polar panel use, as multi-axis control devices help follow the sun as it tracks through the sky.
BY: Josh Cosford, Contributing Editor
| Courtesy of Shutterstock
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There is almost no place fluid power does not have a useful purpose. One thinks of solar energy and flat, stationary panels blanketing the South-facing roof slopes of barns may be the first thought that comes to mind. In actuality, to extract every last photon possible from our closest star actually requires advanced motion control. Solar panels are a modest maintenance avenue into clean electric power. A basic array of panels mount easily to a roof and require nothing but a control panel with an inverter to make use of the power coming from the many separate modules. Unless you live near the equator where you live or work under a flat roof, you compromise your array’s efficiency because of seasonal changes in sunlight. You don’t need to be Galileo to understand the sun changes position in the sky, varying by the minute and week or month. The path our sun tracks through the sky varies as the Earth rotates, rising low in the sky from the East until finally dropping below the horizon in the evening. With flat solar panels, the incident angle varies by 180° throughout the day and nearly as variable with the seasons, depending on your latitude. We’ll omit the North and South Poles, which experience periods of extended light or darkness for simplicity. The ideal perpendicular angle of the panel provides the highest number of photons hitting the cells. When the incident angle is 30°, the light energy halves as the photons spread across twice the surface area. Some simple panel designs allow manual adjustment to compensate for seasonal changes in the sun’s incident angle. You can imagine over a broad panel array this proposition would be tedious. Regardless, twice-yearly panel angle changes improve angular efficiency from 71% to 75% when located at 40° latitude. The efficiency penalty worsens as you move Northerly. However, the improvement from adjusting panelangle seasonally improves. This peak improvement in efficiency occurs during the sun’s peak height, providing little improvement in the morning or evening when the sun is already low in the sky. On the other hand, we can improve
the incident angle to 100% seasonally and through the majority of the daylight hours. With multi-axis control installed on each panel module, the array follows the sun as it tracks through the sky, providing the cells with an optimum incident angle at all times. Enter fluid power … giving multiple solutions for both single and dual-axis tracking. Pneumatic options for tracking motion
The simplest control method moves the array panels through a single East to West pivot throughout the day. For pneumatically powered tracking systems, two ways commonly power the tracking motion. The first method is quite simple, with a pneumatic cylinder. The cylinder spans between the lower frame and support frame on the panel. Because the panel mass is
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Pneumatic actuators like air springs are used to track the cycle of the sun across the sky for the most effective panel use. | Courtesy of Sunfolding
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UNIQUE FLUID POWER DESIGNS FOR SOLAR POWER BY: MARY C. GANNON, EDITOR
While fluid power and electromechanical cylinders are often used to track the motion of the sun on solar panels, air bladder actuators are a unique design by solar company Sunfolding. Engineers there created the AirDrive X actuator to operate a machine specifically designed for solar. The objective was to take high-volume manufacturing methods and advanced materials and utilize them to create a reliable and scalable system that provides slow, precise movements, once per day. The concept applies pneumatics in a new way to the solar space, using a design similar to common air spring actuator technologies used in established industries like marine, transportation and automotive. A single unit, the AirDrive X actuator, does what motors, bearings, and gearboxes are all supposed to do in other tracker systems. Using pneumatic power reduced parts count. Instead of using complex machinery with a huge amount of steel, one unit, the AirDrive X, controls all movement.
Sunfolding’s AirDrive X on site at a solar installation, utilizes pneumatic actuators to increase resiliency, lower cost and accelerate the adoption of clean energy. It reduced costs by being faster to install and easier to operate. Rather than using big, heavy motors, the air-driven actuators allow for shortened tracker rows. The air actuator also requires less maintenance, because instead of dealing with hundreds of moving parts that are found in electrical power systems, the pneumatic system has far fewer critical points of failure and reduces maintenance locations by up to 95%. AirDrive X actuators in the Sunfolding system weigh less than 50 lb. The automotive-grade pneumatic harnesses connect quickly and easily with the supply air system. With fewer components, fewer trips to the equipment staging area are needed. You minimize room for error in the field and make it easy to save a lot of time. “The AirDrive X actuator uses advanced polymers supplied by DuPont, one of the largest chemical companies in the world, making our systems reliable through exposure to wind, heat, rain, and snow,” said Gwen Rose, Sunfolding’s VP of Marketing. “Sunfolding also partners with leading auto industry component suppliers to manufacture AirDrive X, delivering the technical ability to achieve production at a global scale and manage quality to the highest standards. As a result, the design lifetime of the AirDrive X actuator is much longer than the lifetime of the solar panels themselves.” 40
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A hybrid hydraulic design
Actuation systems in solar fields must be efficient, precise, and durable enough to withstand harsh power-generation environments. Parker Hannifin Corp.’s hybrid actuation system (HAS) for renewable-energy actuation applications combines the controllability of traditional electromechanical actuators with the power density, longer life, and resistive-force capabilities of traditional hydraulic systems. The result is an improved actuation system for single and dual axis tracking and other renewable energy systems, with a wider range of capabilities. This high-efficiency, modular system allows for various traditional cylinder mounting configurations and stroke lengths. The hybrid design is a fully self-contained system with no hydraulic hoses or power units. Hybrid hydraulics achieve high economies of scale, with the ability to move over a megawatt from a single point. This makes HAS a good choice for large or small solar arrays. For solar panels, HAS is an ultra-efficient, completely self-contained reversible hydraulic pump and electric motor that eliminate nearly all leak paths into or out of the package. Parker engineers designed a hybrid actuator into the pitch system so designers can move more photo-voltaic panels with fewer actuators and controls, resulting in lower installation costs and longer service over the life of the solar field. The design offers clear advantages over comparable electromechanical actuator (EMA) systems because all the internal-wear items are permanently lubricated for extended life. The power density of HAS is typically three times that of a comparable electric cylinder. HAS Solar Actuators are built for maintenance free operation for several years. Oil volumes are reduced minimal amounts, generally less than 1 gal reservoir sizes. The system can be serviced on site, with Parker’s fluid exchange system. Sunfolding | sunfolding.com Parker Hannifin | parker.com
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By adding tracking, power generation can be increased upwards of 45% over fixed panel installations. Parker’s Hybrid Actuation System (HAS) combines the control of traditional electromechanical actuators with the power density, longer life, and resistive-force capabilities of traditional hydraulic systems.
I N D U S T R I A L
low, the air cylinder gets away with a short effort distance, and the stroke remains reasonably short. However, moving the effort distances outward requires longer stroke cylinders, but provides the benefit of panel stability during high wind conditions. Another method of panel movement actuation employs airbags mounted under each side of the pivots for the panel. These airbags are not like the brake pots from the trucking industry sometimes used as pneumatic actuators. Instead, they are synthetic rubber bladders sandwiched between two plates spanning the upright frame and the panel frame. (See sidebar for more details on Sunfolding’s AirDriveX actuators.) The airbags expand when inflated, pushing on the panel to change its angle. Two airbags may be stacked together to provide a more significant distance of motion. Airbags may use either volume or pressure control to inflate, as they exhibit no “stroke” as would occur with traditional piston rod cylinders. The air actuators for either system receive their power from a centralized compressor and receiver. The pressure and flow demands are low, but typically the receiver is well oversized to provide many cycles of emergency backup should the compressor fail. Compressed air systems are a mature technology and are very reliable, especially for the sometimes harsh outdoor operating environments experienced by solar panel arrays. Although modules and panels are relatively light, when there are twenty or more modules in a single panel, the assembly’s mass starts to increase dramatically. Pneumatic actuators are capable of the force required to move panels through two axes, but with more force comes the requirement for larger diameter actuators. Larger diameter air cylinders need more air to stroke, reducing the Hydraulic cylinders number of cycles the central air receiver can rotate panels permits before the compressor comes effectively to track online to refill. the sun.
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The hydraulic drive systems may also utilize a hydraulic motor driven slew drive system. The slew drive rotates the panel to track East to West through the sky, leaving the cylinder’s azimuth angle to adjust. The low-speed, high-torque motor is reliable and inexpensive, keeping the entire hydraulic package both powerful and economical. The control method for either pneumatic or hydraulic operation is electronic, which requires a small PLC to take one of the various possible inputs and make adjustments based on the seasons, time of day or lighting conditions. The most straightforward feedback system uses sensors reading current lighting conditions fed back into the controller, which will make attempts to track towards a brighter light. Monitoring lighting conditions and controlling for the highest photon input is the simplest option for most situations. The system tracks toward the brightest light, caring not for the time of day or seasons. The controller stops trying to track when it senses actuators are at the end of stroke or if lighting drops below a predetermined level judged as nighttime. Regardless of your choice between pneumatic or hydraulic solar panel tracking systems, either option provides a reliable solution to keeping your solar panel array the most efficient through every possible solar condition. FPW
Compact hydraulics for efficient, sleek designs
On the other hand, compact hydraulics provide a couple of benefits over pneumatic actuation. Hydraulic power density permits the use of small-bore cylinders for actuation, capable of high force. The compact power units may be small since the differential volume of the cylinders allows a tiny reservoir. Compact power units come easily optioned with the pressure, flow, and control valves used to control cylinder positioning. The hydraulic option also requires no external connection to a central system such as pneumatic systems require, enabling the addition of subsequent panels with no more than an additional electrical connection. www.fluidpowerworld.com
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P N E U M A T I C S
Rodless cylinder solutions for
compact pneumatic linear motion Kevin Kakascik • Technical Marketing Engineer, AutomationDirect
Machine and equipment automation projects — whether
Designers requiring linear motion should consider rodless cylinders to realize compact packaging and other benefits for pneumatic actuation, without the cost of electrically-driven options.
performed by an original equipment manufacturer (OEM), a systems integrator (SI), or the capital projects group at a manufacturing facility — include many design phases. Requirements, costs, and benefits are typically assessed before the project is greenlighted and the conceptual design phase begins. A detailed assessment of performance is defined during this phase as the team begins to specify products, technologies, and methods that will lead to successfully accomplishing the tasks at hand, within the constraints of budget and schedule. For many machines, there must be a way to perform and monitor linear motion with sufficient power, speed, and accuracy. This article discusses some considerations for achieving reliable linear motion in a compact footprint, with an emphasis on rodless pneumatic cylinders. Linear motion requirements and methods
Several basic parameters must be considered before selecting a linear motion solution: • • • • •
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The load (and how much force is needed to move it) Overall travel (endpoints in each direction) Are intermediate stops or positioning needed? Speed of travel Accuracy
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Figure 1: Some examples of AutomationDirect NITRA rodless and rodded cylinders: the upper cylinder in each pair is rodless, and the lower is rodded; the upper pair is retracted, and the lower pair is extended.
The two most popular motive technologies for linear motion are electric motors and pneumatic actuators. Each of these methods can be subdivided into a few categories: • •
Electric (servo or stepper motors) Pneumatic (traditional or rodless cylinders)
Linear actions typically require a slide, often with guide rails, to support the mechanism with sufficient strength during operation and minimal friction. The choice for linear motion is how to drive this slide. A servomotor, arranged as necessary with a gearbox and accompanying screw drive or rack-andpinion, provides exceptional control of acceleration, velocity, deceleration, positioning, and accuracy to any location of travel. However, a servo solution is expensive and complex to procure, configure, and install. If the application demands such performance then a servo is the right solution, but many times it is overkill. Stepper motors can be used instead of servomotors to save some money, while sacrificing a degree of precision and performance. They also are relatively expensive to configure and install but can deliver positioning anywhere through the range of linear travel. A traditional pneumatic cylinder design would be a bargain compared to any electric motor drive option. Pneumatic cylinders are effectively tubes with a piston inside, connected to a rod that extends and retracts to provide the motive force as air pressure is introduced or exhausted from one side of the piston or the other. These designs are best for complete-stroke motion from one end of travel to another, although there are
ways to control motion to stop mid-stroke. A traditional cylinder can usually be directacting and does not require much else in the way of mechanical components. It might be packaged within the footprint of the linear travel, but often the pneumatic cylinder requires installation space at the end of the slide, usually somewhat greater than the amount of travel. Besides being simple, basic pneumatic cylinders are inexpensive to install and maintain, and they provide an exceptionally large motive force compared to their size. Linear pneumatic motion can, therefore, be a costeffective method suitable for many applications. An alternate pneumatic option is called the rodless cylinder, which works in a similar way to a traditional, double-acting, rodded cylinder. The rodless cylinder tube also has an internal piston, often magnetized so its position can be detected by sensors, and there two air ports for introducing and exhausting air pressure on one side or the other. However, the difference — as one might guess from the name — is that a rodless cylinder doesn’t have a rod connected to the piston. Instead, there is an external carriage that is connected to the piston, and it slides alongside the body of the cylinder, moving in tandem with the piston (Figure 1). Rodless cylinders deliver many of the advantages of traditional rodded cylinders, but with the added benefit of allowing installation of the cylinder in tighter spaces. For linear motion, this type of packaging can be quite effective. www.fluidpowerworld.com
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P N E U M A T I C S
Keeping the design process in line
Consider a design team for a capital project at a large manufacturing facility. After one or two meetings, they review the linear motion needs. One team member is enamored by the high performance and additional capabilities of servo-driven linear motion. But after investigation, the team agrees to address the equipment linear motion needs with simple rodded pneumatic cylinders because this solution meets the need and compressed air is readily available. Having solved this problem by keeping things simple, they budget accordingly and move on to another topic. Unfortunately, at a subsequent meeting, it is determined that the equipment will be located near a wall. This means that the motion stations planned for operation by pneumatic cylinders would end up with the cylinders extending beyond the machine footprint, which would interfere with the wall. Changing the concept back to electric motor driven actuators would technically solve the problem, but at this point would bust the budget. Fortunately, a rodless pneumatic cylinder can solve both the technical and the commercial issues. Solving a sticky situation
One example of where a rodless cylinder would be better suited than a traditional cylinder is on a glue station. For this station, a glue head needs to travel across a flat sheet of cardboard lying on a table, delivering a bead of glue as it moves. 44
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In this case, a sheet of cardboard 500 mm wide (which means 500 mm of cylinder stroke is needed) is laid on a table, and a 480 mm long bead of glue is required. On one side of the table there is a guide fence ensuring the cardboard on the front side sits flush, while the machine has a space on the table on the backside of the fence that is 150 mm wide. With a traditional cylinder, a model capable of 500 mm of stroke would have an overall retracted cylinder length of about 581 mm, or just under 23 in. long. This cylinder would need to be mounted next to and extending back past the fence. There would be a significant overhang outside the machine footprint, causing a problem since the cylinder body needs to be guarded so no one bumps into it. This overhang will also prevent installing the machine close to a wall, resulting in wasted working space (Figure 2). For several reasons, a rodless cylinder is a better fit for this application than a rodded cylinder. A rodless cylinder with a similar operating rating as the rodded version will have end caps, which consume some space, approximately 150 mm on each end. But when installed above the machine table, the backside of the fence can accommodate this overhang, as can the front side of the table because it is open. Another advantage of the rodless cylinder in this application is that it can support the glue head directly with no www.fluidpowerworld.com
Figure 2: This glue station application depicts how a traditional rodded cylinder (at left) creates a large overhang and requires a mechanical slide, while a rodless cylinder (at right) accomplishes the motion in a small footprint with no additional mechanism.
additional mechanism needed. If a rodded cylinder was used, the designer would need to account for the overhung load of the glue dispenser which would most likely require a mechanical linear slide to be incorporated, adding cost and complexity, and bringing the cost of the rodded cylinder solution close to the superior rodless option. Linear motion knockout punch
Rodless cylinders can save space in orientations other than horizontal, for example when used in vertical applications, such as a punch station. This manufacturing facility is short on floor space but has a high-bay ceiling. As part of a redesign, a horizontal punch station is being updated to a vertical orientation to save floor space. The first and topmost station will punch a hole in a thin steel plate. When this station was on the ground it used a standard cylinder with a 200 mm stroke. The cylinder protruded up above the machinery by about 300 mm (Figure 3). The vertical layout was proceeding
perfectly until one problem was noticed. The punch cylinder would end up just 15 in. away from a fire sprinkler head deflector. Every other part of the machine is more than 6 in. below the top of the cylinder. Per NFPA 13 there must be a minimum of 18 in. clearance from a sprinkler head deflector, so this equipment stackup needed to be reduced by at least three inches. In this case, a complete redesign was avoided by switching to a rodless cylinder, saving the required six inches. Rodless cylinders solve linear motion problems
Rodless cylinders are more expensive than rodded cylinders, and the space saving benefit becomes significant only for longer stroke lengths. However, where space is at a premium for linear motion, especially for long stroke lengths, a rodless cylinder can often be used in place of a traditional rodded cylinder, especially if the mechanism will be attached to a carriage. In any case, the upfront and maintenance costs of a rodless cylinder will be far less than designs using motor-driven linear mechanisms. FPW
AutomationDirect | automationdirect.com
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.
Figure 3: For this punch station example, a rodless cylinder (at right) accomplishes the same linear motion as a rodded cylinder (at left) but saves several inches of stackup height, which can be important for many installations. P.O. Box 6479 · Fort Worth, TX 76115 · V. 817-923-1965 · hydraulicsinc.com 12 • 2020
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H Y D R A U L I C
P U M P S
Rating the real Performance of
Hydraulic pumps Hydraulic component manufacturers
Low- and high-speed tests show that pump and motor performance can vary widely, depending on the speed and pressure. Thatâ&#x20AC;&#x2122;s critically important in electrohydraulic actuators and electric-motor drives.
generally publish pump and motor data that reflect optimal performance under ideal operating conditions. But experienced design engineers know that it is extremely difficult to obtain efficiency or performance data for less-than-perfect, real-world conditions. It even gets harder when looking at new concepts, such as electrohydraulic actuators, which run at very low as well as high speeds. There are almost no data for these applications. To address this information void, Innas recently tested and benchmarked the performance of a number of different pumps and motors running over a range of pressures and flows. We specifically targeted the types of pumps being considered for electrohydraulic actuators designed for implement systems. Moog, for instance, is advocating their radial-piston pump, whereas Rexroth is focusing on axial-piston pumps. Others are looking at gear pumps, both internal and external. Because an EHA is constantly moving back and forth, and a lot of the operation is at low speeds or near standstill, we developed a test bench that can measure at high as well as very low operating speeds. Furthermore, we wanted to know the extent of internal leakage for each unit, since significant leakage will result in a large dead-band. And we wanted to learn the upper speed limits, as electric motor developers prefer speeds of 5,000 rpm or higher, if possible. Our published report shows that current pumps and motors are not made for electrohydraulic actuators. They are built for more or less constant-speed operation, driven by a diesel engine or an electric motor, generally running at 1,500 to 1,800 rpm. Granted, many of the units tested are specified to not operate below a certain minimum speed simply because of significant wear or excessive internal leakage. Nonetheless, these limitations severely hinder their application in EHAs. Both dead-band and severe friction will inhibit the precise operation of hydraulic cylinders, especially because controllability will become much more important in the future. For this reason, we have tested these machines over a wide range of operating conditions. Results indicate that there is a dire need for the development of new concepts. The Innas floating-cup principle represents one such advancement. Its mirrored design with 24 pistons, very short strokes, a small displacement angle and hydrostatic lubrication provides extremely high efficiency even at start-up. And it can precisely control significant loads at speeds of just 2 to 3 rpm with virtually no wear. But we strongly believe that more breakthroughs are required. We
Peter Achten Robin Mommers Innas BV, Breda, The Netherlands
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www.fluidpowerworld.com
Innas engineers tested a number of hydraulic pumps and motors at both low and high speeds, with varying results.
plan to continue to measure the performance of other pumps and motors, and publish updated results on our web site. Testing background
The report contains results for performance measurements on eight different hydrostatic devices: three piston pumps, three piston motors, and two gear pumps. Important specifications are shown in the accompanying table. The piston-type units have from 7 to 24 pistons. From a physical point of view, the number of pistons is similar to the number of teeth in a gear pump. Derived geometric displacement volumes range from 23.7 to 32.7 cc/rev. Each pump and motor was measured using a unique test bench, developed by Innas engineers, which can operate a hydrostatic device at speeds ranging from 5,000 rpm to less than 0.01 rpm. More details are available in the sidebar, “Novel test rig is incredibly versatile.”
During tests, sensors in the mechanical components and hydraulic circuit measured: • • • • • •
Torque on the main shaft, T Speed of the main shaft, ω Pressure on the low- and high-pressure side, and in the housing Oil temperature at the low- and highpressure side, and leakage Main flow rate at the high-pressure side, Q2 Leakage flow rate, Q3.
It is important to note that several definitions used here differ from the current standard for measuring the performance of hydrostatic machines as described in ISO 4409:2019 and ISO 4391 — in particular the compressibility correction factors a1 and a2. A large group of experts from around the world agree with the need for these new efficiency definitions. Overall efficiency. To determine the efficiency of a hydrostatic machine, we first calculated the mechanical power Pm and hydraulic power Ph:
Efficiency and losses
To analyze the different devices, we looked at the measurement results. The three most important quantities used to describe the performance of the test subjects are the overall efficiency ηt, torque loss Tloss, and leakage Q3. Efficiency and torque loss are derived from the measured data, while leakage is measured directly. www.fluidpowerworld.com
Pm = Tω Ph = p2Q2a2 − p1Q1 T and ω are the measured torque and shaft speed, pi and Qi are the pressure and flow rate of oil through line i (1 = low pressure line, 2 = high pressure line), and a2 is a correction factor to account for the compressibility of oil at high 12 • 2020
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H Y D R A U L I C
P U M P S
Tested hydrostatic units Name
P/M
Type
z
Vg (cc) Vr
Pmax (bar) nmax (rpm)
Rexroth A4FM28
Motor
Slipper, axial
9
27.75
0.78
400
4250
KYB MSF30
Motor
Slipper, axial
9
30.17
0.69
250
2000
Brevini SH11CM030
Motor
Bent-axis
7
31.89
0.44
430
4750
Rexroth A4FO28
Pump
Slipper, axial
9
27.87
0.78
400
3750
Moog RKP32
Pump
Slipper, radial 7
32.66
0.08
350
2750
Eckerle EIPH3-025
Pump
Internal gear
13
24.31
0.17
330
3200
Marzocchi ELI2-D-25.7
Pump
External gear
7
25.41
0.00
210
3000
Innas FC24
Pump
Floating cup
24
23.65
0.85
500
5000
pressures. As derived, a2 = 1 + (p2/2Ks) where Ks is the oil isentropic bulk modulus. In a pump, mechanical power converts into hydraulic power, while a motor works the other way around. Overall efficiency ηt is the ratio at which power is converted; for a pump: ηtP = Ph/Pm = (p2Q2a2 − p1Q1)/Tω and for a motor: ηtM = Pm/Ph = Tω/(p2Q2a2 − p1Q1).
Torque loss. Torque losses during operation are calculated by comparing measured torque T to theoretical torque Tth:
TPloss = T − Tth TMloss = Tth – T.
Overview of the specifications of the tested pumps and motors, where z is the number of pistons or teeth, Vg the displacement volume, and Vr the volume ratio.
volume, and a1 a correction factor to account for the compressibility of oil at high operating pressures.
The difference in sign is similar to the difference in sign for the efficiencies: torque drives a pump to generate pressure and flow, while pressure and flow drives a motor to generate torque. The theoretical torque will thus be lower than the measured torque for pumps, to overcome friction and pressure ripples, and the opposite for motors. The theoretical torque can be calculated using: Tth = ((p2 − p1)Vg/2π)a1 with Vg the derived geometric displacement
a1 = 1 − (0.5 + Vmin/∆V)(∆p/Ks) with Vmin the dead volume per cylinder, and ∆V the geometric displacement volume per piston. To compare the torque loss of pumps and motors of different sizes, torque loss can be normalized. The normalized torque loss TNloss is defined as 1 − Tth/T for a pump and 1 – T/Tth for a motor. Oil model. Correction factors a1 and a2 used an isentropic bulk modulus Ks = 1.76 × 109 Pa, which was suitable for our
Comparing the measured power loss at 200 bar for all the devices.
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www.fluidpowerworld.com
These graphs compare the normalized torque losses at 200 bar. Linear scale is on the left, log scale on the right. measurements using a Shell Tellus46 oil at roughly 50°C and pressures ranging to 400 bar. Detailed oil modeling concluded that using a single constant bulk modulus sufficed in deriving the performance of the machines tested. More details can be found in the report, “Performance of Hydrostatic Machines,” available at innas.com. Measurement results
Overall efficiencies of the different pumps and motors were determined based on the above equations. The results for various shaft speeds at an operating pressure of 200 bar are shown in the Overall Efficiency graph. All of the tested subjects followed the same trend: Efficiency is low at low operating speeds; increases rapidly until maximum efficiency is reached somewhere between 1,000 and 2,000 rpm; and as shaft speed increases further, efficiency decreases, but at a much lower rate. At this pressure, the highest peak efficiency of almost 0.96 was realized by the Innas pump at 1,000 rpm, while the Moog pump had the lowest peak efficiency of 0.87 at 1,500 rpm. One outlier is the KYB motor’s measurement point at 2,000 rpm. Here, efficiency decreases much faster than was expected. However, the unit was running near its maximum rated operating speed, which causes additional torque loss and leakage. We then used the torque-loss equations to calculate the difference between the theoretical and measured torque for each device. To
properly compare machines of different sizes, these losses have been normalized. The Normalized Torque Loss graphs show both linear and logarithmic scales at 200 bar. The linear plot shows losses at normal operating conditions, while the logarithmic plot provides some insight into the losses during low speed operation — for example, startup conditions. Overall, the torque loss shows a similar trend for motors and pumps. Below 1 rpm (see logarithmic plot) losses appear to be constant. At some point, the torque loss quickly decreases for increasing shaft speeds, until reaching a minimum. From this speed onwards, the torque loss increases again, but at a slower rate. This trend is very much in accordance with the Stribeck curve, and the three sections describe the transition from coulomb friction (boundary lubrication), to mixed friction, and viscous friction (hydrodynamic lubrication), respectively. In the linear plot, we see that at this pressure level the three motors have similar torque losses at normal operating speeds. Furthermore, the logarithmic plot shows that the Brevini motor outperforms the other two motors in the low speed range, where it has less torque loss than the KYB and Rexroth motors. The five pumps show larger differences with respect to each other. Overall, the Innas pump has the lowest torque loss at this pressure, especially in the low speed range. This can be explained by the fact that this is www.fluidpowerworld.com
a floating-cup type pump, which has almost no contact between the piston and bore, and thus very little coulomb friction. In the viscousfriction section, torque losses in the Rexroth, Eckerle, and Innas pumps increase at roughly the same rate. Torque loss for the Moog pump increases at a faster rate, while the torque loss of the Marzocchi seems relatively constant at higher operating speeds. The graphs show that torque loss is more or less constant at operating speeds below 1 rpm, due to coulomb friction. During the low-speed measurements, each unit can be tested during both pump and motor operation. (Because the Eckerle pump is an internal gear pump, it cannot be tested as a motor.) For most piston machines the torque loss due to coulomb friction is larger when it is driven as a pump. The exception being the Brevini, which has more or less the same torque loss for both directions. This can be explained by the direction in which the piston moves during the high pressure stroke. When operated as a pump, the piston pushes the barrel to the portplate during the high pressure stroke, increasing the friction between those two surfaces and, therefore, the torque loss. When operated as a motor, the piston pulls the barrel away from the portplate, decreasing friction. The highest torque loss was found on the Rexroth pump, which loses up to 60% of torque at these operating speeds. It is worth noting that the two Rexroth units are, apart from 12 • 2020
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Novel test rig is incredibly versatile The Innas test bench can operate hydrostatic pumps and motors over an extremely wide speed range — from 5,000 rpm to less than 0.01 rpm — thanks to two different types of actuators. The pump or motor tested is coupled to the main shaft, followed by two different-sized sprockets. An electric linear actuator can connect with either sprocket to drive the shaft at speeds from around 1 rpm to less than 0.01 rpm. A coupling next to the sprockets lets technicians switch to operation by a large electric motor. This electric motor can rotate the test subject at any speed between 10 and 5,000 rpm. A second hydrostatic unit can be attached at the back end to recirculate the generated power. It operates as a pump when the test involves a motor, and vice versa. Before each measurement, the test subject is driven at a moderate speed and pressure, to allow it and the oil to warm up. When both are at a steady temperature (around 50°C), test parameters are measured during operation at a number of predetermined speeds and pressure levels. This procedure is in accordance with ISO4409:2019 and is used to determine the geometrical displacement. After high-speed performance tests, low-speed tests are performed by shifting the coupling and connecting the linear actuator. The integrated set-up ensures that the test object, all sensors and hydraulic lines remain on the test bench. Additionally, the oil and pump or motor remain at warm operating temperatures. During low-speed measurements, the linear actuator first makes a downward stroke followed by an upward stroke. Thus, the unit is tested both as a motor and as a pump. silencing grooves in the portplates, the same product. This was confirmed by comparing the torque losses when they were driven in the same direction. The normalized torque loss of the Innas pump during low speed motor operation becomes less than zero. In other words, more torque was delivered to the shaft than the theoretical maximum. At these low speeds, leakage will be larger than the amount of displaced oil. In this case, an additional pump provides the right pressure level. Unfortunately, the calculations no longer apply in this situation, making it impossible to derive the overall efficiency. This approach emulates the behavior of units as part of a larger hydraulic network, which is often the case. It is currently hypothesized that the pressure delivered by this supply pump affects torque on the test specimen’s shaft 50
FLUID POWER WORLD
12 • 2020
Linear actuator with built-in position sensor
Sprockets for the counterweight
The test bench offers low and high-speed measurements. Sprockets, with 36 and 60 teeth, are for low-speed tests.
Hydraulic motor or pump for power recirculation Frequency controlled, water cooled electric motor
Sprockets for low-speed tests Torque and speed sensor
Switchable coupling
Coupling for the pump or motor
as well. Further research will be needed to determine why this is the case, and what it means for further analyses. Results also show that at these low speeds there is a significant variation in torque loss at different angular shaft positions. In the case of pumps, this normalized torque is larger than 1, meaning that a certain amount of additional torque is needed to overcome the friction. Some of the tested specimens needed as much as 80% extra torque to operate at this speed. In the case of motors, the normalized torque is less than 1, meaning that less torque is provided by the supplied oil. One unit showed a torque loss as much as 30%. Leakage flow rate
The leakage flow rate from the rotary group to the pump or motor housing is measured directly in the test bench. (Note that the gear www.fluidpowerworld.com
pumps do not have an external leakage port, so leakage cannot be measured.) Internal leakage affects the total output flow rate and, thus, the efficiency calculations. Measured leakage for each device at 200 bar showed that for most, leakage increases slightly for increasing shaft speeds. This makes sense, because increasing the shaft speed will linearly increase the amount of displaced oil. However, the relatively constant leakage flow rates at low operating speeds suggest that it does not only depend on shaft speed. A constant leak flow generally means that the gap through which oil leaks does not change much, indicating that this is probably caused by the precision with which the parts have been made and how accurately they fit together. Similar to the low speed torque losses, the Low Speed Leakage Flow Rate graph shows average leakage conditions for
H Y D R A U L I C
P U M P S
A comparison between the measured leakage flow rates at higher speeds.
measurements at speeds less than 1 rpm. Tests showed a sizeable variation in leakage between the different measurements. Main factors for these larger ranges seem to be the oil temperature (which is difficult to control during low speed measurements) and the case pressure (mainly for the Moog pump). Even though there is a significant spread in the flow rate measurements at different low speeds, leakage is generally higher during motor operation for most machines. When operated as a pump, the piston pushes the barrel to the portplate during the high pressure stroke, decreasing the size of this leakage path. When operated as a motor, the piston pulls the barrel away from the portplate, which allows for more leakage. Exceptions are the Innas pump, which has more or less equal
leakage in both directions; and the Brevini motor, which has more leakage when driven as a pump than as a motor. Interestingly, while the two Rexroth units showed similar torque losses, there is a large difference between their leakage flow rates — most likely due to the difference in portplates. Because these measurements take a long time, and only little oil flows through the unit, housing temperature decreases over time. This has a large effect on the viscosity of the leakage oil, causing oil to flow slower at lower temperatures. When measurements are conducted in succession, the housing and oil need to be heated between each test run. FPW
Innas | innas.com
This graph shows average leakage flow rates during measurements at less than 1 rpm, for units driven both as a motor (left side) and as a pump (right side). The width at each pressure indicates the range of leakage measurements.
www.fluidpowerworld.com
12 • 2020
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PRODUCT WORLD
Readily biodegradable hydraulic fluid Environ MV R is the companyâ&#x20AC;&#x2122;s ďŹ rst hydraulic ďŹ&#x201A;uid using ultra-pure severely hydrotreated base oils to meet the OECD 301B requirements for ready biodegradability. According to Petro-Canada Lubricants, the design makes Environ MV R the ďŹ rst hydraulic ďŹ&#x201A;uid of its kind to meet these requirements, providing longer life and increased value without compromising performance. Environ MV R combines select, ultra-pure, severely hydrotreated base oils with a premium ashless additive system to oďŹ&#x20AC;er operators the protection of a premium mobile and industrial hydraulic ďŹ&#x201A;uid â&#x20AC;&#x201D; while also being OECD 301B readily biodegradable to help protect sensitive environments. The absence of zinc and other heavy metal-based additives also makes the ďŹ&#x201A;uid safer for the environment by minimizing the risk of creating long-lasting damage to terrestrial and aquatic organisms or water resources. Environ MV R joins the Environ product line of environmentally friendly hydraulic ďŹ&#x201A;uids.
Hydraulic pressure intensifiers provide high pressure on demand HC21 hydraulic pressure intensiďŹ ers from miniBooster provide high pressure on demand. With these devices, if a user wants to boost pressure instantly, they can ďŹ&#x201A;ip on the electric signal and the new HC21 will boost pressure up to 800 bar immediately. The HC21 comes with a range of directional valves, open and closed center, coil voltages, and side ports, eliminating the need for additional tubing for gauges, pressure transmitters, and so on. It also has an easy inline mounting design and compact footprint, weighing just 3.2 kg. It oďŹ&#x20AC;ers 15 diďŹ&#x20AC;erent intensiďŹ cation factors. Finally, all miniBooster solutions oďŹ&#x20AC;er the added advantages of low noise, nearly zero weight, and the ability to boost readily available vehicle pressure when you need it.
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Multi-function joystick handles
J.R. Merritt Controls expands its line of heavy-duty joystick handles with the introduction of the G56 and G58 multifunction handles. The G56 and G58 were engineered for ultimate usability and feature their own unique shapes. The G56 boasts an ergonomic design that leans forward and inward towards the operator and is available in left-hand and right-hand models. The G58 has a comfortable, straight design that can be used for left-hand or right-hand operation. The G56 and G58 oďŹ&#x20AC;er a high degree of ďŹ&#x201A;exibility with a selection of individually conďŹ gurable device plates that can be populated with pushbuttons, rocker switches, thumbwheels, and mini joysticks. Both models can also be conďŹ gured with devices on the rear side of the handles, with the G58 oďŹ&#x20AC;ering an option for a trigger. Features: G56 Multi-Function Handle â&#x20AC;˘ Ergonomic design that leans forward and towards the operator â&#x20AC;˘ Available in left-hand or right-hand models â&#x20AC;˘ Eight standard front plate layouts featuring push buttons, thumbwheels, and rocker switches â&#x20AC;˘ Four standard rear plate layouts with push buttons, thumbwheels, and rocker switches G58 Multi-Function Handle â&#x20AC;˘ Robust design for high duty applications â&#x20AC;˘ Straight shape for left-hand or right-hand operation â&#x20AC;˘ 17 standard front plate layouts with push buttons, thumbwheels, and mini joysticks
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PRODUCT WORLD
Linear transducers with redundancy
PRECISION PRESSURE CONTROL FOR PNEUMATIC AUTOMATION
ProportionAir.com Get a fast quote
Balluff balluff.com With up to three independent measuring systems operating concurrently in a single housing, Balluffâ&#x20AC;&#x2122;s new fail-safe magnetostrictive linear position sensors with digital interfaces ensure uninterrupted processing for uptime critical applications, such as hydraulic cylinders used in steel manufacturing. Available in four form factors, these rod-style transducers have either two or three separate sets of electronics and sensing elements operating concurrently in a single housing. They are available with either SSI and Start/Stop digital interface. These new digital versions are less noise susceptible while offering greater resolution down to 0.5 Âľm. They deliver up to 1,000 Hz sampling frequency for fast data acquisition. They are pressure rated to 600 bar and provide an IP67 rating, so they are insensitive to contamination. They measure from 25 up to 7,620 mm, depending on the model.
887.331.1738
Live tech support (M-F 8A-5P EST)
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FLUID POWER WORLD
Oil sensor with real-time, 24-hour monitoring
Proportional directional control valves
The OQS 2 Oil Quality Sensor puts users in control with real-time, 24/7 monitoring of oil degradation, oil condition, and water ingress and is now available for purchase. The sensor is a live, highly ďŹ&#x201A;exible, and cost-eďŹ&#x20AC;ective condition-based monitoring solution, designed to be permanently mounted within any lubrication system on any machine. Over 60 times more sensitive to oil contamination than any other dielectric constant measuring sensor, it provides real-time monitoring of oil condition, water ingress, and oxidation levels. The OQS 2 is completely redesigned and has included the following features:
New PWK06J series of proportional directional control valves is currently available in Motor Spool â&#x20AC;&#x153;J,â&#x20AC;? with a closed center option to follow. Though the size is small, the features are big and include:
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Increased sensitivity and accuracy A redesigned housing A new durable connector IP68 certiďŹ ed (when connected) Fluid pressure resistance up to 70 bar / 1,015 psi
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Compared to any other 3 position 4-way proportional directional valve, this is a fraction of the size and provides great low ďŹ&#x201A;ow accuracy and repeatability Internal leakage less than 100 cc/min Hysteresis less than 6% Linearity within 3% Repeatability within 3% 12W â&#x20AC;&#x2DC;Dâ&#x20AC;&#x2122; or â&#x20AC;&#x2DC;Pâ&#x20AC;&#x2122; type coils in all voltages and connections 1000-hour salt fog rust protected
Ethernet communication module The PCH Network Portal minimizes machine costs, shortens start-up time and oďŹ&#x20AC;ers built in features to help reduce end user downtime in factory environments. As an ethernet node with IO-Link master capability that supports multiple Industrial Ethernet communication protocols, it can communicate with many industrial controllers in the automation industry. It was engineered for ďŹ&#x201A;exible manufacturing applications where machine changes are common, PLCs are not always accessible, and where obstacles on the plant ďŹ&#x201A;oor make set up, conďŹ guration and troubleshooting time consuming. ClassiďŹ ed as a Cyber Physical System for its ability to communicate across machinery, the PCH Portal oďŹ&#x20AC;ers maximum function integration, simplicity of use and signiďŹ cant architecture cost reductions. www.fluidpowerworld.com
12 â&#x20AC;˘ 2020
FLUID POWER WORLD
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PRODUCT WORLD
Vacuum-based soft pinch gripper
Directional blocking poppet valve with soft shift option
Piab piab.com
Sun Hydraulics sunhydraulics.com The DTAFS is a FLeX Series, solenoid-operated 2-way, 2-position direct-acting directional poppet valve with a soft shift feature. These valves feature a pressurebalanced design, low leakage, and allow flow or blocking in both directions. They are available in either normally open or normally closed configurations. This delayed-response option is designed to extend response time and, as a result, minimize hydraulic shock in a system when shifting a valve or unloading a main stage valve. And like all FLeX Series valves, the DTAFS is tested to 10-million operational cycles at full-rated pressure and is zinc-nickel plated for 1,000-hour salt fog protection. It is rated for maximum operating pressure up to 5,000 psi.
piSoftgrip family now includes a pinch gripper developed for the automation of the food/chocolate industry. The vacuum-based soft gripper can grip sensitive and lightweight oblong objects with odd geometries and/or objects with an unusual surface. piSoftgrip has two gripping fingers and a sealed vacuum cavity, all made in one piece. The product is not sensitive to dust and the gripping force is easily adjusted and controlled by the applied vacuum level. The gripper can easily be put in rows (multiple mode) to support picks of extended objects. piSoftgrip is made from silicone, which is approved for direct contact with food (in accordance with FDA 21 CFR and EU 1935/2004 regulations). Gripping force is controlled by simply adjusting the vacuum level. The new soft gripper can grip objects with a width of up to 50 mm (1.18-in.). The soft gripping vacuum tool is as easy to control and install as a suction cup. It can be used for multimode applications, putting several piSoftgrip 50-2 in rows or other grid structures, supporting the picks you want to make. The piSoftgrip 50-2 uses same fittings as Piab’s piGRIP suction cups.
New high-accuracy hydraulic flow dividercombiner valve Webtec webtec.com Webtec has unveiled a new high-accuracy hydraulic flow divider-combiner valve called the FDC140. Suitable for driving two cylinders or motors in close unison regardless of individual loads or flow direction, this high-flow spool valve is the big brother of the current FDC60. The “140” in the name indicates a larger flow capacity of 140 lpm (37 gpm) and above, making it a good choice for large, heavy-duty applications such as container handling systems, large-capacity forklifts, skip handling, synchronized crawler drives, loading ramps, and mining machinery. FDC140 valves can divide a single flow into two separate flows. These will always be in the same ratio regardless of any pressure differential (unequal load). The FDC140 delivers a divisional accuracy of ±1.5%. Accuracy in this range makes it competitive with some gear flow divider products at a fraction of the price. If required, a single flow can also be divided into two unequal flows, with split ratios extending from 10-90% (in 10% increments).
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USCG-accepted hightemperature hose Recommended for high-pressure, high-temperature hydraulic oil lines, this SAEJ1942 hose is USCG accepted for hydraulic only. It has two high tensile steel wire braid internal reinforcements with a highly durable blue abrasion, ozone and weather resistant synthetic rubber MSHA approved covering. It is designed for temperature range applications from â&#x20AC;&#x201C;10° to 300°F and is available in Âź- to 1-in. sizes. Recommended for medium pressure, high-temperature oil lines, truck engines, compressors, oil, and fuel service, the SAEJ1942 hose is USCG-accepted for all services. It has one high tensile steel wire braid internal reinforcement with a highly durable blue abrasion, ozone and weather resistant synthetic rubber MSHA approved covering. It is designed for temperature range applications from â&#x20AC;&#x201C;10° to 300°F and water and water-based ďŹ&#x201A;uid applications at 158°F max and is available in Âź to 1-in. sizes.
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The Mobile Hydraulic Experts. The Mobile Hydraulic Kraft Fluid Systems helps Experts. you sell more machines The Mobile Hydraulic Experts. by allowing you to focus on your customers Kraft Fluid Systems is the leading distributor and systems integratorand
Kraft Fluid Systems is the leading distributor andyou systems integrator letting our experts help with hydraulic of hydraulic equipment and electric drive technology foryour mobile Kraft Fluid Systems is the leading distributor and systems integrator of hydraulic equipment and electric drive technology for mobile off-highway applications. With more than 45 yearsWe of experience, and electric drive systems. are the leading ofoff-highway hydraulic equipment andWith electric drive technology forexperience, mobile applications. more than 45 years of Kraft is the preferred distributor when seeking hydraulic distributor and systems integrator of hydraulic off-highway applications. With more than 45 years of experience, Kraft is the preferred distributor when seeking hydraulic components, power transmission equipment and electronic equipment andseeking electric hydraulic drive technology Kraft is the preferred distributor when components, powerOEM transmission equipment controls for mobile integrated solutions.and electronic for mobile off-highway applications. components, power OEM transmission equipment and electronicWith controls for mobile integrated solutions. controls for mobile OEM integrated solutions. nearly 50 years of experience, Kraft is Sales | Service | Inventory preferred distributor when seeking Sales | Service | the Inventory Serving Connecticut, Indiana, Kentucky, Sales | Service Delaware, | Inventory hydraulic components, power transmission Serving Connecticut, Delaware, Indiana, Kentucky, Maryland, Michigan, New Jersey, New York, Ohio, equipment, and electronic controls for Serving Connecticut, Delaware, Indiana, Kentucky, Maryland, Michigan, New Jersey, New York, Ohio, Pennsylvania, West Virginia and Wisconsin. Maryland, Michigan, Newmobile Jersey, Newintegrated York, Ohio, solutions. Pennsylvania, West Virginia andOEM Wisconsin. Pennsylvania, West Virginia and Wisconsin.
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We make our
pitch control valves to last more than 5 years. We warranty them for 3 years. No one else does.
UNEXCELLED IN SPEED AND LIFE You can trust Yuken proportional valves, linear servo valves and servo-controlled systems.
Master Distributor: ALA INDUSTRIES LIMITED • Portage, IN • 877-419-8536 • www.yuken-usa.com Yuken 2020_REVISED_FINAL2 11-20.indd 1
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COMPONENT FOCUS Brent Schenk • Global Product Manager, Medium-Duty Closed-Circuit Piston Pumps, Eaton
Drive performance with interconnected propel solutions The equipment industry — from construction to agriculture, mining and beyond — is moving to adopt smarter, more efficient systems and machines. To maximize efficiency and productivity, users need machines that are easier to maneuver on the worksite, simpler to operate and packed with more power to handle every job.
For OEMs, these evolving expectations mean rethinking how they design and build the critical systems that power their machines. As the footprints of these machines shrink to reduce weight and improve efficiency, OEMs must find new ways to pack more power into tighter spaces. It’s no longer just about components; it’s about how components connect to create intelligent sub-systems that are greater than the sum of their parts. Every part must work together seamlessly to unlock new efficiencies and enhance productivity. Eaton’s new X3 portfolio is designed to help OEMS meet today’s diverse industry demands by combining capabilities for best-in-class performance in a compact package. They provide the ability to pair the X3 two-speed cartridge motor with single or back-to-back pump configurations. The X3 two-speed cartridge motor is available in 41 and 49 cc displacements, which helps provide more top-end horsepower at the wheel while ensuring most small mobile application needs are covered. The motor also has a built-in speed sensor port, making it easy to add a sensor to measure speed and direction. Using a standard SAE B 2-bolt mount, the motor will fit into virtually any existing machine design and can also be positioned as a drop-in replacement for several motor configurations. Built for durability in the toughest mobile environments, the X3 motor pairs with back-to-back
or single pump options which offer a 36% increase in the side load capacity over previous generations of Eaton pumps. The compact size makes it easier for designers to fit the pump into smaller machines, a key advantage given the increasing need to save space in construction and agricultural equipment. The pump also has improved packaging that better protects the control solenoids against damage. The X3 pump is available with a variety of controls, including a non-feedback electrohydraulic control, a hydraulic remote control and a manual servo control. The X3 pumps are Pro-FX Ready and ideally paired with an Eaton HFX Programmable Controller. Eaton’s X3 portfolio can actively sense Speed-sensor-ready and dynamically adjust parameters X3-SAE-mount motor such as position and flow – taking dynamic machine control to a whole new level. When combined with Eaton’s HFX controller, the X3 pump delivers among the lowest amount of hysteresis (variation) of any pump in its class. By improving accuracy of output flow, engineers are empowered to design systems that deliver greater repeatability — another major ingredient for advancing machine reliability and efficiency. By combining a cartridge motor, pumps and controls together in one robust solution, the X3 portfolio empowers OEMs to build the powerful equipment that end users demand — offering tight control, smooth operations and fuel savings. Allowing engineers to reimagine system design and introduce advanced connectivity, X3 provides the foundation for more reliable, stable and productive machines. FPW
Eaton | Eaton.com/X3
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