FLUID POWER WORLD DECEMBER 2022

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Mary C. Gannon • Editor-in-Chief

The future is sustainable and it’s here to stay

Last month, organizers for CONEXPOCON/AGG and IFPE announced that a key focus of the 2023 events will be on next levels of sustainability in construction, highlighting the many aspects of the shows designed to ensure a sustainable future. This is a reflection of an industry moving towards a sustainable future.

First up are manufacturers that plan to highlight their electric, autonomous, or digital technologies, such as Volvo Construction, Caterpillar, Skyjack, and many others, who will be introducing electric-powered, emission-free machinery at the event.

If the machines and technologies highlighted at bauma in October are any indication, reducing emissions while remaining powerful are keys to the future. I expect we will see many of the same machines launched at bauma on the CONEXPO-CON/AGG lots. We’ve highlighted a few of those on page 34, with a look at Liebherr’s Hydrogen-powered excavator, Komatsu and Proterra’s battery powered excavator, and more. It is important to note that in many of these larger machines, the hydraulic systems remain the same because you can’t beat the power density provided by hydraulics in heavy-duty operation.

Additionally, many of the education programs offered on the IFPE and CONEXPO-

CON/AGG side will be geared towards sustainability. Here’s a look at some of the IFPE sessions — and be sure to turn to our pre-IFPE coverage on page 38 to see more indepth looks at some of the IFPE sessions and also what’s new in Las Vegas since 2020.

• Efficiency in hydraulic systems,

• Efficiency in pneumatic systems,

• An integrated electrohydraulic unit for fluid power applications,

• What can you do to make your machine more efficient,

• Advancing autonomy from operator assist to driverless vehicles,

• Electrification of vehicle powertrains, and

• Reducing energy consumption in fluid power systems.

Additionally, CONEXPO-CON/AGG has given sustainability its own education track in its seminar offerings, now with 13 sessions dedicated to the topic. They tackle subjects like reducing the carbon footprint of concrete, getting and managing electric construction equipment, asphalt and concrete recycling, carbon neutrality, and a “Sustainability 101” session.

Show organizers are promoting several initiatives less relevant to the engineer but still part of their move to a more sustainable show. For example, they have partnered with the Arbor Day Foundation, and are working toward planting 130,000 trees in

forests of greatest need, one for every show registrant. Exhibitors and attendees can contribute to the Arbor Day Foundation’s funds. Each dollar contributed will result in one tree being planted in a forest in need.

And finally, CONEXPO-CON/AGG and IFPE are committed to reducing the environmental impact of the show. This includes partnering with vendors dedicated to sustainable practices and reducing waste, helping exhibitors choose more sustainable options, and measuring its total 2023 environmental impact to identify future improvements.

Show organizers say that registration for 2023 is outpacing all previous shows in attendee registration. To continue this momentum, they have extended a special registration code to our readers to January 6, 2023. By registering with the code PR30, you can save 30% off registration.

I hope to meet many old and new friends in March at IFPE. Be sure to mark down our booth number, SL80022 and stop by to say hello. And stay tuned for our February issue, which will include our complete IFPE coverage. FPW

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Paul J. Heney • VP, Editorial Director

Seeing some old names — anew

At the recent Danfoss Distributor Meeting in Orlando, I caught up with Eric Alström, the company’s President. Danfoss is a bit more than a year removed from the purchase of Eaton’s hydraulic business, and Alström told me that the merger’s gone better than one may have imagined.

“As of January 1st [2022], everybody knew who they were reporting to. And remember, we went from a regional P&L structure in Eaton to our global product line structure in Danfoss. So, it’s a big change for many Eaton team members. And we also had financial transparency as of January 1st, which is, of course, really important. So basically, we have been operating as one company since then,” he said. “However, there are some things that take longer, like the IT backbone and CRM systems. We have one ERP now in Danfoss that we’re rolling out. And Eaton will, of course, also be brought onto the same ERP system — and that takes a little bit longer. So that is a journey, but nothing that’s stopping us from doing regular work and being together as one company.”

I also asked Alström about the return of beloved fluid power industry names. For example, on the event’s tradeshow floor, I regularly saw the Vickers name — one that takes me back to my first days in the industry in the early 1990s.

Alström said that, leading up to the acquisition, they did some exploration and asked innocent questions of partners, including about brand strength. It became very evident that in the industry, Vickers was still a strong brand — and the only reason that it had been diminished was lack of investment.

“So now we are investing in Vickers,” he said. “We are investing in all of the fluid conveyance brands. Anecdotally, on day two of coming together as a new company, on August 3rd, I got an email from a distribution partner that started with, ‘My brother and I have had our fluid conveyance company since 1972. We’re a proud distributor of Aeroquip products. Please don’t do what Eaton tried and put Danfoss in the front. Nobody ever bought an Eaton Aeroquip hose. Everybody was buying an Aeroquip hose.’ That just resonated very strongly with me. We confirmed that these brands are really strong. Let’s nurture them. Let’s come up with new products and innovations so that people see that they’re alive again.”

Alström concluded by saying that Danfoss is putting the brands in the foreground and promoting them as, “By Danfoss.” So, they’ll be Boston by Danfoss and Aeroquip by Danfoss. The goal, he said, will be to invest in and breathe life back into those legacy brands that are still industry favorites to so many. FPW

Paul J. Heney VP, Editorial Director pheney@wtwhmedia.com On Twitter @wtwh_paulheney

FEATURES

PNEUMATICS

An introduction to pneumatic actuators Learn what are the key considerations for selecting the right pneumatic actuator for your unique application.

INDUSTRIAL HYDRAULICS

Refrigerator-sized hydraulic power units that don’t make a peep Technology advancements enable smaller, quieter, and more energy-efficient hydraulic power units that save space and reduce the total cost of ownership.

MOBILE MACHINERY ROUNDUP

Sustainable machinery designs top Bauma innovations While many compact machines boast all-electric systems, several prototype designs feature alternative options to power larger, heavier-duty equipment.

IFPE EDUCATION

Efficient fluid maintenance is core to sustainability

IFPE conference programming will take in-depth looks at fluid cleanliness and life to ensure sustainable, efficient systems.

IFPE TRAVEL

The new Las Vegas is ready for IFPE A lot has changed in the Nevada desert since the last show took place in March 2020 — here’s what to expect for 2023 visitors.

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EDITORIAL

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Robert Sheaf • Founder/CEO of CFC Industrial Training

The circuit shown here is used to open and close the cage doors on a zoo enclosure. The staff would start the hydraulic system when they needed to open and close the gates. They then would shut it down when all the gates were closed.

After having trouble opening one of the larger cage doors, they spent time making sure there wasn’t a mechanical obstruction and that the gate wheels rotated freely. A local repair shop told them to increase the pressure on the electric motor-driven pump, but it would not go any higher. They tried increasing the setting on the relief valve and it also would not increase the pressure.

They tried to start the gas engine stand-by system but could not get that up and running, either. They also noticed the oil temperature kept climbing the longer they allowed the power unit to run.

Can you identify what was the problem? We welcome responses of all kinds directly to Robert Sheaf at rjsheaf@cfc-solar.com or to mgannon@ wtwhmedia.com. The solution will be provided next month, in conjunction with our February 2023 issue. FPW

Pressure problems on a multi-circuit system Solution to system overheating on drum pusher system

After finding the circuit drawing on the drum pusher system which was overheating, the service technician found that the unloader valve was stuck in the shifted position and both filter elements were missing. To solve the problem, both filter indicator switches were disconnected at the terminal strip to keep the machine from shutting down.

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Edited by Mary C. Gannon • Editor-in-Chief

IFPS launches online instructor-led certifi cation review training

The IFPS announced that it has officially launched an online instructor lead Hydraulic Specialist Certification Review Training course.

Tom Blansett, CFPAI, IFPS Technical Director, will facilitate this 12-week virtual/online training course to help candidates prepare for the Hydraulic Specialist Certification test. Classes will be held Thursdays from 10:00 AM -1:00 PM EST beginning on March 9, 2023 (skipping March 16). The registration fee includes the training and the testing fee. Three additional online pretests are also included with this workshop.

Throughout the training program, each Outcome contained within the study manual will be explained in detail. Many animated hydraulic circuit schematics are shown to aid in comprehension and understanding. All Outcome review questions will be explained along with a detailed explanation of how the answer was found. This training is limited to 15 participants. Participants can take the course only or pay for the course and the testing.

Recommended prerequisites include an engineering degree or 3-5 years of hydraulic application experience. The IFPS Fluid Power Math course (coming soon) is highly recommended prior to the start of this course.

Recommended publications for this training course:

• Hydraulic Specialist Study Manual*

• Fluid Power Reference Handbook*

• Fluid Power Math Handbook*

*Select the bundle during registration to receive a discount price on these publications. FPW

Learn more at ifps.org.

IFPS launches new series of safety posters

The International Fluid Power Society has always offered access to free safety posters from the International Hydraulic Safety Authority, but members can now access free safety posters created by the IFPS itself.

Posters are available to members only and are available for printing for free. Topics include hydraulic injection injury, lockout/tagout, cylinder pressure, eye safety, and hydraulic systems. More poster topics will be added throughout the year.

Additionally, IHSA posters are also available for download, on a variety of topics, such as hose charging, fluid spray, safety blocks, high-temperature burns, and more.

IFPS membership is required for download. Visit ifps.org to download. FPW

NFPA encourages members to engage with students

The Fluid Power Action Challenge is a STEM-based competition that challenges middle school students to solve an engineering problem using fluid power. The students work in teams to design and build a fluid power mechanism and compete against other teams in a timed competition. The Fluid Power Action Challenge provides a bridge from the classroom to the community by teaching students about the technology and its applications, which creates needed visibility in the minds of tomorrow’s workforce so they can consider fluid power as a career path.

As NFPA seeks to increase the number of educated technicians and engineers in our industry, the Action Challenge aims to introduce our technology and spark interest in a fluid power educational path. With that building block established, NFPA has created workforce development pathways in several states with a high concentration of NFPA members. This program, Fast Track to Fluid Power, intends to guide students along a track that leads to careers at NFPA member companies.

Fluid power experts are encouraged to join the NFPA this spring as volunteer judges are welcomed and appreciated by teachers and event organizers.

Upcoming Fluid Power Action Challenge events with Fast Track to Fluid Power Hubs include:

• Master Pneumatic & Macomb Community College, Warren, Michigan, Workshop Day 1/18/23 and Challenge Day 3/29/23

• Price Engineering & Waukesha County Technical College, Waukesha, Wisconsin, Workshop Day: 2/3/23 and Challenge Day: 3/10/23

• Deltrol Fluid Products & Triton College, River Grove, Illinois, Workshop Day Friday 2/17/23 and Challenge Day Friday 4/28/23

Learn more about getting involved with Fluid Power Action Challenge events by emailing workforce@nfpa.com. FPW

Development of ISO Standards continues

The U.S. Technical Advisory Groups (TAGs) for contamination control (TC 131/SC 6) and connectors (TC 131/SC 4) met recently to continue the ISO standardization work in fluid power systems. More than 30 connector and filter test engineering experts attended inperson or virtually. Both NFPA and non-NFPA members, representing many fluid power-related companies, were in attendance, including Holmbury, Donaldson, Pall, Parker, Cummins, Eaton, Danfoss, Caterpillar, Mann+Hummel, and John Deere.

There are 88 published ISO standards and 17 projects in various stages of development under the direct responsibility of the contamination control and connector subcommittees. In the international arena, the U.S. TAG develops and advocates for the U.S. position in each of these standards. Here is a sample of the projects currently under development:

• TR 6049, Hydraulic fluid power —Procedures used to NIST certify the standard reference material SRM 2806x a calibrant for liquid automatic particle counters

• ISO/FDIS 23369, Filter multi-pass test under cyclic flow conditions

• ISO/DIS 12829, Hydraulic spin-on filters with finite lives — Method for verifying the rated fatigue life and the rated static burst pressure of the pressure-containing envelope.

• ISO/FDIS 1179-2:2013 — Connections for general use and fluid power — Ports and stud ends with ISO 228-1 threads with elastomeric or metal-to-metal sealing — Part 2: Heavy-duty (S series) and light-duty (L series) stud ends with elastomeric sealing (type E)

• TS/AWI 11686 – Connectors for fluid power and general use — Assembly instructions for connectors with adjustable stud ends and O-ring sealing.

• ISO 171651 (hydraulic hose lengths and requirements) – reference document 131/4/6 N 458 (U.K. experts’ matrix of hose assembly length tolerances in ISO 171651).

The next U.S. TAG to TC 131/SC 6 and TC 131/SC 4 meetings will be held in a hybrid format in the March/April timeframe. Other U.S. TAGs continue to meet virtually as needed. NFPA is looking for engineers interested in participating in standards development activities as experts in ISO/TC 131 and/or the U.S. TAG to TC 131.

If you are interested in attending and/or participating in standards development, please contact Denise Husenica at dhusenica@nfpa.com.

Edited by Rachael Pasini • Senior Editor

in the 2022 LEAP Awards Hydraulics innovations are recognized

The annual LEAP Awards (Leadership in Engineering Achievement Program) acknowledges innovation and engineering achievements from around the globe. Our expert independent judging panel received numerous submissions this year and selected 44 gold, silver, and bronze winners and honorable mentions across 14 categories.

This year’s Hydraulics submissions showcased a range of technologies that demonstrate the fluid power industry’s advancements. Our judges awarded gold, silver, and bronze awards to three innovative designs.

The 2022 Hydraulics category winners are:

Gold

DGD Fluid Power Cartridge Flow Transmitter (CFT)

The judges commented: “This product lands in the ‘Why didn’t I think of that?’ category. One of the major hassles in using a flow meter is installation, packaging, and footprint. Conceptually, the CFT addresses these challenges in a practical and useful way with a form factor that is easy to implement into a circuit.”

The DGD Fluid Power CFT is a turbine flow meter configured as a cartridge valve. It offers easy integration into hydraulic systems, requiring no additional hardware or connections for continuous flow monitoring of all critical hydraulic functions. It also provides real-time data for predictive maintenance and remote troubleshooting and offers turbine flow accuracy. The CFT is available in standard M42 cartridge style design and Sun Hydraulics cavity T-18A.

DGD Fluid Power’s Cartridge Flow Transmitter (CFT) is a turbine flow meter configured as a cartridge valve that easily integrates into hydraulic systems.

A patent is pending for the CFT, which is centered around the design of a turbine flow meter within a cartridge body. The speed of the turbine is sensed differently than existing in-line meters on the market. Existing units use a sensor positioned to sense the tips of the turbine blades passing by. Currently, the geometry necessary to do this made packaging within a cartridge body impossible. To overcome this, the CFT design uses a Hall Effect sensor to monitor the speed by sensing magnets in the turbine’s hub. This allows the sensor to be placed along the axis instead of positioned on the turbine’s circumference. This also removes the need for dynamic seals or rotating parts other than the turbine, which rides on two bearing points on the shaft and with a finite spherical point against the sensing element.

The CFT is unique because it can be designed into a hydraulic manifold. Current manifold assemblies usually require designers to disassemble in-line flow meters and reassemble the internal components inside integrated manifolds. The CFT eliminates the need to do that and makes replacement feasible as needed.

The CFT is suitable for hydraulic fluids, transmission fluids, oil-in-water emulsions,

water and glycol mixtures, and Skydrol with temperatures between -20 and 70° C. The device’s steel body has a stainless option, and the standard seal is made of synthetic rubber. The CFT four factory-configurable hydraulic flow ranges from 0.5 to 100 gpm and is pressure-resistant up to 5,000 psi, depending on the application.

Silver

Danfoss Power Solutions

shhark low-noise gear pump

The Danfoss shhark low-noise gear pump improves operator comfort by reducing noise in the cab of off-highway machinery. Compared to standard gear pumps, the shhark pump reduces noise by up to 10 dBA. Noise generation is at lower frequencies, which operators are less sensitive to, thus improving sound quality. In addition, flow pulsation is reduced by 78%, resulting in less vibration.

The shhark pump features a patented asymmetric gear tooth profile that ensures low-noise performance, better sound quality, and higher efficiency, even after many hours of heavy-duty operation. Unlike dual-contact flank pumps, in which the low-noise performance can decline over time, shhark pumps maintain consistent low-noise performance throughout the pump’s life.

In the mobile machinery market, noise reduction is becoming as important as improving efficiency and reducing emissions. Several regulations have set 80 dBA as the maximum noise level allowed in the cab to protect operator health and comfort.

After the diesel engine and the cooling system fan drive, the hydraulic gear pump used for steering is the most significant source of noise in the cab. However, given the trend of electric and hybrid machines, along with quieter drivetrains in general, the high-frequency noise emitted by gear pumps is becoming more noticeable. A common solution to reduce sound level in the cabin is to install an end-of-line noise reduction device — such as a muffler, damper chamber, or accumulator — downstream from a standard gear pump. Usually, these components reduce the ripple pulsation only for specific frequency ranges, not for the complete frequency spectrum of the pump ripple. As a result, there’s a growing demand for a product that produces low-frequency and low-intensity noise throughout the entire frequency spectrum. This can be done only by replacing the standard gear pump with a low-noise gear pump. When used in place of standard gear pumps, the shhark pump eliminates the need for end-of-line noise reduction measures, reducing costs and saving space.

The shhark low-noise gear pump is available in displacements ranging from 6.18 to 29 cm3/rev. It has a rated pressure of up to 250 bar and an operating speed of up to 4,000 rpm. Multiple pump configurations are available, including a compact configuration, with SAE, DIN, and European standard

DGD Fluid Power dgdfluidpower.com

The Danfoss shhark low-noise gear pump reduces noise and vibration in off-highway machinery cabs, improving operator comfort and reducing space and costs.

mounting flanges and shafts. An integral relief valve is also available and interchangeable with all standard models.

The shhark low-noise gear pump is ideal for any cab-equipped off-highway machine, particularly tractors, wheel loaders, telehandlers, sweepers, harvesters, rollers, and electric and hybrid machines. Additional applications include indoor lift trucks, aerial platforms, material handling equipment, and others requiring low noise and high efficiency.

Danfoss Power Solutions danfoss.com

Bronze Webtec RFS200 Run-time Meter

Webtec’s RFS200 run-time meter is ideal for recording the time that construction or agricultural equipment is operational, apportioning the use of shared hydraulic tools between many users, or accurately monitoring the service interval of attachments. It ensures that maintenance can be conducted on a time-used basis, rather than machine hours, allowing for more astute and costeffective management of hydraulic system health.

The design is based on Webtec’s Reverse Flow Indicator (RFI) technology and is repackaged and enhanced to provide the desired timing functionality.

The RFS200 run-time meter is activated by the passage of hydraulic fluid and allows precise monitoring of system usage. In comparison, other products typically rely on hydraulic pressure to operate the timing function. When an attachment is removed from the machine, the hydraulic fluid is invariably isolated in the pipework. As the environment warms, the trapped fluid expands, the pressure rises, and the counter is activated. Webtec’s solution is immune to this phenomenon.

Webtec used its Make it Blue process to create the RFS200. Make it Blue is a four-step process defined as Begin, Listen, Upgrade, and Engineer, in which the Webtec team works with the customer to understand their requirements before moving on to the next stage. Customers were instrumental and established initial requirements that Webtec adjusted during development to ensure the device met customer needs within budget. FPW

Webtec webtec.com

Webtec’s RFS200 run-time meter allows precise monitoring of system usage to ensure that maintenance can be conducted on a time-used basis.

DESIGN NOTES

Edited by Rachael Pasini • Senior Editor

monitoring and predictive maintenance Pneumatics devices that improve

Pneumatics products continue to evolve as technology advances. This year’s LEAP Awards judges evaluated a range of devices that help machine builders simplify communication, improve real-time data and analytics, and digitally transform their systems. Two notable products stood out and received recognition.

The 2022 Pneumatics category winners are: Gold Norgren

Excelon Plus Integrated Electronic Pressure Sensor (IEPS)

The judges commented: “Love the space savings, and the addition of the pressure sensor is an excellent idea.”

The Excelon Plus IEPS represents the latest generation of pneumatic air preparation equipment with its fully integrated design. It improves monitoring through an easy-toread 1.44-in. color TFT display and IO-Link functionality.

The visual display changes color based on pressure levels for optimal system performance. It provides secondary pressure readings when the system is at or above the pressure setting (green), when the secondary pressure is below the setting (red), and when there is a system fault (yellow).

The IO-Link mode operates via the PLC/ automation system and provides real-time process data to alert operators of issues, such as leaks, clogged filters, or pressure setting adjustments. This helps operators take corrective actions immediately rather than during the next scheduled maintenance.

Pressure sensor calibrations can be adjusted for offset and span correction, while built-in diagnostics, self-testing, and fault reporting present an accurate measure of

gauge status. In addition to IO-Link mode, the IEPS features near-field communication (NFC) for additional read/write functionality of attributes and settings.

The new design evolved from bolton type pressure sensor designs. Bolt-on pressure sensors extend the footprint of the assembly, are prone to mechanical damage, and can require additional installation time. With a compact, lightweight design, the IEPS maximizes machine real estate and protects against corrosion with micro fog and oil fog lubrication. It can achieve up to 98% of water extraction and features a flush-fitting integrated gauge to reduce damage. It also has a unique, double-safety bowl lock, so the bowl cannot be removed when the sensor is in use.

The IEPS conforms to standard environmental tests for temperature, humidity (ETSI 300 019-2-3), and shock and vibration (BS EN 60068-2-6), and the sensor can withstand 1.5 times overpressure without compromising accuracy. It has electrical protection against overvoltage, reverse polarity, and short circuits on signal lines. An electrophoretic coating protects it from water in the airline.

Norgren’s IEPS is a standard option for

Excelon Plus 84 regulators, filter/regulators, combo units, or a standalone pressure sensor unit. The Q84G standalone module can be installed as a standard digital pressure switch or a pressure transducer with IO-Link. The R84G pressure regulator and B84G general-purpose filter/regulator have a push-to-lock adjusting knob with a built-in tamper-resistant feature.

Adjustable settings for all units include setpoint, tolerance, hysteresis, pressure units, temperature units, screen orientation, digital output type (NPN, PNP, Push-Pull), and digital output state (Normally High, Normally Low). Various accessories, such as gauges, porting blocks, adapters, padlocks, and mounting brackets, are also available.

The Excelon Plus IEPS can be used in various applications, including material handling, machine tools, metal forming, materials (glass, rubber, wood, and plastics), packaging, printing, paper, and electronics. The IEPS is an option for machine builders looking to align with Industry 4.0 and digitally futureproof their systems. FPW

Norgren’s Excelon Plus IEPS is a digital option for regulators, filter/ regulators, combo units, or as a standalone pressure sensor unit.

DESIGN NOTES

Silver Emerson AV/AES Valve System with integrated OPC UA

Emerson’s Aventics series Advanced Valve (AV) valve system with Advanced Electronic System (AES) Profinet and Ethernet/IP is the first valve system with preinstalled Open Platform Communications United Architecture (OPC UA) functionality. Key protocols, such as OPC UA, embedded in technologies enable device monitoring and machine connectivity when sending data from a valve system to an upper system. The AES helps users solve interoperability challenges, access data more efficiently, and improve productivity and efficiency by integrating a digital twin.

The AV/AES valve system simplifies communication by allowing direct access to valve system data and analytics without going through a gateway. No gateway is

needed unless deeper analysis or local dashboards are required. This can result in cost savings since receiving analytics from a valve system without OPC UA is more complex and expensive.

The system also provides easy integration for new or existing applications and machines. Simplified connectivity to edge computing and cloud systems makes the AES flexible and provides easy access to data and analytics without changing the PLC. Instead of dealing with bits and bytes, the product’s structure includes self-describing and tagging.

The AV/AES Valve System includes a digital twin of devices, which is the starting point for the digital twin of a machine. The digital twin with OPC UA provides actual

data via valves, analog signals, and digital signals, in addition to system info and a digital nameplate. Digital twin add-ons can include additional analytics, such as valve switching counters, time measurements, and sensor statistics.

OPC UA functionality also expands the valve system’s capabilities, making it easier for industries such as automotive, food and beverage, packaging, and pulp and paper to digitally transform. The AV/AES valve system can be used for any pneumatics application that uses data for analytics or predictive maintenance. FPW

Emerson emerson.com

Emerson’s AV/AES Valve System simplifies communication, integration, and connectivity.

DESIGN

Edited by

More LEAP winners recognized for innovative achievements

the LEAP Awards recognizes fluid power innovations across many categories, including Sensors and Switches and Motion Control.

Festo wins silver for Sensors and Switches Festo took home a silver medal in the Sensors and Switches category for its SDBT-MSX proximity switch. The Sensors and Switches category covers equipment feedback devices, such as mechanical switches and photoelectric, proximity, reel, and hall-effect sensors. Submissions also included pressure, speed, temperature, and vibration sensing devices, vision systems, and edge devices.

Festo’s SDBT-MSX is the first programmable proximity switch with an automatic switching point setting. With an initial detection range of 20 mm, the SDBT-MSX is easy to install and commission, especially in applications where mounting is difficult. The switch is ideal for all standard applications, including factory automation, the electronics industry, and small parts handling.

Installing an SDBT-MSX requires only two steps. First, the user fits the switch in the approximate end stop position within the 20 mm detection range marked on the sensor. Then, the user connects the cable to the controller (PLC). No power supply is needed during installation.

During initial operation, the proximity switch detects the end position of the piston stroke and automatically learns and remembers the switching point. This is an industry first for a solid-state positioning switch.

reduce the variety of sensor types needed to

The SDBT-MSX fits in all drives with a T-slot. It pairs best with Festo drives, such as the DSBC cylinder, ADN and ADN-S compact cylinders, and DGST mini-slide. Such pairings give users access to the switch’s full capabilities.

Festo festo.com

power efficiency requirements and could tolerate high-shock loading. The actuators

Festo’s SDBT-MSX proximity switch is easy to install and includes an automatic switching point setting.

Kyntronics supplied 18 SMART ElectroHydraulic Actuators to the legs of an Autonomous Field Supply Vehicle.

Quality Precision Performance Reliability

Kawasaki is a world-leader in pump efficiency and performance. Inside our range of products you’ll find some of the most efficient axial piston pumps available on the market today. Our engineers understand our customers’ needs, each pump has been designed to deliver high performance across a diverse range of applications.

allowed the vehicle to control pitch and roll angles and body height during the vehicle’s walking cycle. In addition, the AFSV was developed for autonomous behaviors, including recovery gait, putting the body on the ground, leveling the body independently of the terrain, and using an autopilot system.

Kyntronics provided three configurations of actuators based on the force and speed requirements of the specific leg joints — the coxa, femur, and tibia joints. The actuators were integrated with RMD’s gait engine control software, which uses position and force feedback from the actuators to control the vehicle’s legs and body.

The coxa actuator was responsible for rotating the leg around its vertical axis (analogous to the hip joint). A linkage was used to transform the 6-in. stroke of the actuator into 180° of rotation.

The femur actuator was installed on the leg and on its side to reduce the vehicle’s overall thickness. By installing the femur actuator inside the coxa structure, RMD reduced the inertia of the leg, improving walking performance.

The tibia actuator was installed in the last active leg joint. The tarsus joint, attached to the foot, was driven by a bellcrank mechanism that kept the foot perpendicular to the ground without requiring active control. A position sensor was mounted on the side of each actuator to provide rod position feedback. Position sensor data was used to calculate the overall pose of the leg. The force in each cylinder was also monitored to ensure that the loads on the legs were maintained within safe limits.

Kyntronics SMART Electro-Hydraulic Actuators installed on these three critical leg joints delivered the force density and durability of a hydraulic solution while being energy-efficient and eliminating leak risks inherent with hydraulics. Additionally, the valving inside the Kyntronics actuator allowed the actuators to hold a static load without consuming any power. FPW

By Josh Cosford • Contributing Editor

Piston pump technology ensures power and effi ciency

Axial-piston styles

The fixed-displacement piston pump offers designers a relatively inexpensive entry point to the piston pump. They provide reliable, high-pressure fixed flow for open-circuit hydraulic systems with no fancy controls. However, the control options available to piston pumps offer many clever tactics to control your hydraulic system, from pressure compensation to electrohydraulic proportional control with onboard pressure transducers.

or decrease displacement as required by the compensator as directed by the control piston. As a result, the control piston moves in the same axial plane as the rotating shaft, serving up a compact and powerful package.

Bent-axis piston technology

A hydraulic pump is literally the heartbeat of your hydraulic system. If you’re new to hydraulics, you’d be surprised at how many ways you can push fluid under pressure. The rotating and/or reciprocating of gears, vanes or pistons offer a designer constrained by any performance or budget envelope the options to best suit any application, especially since each of the primary pump construction styles offers unique options within each series.

Piston pump technology exclusively employs axially or radially reciprocating pistons relative to the input shaft. Fixed and variable displacement pumps are offered in all three primary construction variations — axial swashplate, bent-axis and radial. For both axial and bent-axis piston pumps, you will notice their pistons reciprocate in parallel as the rotating group orbits the shaft. Radial piston pumps look more like old wartime engines from aircraft, with their pistons reciprocating perpendicular to the input shaft. Although the most complicated design, piston pumps enjoy power and efficiency not possible in gear or vane pumps.

A pressure compensator is a relief valve for the control piston of the variable-displacement pump. The compensator is a very low flow component that essentially controls the swashplate angle to modify displacement in such a way as to maintain a set pressure. Any downstream flow demand lowers pressure drop at the pump, causing the pump to increase flow to maintain pressure. So long as downstream flow demand does not exceed the pump’s maximum flow rate, the pump can compensate and remain at full pressure. However, any flow exceeding its maximum rating will be subject to the downstream actuators’ load pressure. Manufacturers offer various forms of displacement and pressure control. For example, load sensing control allows the pump to read downstream load pressure signals to reduce flow during off-demand periods and at reduced pressure equal to a few hundred psi higher than the highest load. A step further, you’ll find horsepower limiting (sometimes called torque or power limiting), which provides the machine maximum flow and pressure so long as the total demand is less than the prime mover’s capacity. Should a machine, such as an excavator, demand higher flow and pressure than the engine can supply, such as when multiple high-pressure actuators are simultaneously activated, the pump will automatically restrict flow to reduce the total power required.

Regardless of compensator type, each variation achieves its result by varying only the swashplate angle. For axial piston pumps, the swashplate pivots to increase

Although axial piston pumps are easily the most popular, other piston pump designs are offered with variable displacement. You may be aware of the bent-axis piston motor (Figure 1), which is famous for its high power and high-speed reputation. Its shaft and bearing assembly rotate at a taper relative to an axial piston motor. Despite their high-pressure design, the bent-axis configuration offers 25% higher rotational speed than straight-axis motors, and their bearing design is better suited to pulley or gear-driven applications. The force vector from a gear or pulley must oppose the bent direction of the motor (Figure 2), much like your arm pulling against a surgical band from underfoot to do bicep curls.

The tapered, oversized roller bearings inside a bent-axis piston motor provide superior side load protection to resist the steeply angled rotating group side load. For example, a swashplate on an axial piston motor may allow a maximum of 15-22° angle, while the bent axis piston motor

The radial force applied to a bent axis piston motor must originate from the opposite direction of the bend. This opposing orientation balances the forces created by the pistons pushing against the rotating group on an angle.

Bent axis variable displacement axial piston motors.

| Courtesy of Bondioli & Pavesi

1 “Clockwise” rotation, pressure at port B

2 “Counter-clockwise” rotation, pressure at port A

operates at 40° or more. This extreme angle allows the motor to achieve high displacement in a small package, resulting in a high radial load on the input shaft. Resisting these side loads requires the heavy-duty tapered bearings like those you see in Figure 3 and explains the necessity to pull from the opposing direction as the motor angle.

The same benefits of the bent-axis piston motor apply to its pump kin. Superior power density, high-speed operation and high resistance to radial load make these the top choice for mobile hydraulic designs driven directly by diesel or gas engines. In addition, their inherently robust design makes them the top choice for gear or pulley-driven pump applications (as long as the installation recommendations are adhered to). Although the tapered roller bearings provide high side-load resistance, because the bearings are loaded to remove excessive clearances, excessive wear may occur. As a result, you’re more likely to replace the bearings on a bent-axis piston pump than in other designs.

You may be surprised to know that variabledisplacement bent-axis piston motors are offered by manufacturers. Unfortunately, their appearance doesn’t seem to offer any place to mount any useful swashplate angling device. Their construction varies significantly from a swashplate variable-displacement pump, where instead of varying swashplate angle, the entire lens plate slides up and down inside the port plate.

A stroke piston opposed by a bias spring and control piston works much the same as in an axial piston pump. The compensator receives a pilot signal from the pressure port to balance the pressure drop at the pump’s outlet, varying the angle of the rotating group as required to maintain pressure.

The leading manufacturers of piston pumps offer most, if not all, control options for

their bent-axis piston pumps. Basic pressure compensation with no other function often goes by pressure cut-off in product literature (or pressure override). The basic pressure cutoff control simply observes outlet pressure and adjusts the swashplate angle to alter flow rate, thereby maintaining a set pressure drop. So long as system demand is less than maximum flow, the outlet pressure remains at compensator set pressure. However, should demand rise above maximum pump flow, your circuit is at the mercy of the path of least resistance.

To be honest, selecting a pressurecompensated bent-axis piston pump for anything other than high-speed belt or pulley driven applications is an expensive bit of overkill. The control devices of variable-displacement bentaxis piston pumps are often quite advanced; you can expect various advanced controls such as horsepower limiting, hydraulic proportional control or even electro proportional control. I’m aware of one particular manufacturer that offers no less than seven kinds of horsepower-limiting controllers for one pump!

Proportional pump control uses proportional pressure-reducing valves in place of standard pressure compensators. For example, imagine a bent-axis piston pump where the spring offset stroke piston fights against spring pressure by infinitely varying the pressure inside the control side of the piston. Precise pressure observed by downstream transducers offers a closed-circuit feedback loop for the machine controller to adjust the proportional valve setting to match the desired outlet pressure. Some pumps may even take it a step further to include a linear transducer to provide precise displacement feedback, guaranteeing your circuit precise output flow and pressure despite fluctuations from the load, temperature, or viscosity.

With so many pump options on the market, do we really need so many advanced options for a single pump style? My vote is yes because the bent-axis piston pump offers unique advantages over other designs.

| Courtesy of Adobe Stock

The variety of control options available ensures that your system, no matter how complex, has the pump design you need. FPW

Cross section of bent-axis piston pump highlights the bearings used to resist side loading.

Are two VSD compressors a problem?

Question: I’m a compressor salesperson. Lately, the large building tenders we’ve seen have been spec’d for two variable speed screw compressors to run together sharing the load. This would make sense to me if one was a 100% backup and they never ran together, but that does not seem to be the case. Everything I’ve ever learned about multiple compressor systems indicates that two variable speed units running together will cause issues.

At the time of our quote, there was no way to get back to the actual decision maker and if we quoted any other configuration, it would be up to the contractor to sell it … and we know that isn’t going to happen …

Clearly, we need to do a better job of getting with the local engineering firms so we can be doing the spec’ing, but I’m just wondering about your thoughts on this situation that we’ve kind of been forced into.

Answer: Yes, any compressed air system really needs only one properly sized VSD, but it drives maintenance guys crazy if one compressor gets all the hours — while the other gets minimal run time, which needs to be the case with a mix of VSD and fixedspeed compressors.

So, the result is often the purchase of two or more VSDs. It is possible to run efficiently with two variable compressors, but the settings need to be adjusted so the control points are stacked. This way, you don’t have two VSDs running together at part load, which can happen (for example two units running at 25% instead of one at 50%). VSDs running at low speeds are inefficient and can cause internal condensation problems and high oil carryover.

But, even with this, the compressor with the highest setpoint will get the

majority of hours. Some manufacturers have two sets of pressure setpoints that can be programmed into the compressor controllers, and even set on time schedules. This can be used to easily to swap settings, and still maintain compressor coordination, if operators want to change which compressor is in the lead position.

I’m unsure what can be done about the poor specifications, I can only hope your tender writers are reading this. FPW

It is poor practice to run two VSD compressors sharing the load. This leads to inefficient operation where both are running in an inefficient part of their control bands. Stacking the pressure settings solves this problem.

An introduction to

pneumatic actuators

By Dietmar Grün, Product Manager, Motion Control, Actuator, Norgren

Pneumatic systems harness the energy generated by the controlled release of compressed air to power and move tools and machinery used in the engineering, manufacturing, construction, medical, and amusement industries and are especially prevalent in industrial automation and food, beverage, and pharmaceutical manufacturing applications. Pneumatic systems use air compressors to reduce the volume of air in the system, which increase its pressure and then pass that pressurized air through one or more filters and lengths of pneumatic tubing, where it’s controlled by valves, until it reaches a pneumatic actuator. The actuator produces the linear or rotary motion and force required to power the end process, such as a pushing, lifting, gripping, punching, or vacuum device.

Pneumatic actuators provide alternatives to electric actuators and motors and are typically used to power devices that handle relatively small, lightweight loads since pneumatic systems produce less force than hydraulic systems. But that doesn’t make these systems any less vital to the many industries they’re employed in. In fact, due to a combination of the relatively low cost required to maintain pneumatic systems and engineering advancements including corrosion-resistant seals that help prevent leaks, the application range for pneumatic systems is now comparable to that of the electric automated systems also used to handle smaller loads.

Learn what are the key considerations for selecting the right pneumatic actuator for your unique application.

Industrial automation applications often employ material handling solutions like pick and place equipment. The automated process pictured here features pneumatic actuators equipped with vacuum cups that can grip and move delicate items like glass.

Pneumatic actuators

Pneumatic actuators, also known as pneumatic cylinders, are the business end of a pneumatics system. When compressed air is forced into an actuator, it moves the piston housed within it and generates the linear or rotary motion and force required for the end device attached to the piston — such as a pushing, lifting, gripping, punching, or vacuum mechanism — to do its work. Pneumatic actuators are lightweight, require little maintenance, can be used in challenging environments exposed to extreme temperatures and corrosive materials and are widely available in National Fluid Power Association (NFPA-) and ISO-compliant models for international compatibility. Their bore, or their inner diameter,

determines their output force, and the larger the bore, the greater the force. They do produce less force and operate at slower speeds than hydraulic or electric actuators, but they remain a popular, cost-effective alternative to those technologies.

The key components of a pneumatic actuator include an end cap, a piston, a piston rod, a cylinder barrel, a wiper seal, and a cushion sleeve and seal. In a simple circuit, a singleacting pneumatic actuator can be operated by a button. When the button is pressed, the

compressed air moves the piston rod outward to generate the required linear or rotary motion and force needed to operate the end device, like an arm that moves a load along a linear path, a gripper that picks and places a component, or a vacuum cup used to handle glass.

Types of pneumatic actuators

Several types of single- and double-acting pneumatic actuators are engineered to suit many different applications.

Single-acting pneumatic actuators have a single air-entry port and push the piston in a single direction. The piston is returned to its original position by a spring. They have a limited stroke length, which makes them ideally suited for slower moving operations, and they use less air than double-acting actuators, which helps increase efficiency and reduce operating costs.

Double-acting pneumatic actuators have two air-entry ports, which enables them to execute both an instroke and an outstroke and move the piston back and forth without the use of a spring.

Tie-rod actuators are the most prevalent actuator design in the pneumatics industry and are widely used in heavy-duty

and high-temperature industrial automation applications.

Square or rectangular end caps are secured to the barrel by threaded tie rods and nuts. They are equipped with static seals to prevent air leakage and are available in standard, compact, and lightweight variations. They are also available with profile barrels — which feature concealed tie rods, enable direct assembly for flush-mounted switches, and offer a cleaner appearance — and round barrels, which feature exposed tie rods, are available in a wide variety of configuration and mounting options, and can easily be adapted to solve difficult actuation challenges.

Welded actuators are lighter and more compact than the standard tie-rod configuration and, as such, are widely used in lighter duty and lower force applications including mobile equipment. Instead of tie rods, these pneumatic actuators feature barrels welded directly to the end caps and ports welded to the barrel. Their front rod glands are generally bolted or threaded into the cylinder barrel to allow the piston rod assembly and rod seals to be removed for service and they typically come with fixed or buffer cushions, although some models offer adjustable cushioning upgrades.

Norgren ’ s ISOLine actuators conform to the latest ISO 15552 standard and are available in both profile (front) and tie-rod options (back) as well as in ISO-6432-compliant versions optimized for highly corrosive environments. They also feature Norgren ’ s Adaptive Cushioning System and are in stock at Allied.

Norgren offers rotary actuators in rack and pinion (left) and rotary vane variants (right).

Compact actuators are designed for applications where space is at a premium and are available in a variety of options. Norgren, for example, offers compact pneumatic tie-rod, welded, and clamp actuators.

Clamp actuators are used to hold a workpiece in place while work is being done. They combine a standard pneumatic actuator with a clamp and a toggle mechanism and are often designed to exhibit robust resistance to weld splatter to ensure long lifetime performance.

Valve actuators generate linear or rotary motion to open and close valves. These pneumatic actuators are compatible with a variety of valves, including ball and butterfly valves.

Rotary actuators produce a reciprocating angular or turning motion that enables an oscillating stoke motion through a defined angle. These pneumatic actuators are available in rack and pinion, rotary vane, and helical options; feature simple, durable designs that reduce maintenance requirements; and typically deliver relatively high force (torque) for their size. Rotary vane actuators are small, selfcontained, double-acting actuators that take up less space than rack and pinion actuators but deliver lower torque. Rack and pinion actuators offer greater torque but can require a larger footprint to achieve certain angular motions.

Rodless actuators, unlike other pneumatic actuators, don’t have a piston rod that extends

outside of the cylinder body. Instead, these pneumatic actuators contain the movement they produce within the length of their cylinder body, which, also unlike piston rod cylinders, allows them to support the load during movement.

Key considerations for selection

Several key considerations can help you choose the right type of pneumatic actuator with the right physical and electrical characteristics for your unique application.

Type of motion: Pneumatic actuators can generate linear or rotary motion.

Single-acting or double-acting: Pneumatic actuators come in single-acting, springreturn, and double-acting, pneumatic-return variations, and selections will depend on the amount of force and accuracy required, as well as the size of the job.

Pressure and flow requirements: Remember, the larger the cylinder bore, the greater the force. Pneumatic actuators are widely available with bore sizes extending from 8 to 320 mm.

Operating environment: Several manufacturers offer pneumatic actuators designed to deliver robust, long-lifetime performance in environments exposed to hazards including extreme temperatures, corrosive materials, and dirt and dust.

Special features: If you’re looking to save energy, ensure that the actuator is right-sized and appropriate for the operation at hand and consider using an IVAC product. FPW

Allied Electronics | www.alliedelec.com

Norgren | www.norgren.com

Norgren ’ s welded Roundline actuators are available in single- and double-acting versions with bore sizes spanning 8 to 63 mm and switch brackets that enable both standard M/50 reed switches and solid-state switches to be mounted on the outside of the barrel. They are also available in space-saving, corrosionresistant stainless steel, high-temperature, nonrotating, guided, double-ended piston rod and ISO6432-compliant versions and are in stock at Allied.

Refrigerator-sized hydraulic power units that don’t make a peep

By Rachael Pasini, Senior Editor

Thecommon perception of conventional hydraulic power units is that they are large, loud, and inefficient. Such claims are valid for facilities that still use power units from the 1960s and 1970s and among engineers unaware of the latest technology. However, the notion that hydraulic system designs are static in time is an outdated misconception. With the new CytroBox and CytroPac, Bosch Rexroth aims to educate machine builders on modern hydraulic power unit advancements and inspire a shift in perspectives.

The CytroBox and CytroPac defy traditional hydraulic power units with their compact, quiet, and energyefficient designs. They include small “smart” pumps and motors that only run when needed and at low torque when not in use. The smart pump and motor group reduces heat generation and makes the system run more efficiently.

While common industry opinions may deem it difficult to work with such newer technology, modern units like the CytroBox and CytroPac require less maintenance and reduce the total cost of ownership compared to older, conventional units. Though newer technology might incur higher upfront costs, long-term cost savings related to maintenance, commissioning, and energy add up. Not to mention, the new systems are quiet and simpler to control.

Compact size without compromising power

For some applications, space is scarce, and systems require smaller footprints. Conventional hydraulic units vary in size and can be as large as Olympic swimming pools, necessitating vigilant monitoring and maintenance to cover the physical span.

In contrast, the CytroBox looks more like a refrigerator, standing just under 8 ft high. Its maximum pressure is 315 bar, and machine designers can tie multiple tanks together to create a tandem system and increase flow. Each unit’s performance ranges from 7.5 to 30 kW and can be installed into existing production lines.

For extra space savings, the CytroPac is nearly 24 in. high with a diameter slightly greater than 14 in. The CytroPac provides up to 240 bar of pressure and a performance range of 1.5 to 4 kW. “You could probably stack six or seven CytroPac units in the corner of a plant and not take up any space,” said Tyler Stahl, application engineer and Cytro product specialist at Bosch Rexroth.

Quiet operation with visual indicators

Hydraulic units are typically loud, which causes safety hazards and requires anyone near them to wear earplugs. However, the CytroBox is so quiet that its operation can go audibly unnoticed. This means testers can sit next to the unit instead of in a different room for test applications, and operators can hold conversations without yelling at each other.

Technology advancements enable smaller, quieter, and more energy-efficient hydraulic power units that save space and reduce the total cost of ownership.

Modern hydraulic power units are compact, quiet, and energy efficient. Courtesy of Bosch Rexroth.

The significant noise reduction is attributed to advanced motor and pump designs and system components that help dampen noise within the box. The CytroBox uses small motors and pumps that operate at high speeds and reduce motor torque. Improved piston pump designs, quieter internal gear pumps, and reduced average motor operating speed decrease the average hydraulic system noise levels by more than 10 dB without requiring sound enclosures. Additionally, the CytroBox has a special housing that helps capture noise, and the bottom of the box is made of polymer concrete to help dampen motor vibrations.

To monitor operation, LED lights outside the CytroBox and CytroPac indicate green when the system is running, yellow when it’s stalled, and red when it’s not running. Replacing audible cues with visual indicator lights may concern those who favor more conventional systems, which often “speak” to operators and maintenance engineers through various pitched hums. However, LEDs provide discrete and immediate monitoring capability, which is common and favorable among electromechanical drives and other modern equipment.

Reducing total cost of ownership

Smart pumps provide energy e ciency

Pumps and motors in older hydraulic units constantly run at full capacity regardless of the application’s requirements. Therefore, a few decades ago, engineers developed “smart pumps” to run at variable speeds and improve energy efficiency. These pumps were designed to control flow and pressure in a system by varying the displacement (volume per revolution) as needed. Advanced

In some designs, the machine PLC must include the needed hydraulic calculations for motor speed based on both flow and pressure. However, the Bosch Rexroth version of this type of smart pump includes flow and pressure calculations in the electric drive (both VFD and servo drives), eliminating the need for complex PLC programming.

Software tools that compare hydraulic drive solutions and display the energy consumption differences allow hydraulic system

CytroPac — The Power Unit Revolution Compact — Radical New Design

calculations within the pump controller determined the flow and pressure. Widespread use of variable-speed hydraulic drives propelled improvements to this smart pump technology.

Newer versions can calculate the most efficient combination of pump displacement and motor speed based on flow demand. The smart pump electronics send a speed command directly to a motor VFD without the need for any programming in the machine PLC.

More recently, smart pump advancements include speedcontrolled fixed displacement pumps, which use efficient variable drive speed but can’t vary the pump displacement.

designers to model a machine cycle and optimize the pump and motor to achieve the highest possible energy savings.

Simplicity yields more space savings

The CytroBox is more of a valveless design that eliminates the need for proportional valves, which help control flow and pressure but can be expensive. Machine builders can still mount valves on the back of the unit if desired or needed. The CytroBox also has a built-in, sand-casted manifold that helps optimize flow and reduce pressure loss and heat emission.

Both the CytroBox and

Though the modern hydraulic power unit may have greater upfront costs, the total cost of ownership is less than conventional units Courtesy of Bosch Rexroth.

The CytroBox reduces oil consumption by 75% and noise levels to less than 75 dB. Courtesy of Bosch Rexroth.

The CytroPac is small but mighty and simpler to operate without needing complex hydraulics knowledge. Courtesy of Bosch Rexroth.

CytroPac use mineral oil HLP, which is a commonly used fluid. Being more compact, these systems use less oil, reducing the quantity facilities need to maintain. The CytroPac has a 20-L tank, and the CytroBox has a J-shaped, 150-L reservoir designed to help degas any trapped air bubbles in the fluid.

The CytroBox comes with either a 4or 10-kW cooling option. The bottom of the cabinet has a built-in heat exchanger with a kidney loop that distributes cooling water. Add-on packages and products can also be installed on top of the CytroBox to create a fully closed cooling system if a facility doesn’t have water to supply to the unit.

Industry 4.0 integration

In conventional units, machine builders manually wire the motor, pump, cooler,

CANect® Telematics

and reservoir to an HBU control for the motor conductor, sensor analysis, and the safe torque off (STO). Comparatively, the CytroBox and CytroPac are prewired and include a multi-ethernet connection for integration with any network.

Additionally, all Cytro units include CytroConnect, a digital monitoring system that displays a unit’s operation and performance dashboard. System owners can pull up the dashboard on any desktop, laptop, tablet, or phone to locate the unit and assess operation in real time. Optional paid add-ons are available to monitor fluid cleanliness, system overheating, and other system parameters.

“There have been cases where someone logged into CytroConnect to look at a unit while the shop was down during a holiday break and noticed that the heat was rising above their

The CytroBox stands just under 8 ft high and uses a small motor and variable-speed pump to reduce energy consumption. Courtesy of Bosch Rexroth.

CANect® is a complete OEM telematics system designed to manage your vehicle assets.

INDUSTRIAL HYDRAULICS

Sensors inside the CytroPac unit detect fluid contamination, oil level, and temperature for continuous monitoring and maintenance scheduling.

Courtesy of Bosch Rexroth.

preference,” said Stahl. “A technician went out and observed that the cooling water was dumping backward. This saved them from destroying the whole unit and losing money on machine downtime.”

Paid monthly add-ons are more

advanced and help detect when a part will fail. For example, a leakage sensor can notify when a part is determined to fail so that owners can predict maintenance, downtime, and component ordering and replacement schedules.

Holding high pressure longer

The compact hydraulic power units, especially the CytroPac, were initially intended for machine tool applications. Manufacturers can keep 10 to 15 CytroPac units on hand because they’re smaller, convenient to store without taking up much space, and easy to swap out as needed.

Pressing applications benefit immensely from CytroBox’s power and energy efficiency, as the pump and motor group help hold pressure for longer. Holding high pressure with equal-sized traditional hydraulic systems consumes approximately 5 kW of power. With its servo motor technology, the CytroBox can hold high pressure while consuming extremely low power (less than 0.5 kW), potentially yielding 90% energy savings during pressure holding compared to a traditional system. FPW

Bosch Rexroth boschrextroth.com

ALA Industries Limited is a leader in engineering. Leadership in engineering can be seen through teamwork not only within ALA Industries but with our manufacturing companies that we represent. We aim to create a seamless flow from our manufacturers to our distributors. The combined effort of all affiliated companies help ALA to better ourselves and provide excellent service and products. We focus on delivering outstanding communication, accountability, and transparency with all companies that we work along. ALA Industries is a leader in engineering due to the goal and ability to create and maintain long-term relationships with our distributors and the manufacturers that we represent.

ALA provides a prestigious product line throughout the Americas that aids the maximization of the end users hydraulic systems. The overall goal of ALA Industries Limited is to focus our time and energy not only

on the success of our products, but also to be able to acknowledge areas of improvement and fix them within a timely manner. ALA Industries also seeks to expand their product market to help sustainability efforts, such as pitch control valves for wind turbines. Within ALA Industries, our employees are dedicated, dependable, and respectful to their fellow employees and clients. They have a focus on servant leadership. Overall, ALA Industries Limited has positioned themself as a leader in engineering due to their ability to have open communication with clients alongside providing premier products.

Sustainable innovations machinery designs top Bauma

machinery makers touted new or prototype designs that feature low-carbon, sustainable systems. Electrification was a hot topic as it has been, but all-electric designs were mostly limited to compact machinery. For mid-size and large equipment, alternative systems took the stage.

earns Bauma Innovation Award

By Mary

produced at Liebherr Machines Bulle SA, the Liebherr Group’s engine competence centre in the Swiss canton of Fribourg.

In terms of power, dynamics, and responsiveness, the R 9XX H2 hydrogen excavator gives nothing away to any conventionally powered machine. Nor is it dependent on a continuous energy supply either. Henrik Weitze, product manager, said there were no plans to change the hydraulics in the excavator.

The emissions make the difference:

On a “tank to wheel” basis, i.e. when used on a construction site, a hydrogen excavator emits almost no CO2. “Cradle to grave” or from production to decommissioning, CO2 emissions are 70% lower than those of comparable conventionally powered excavators.

The R 9XX H2 is powered by a Liebherr H966 hydrogen combustion engine. The engine has six cylinders and uses port fuel injection (PFI), which Liebherr employs along with direct injection (DI) for its hydrogen

Suitable for use under extreme temperatures, shock, and high-dust conditions on construction sites, the 50 ton-operating weight R 9XX H2 may in future offer a robust solution for earthworks and quarrying applications.

engines. Liebherr’s components product segment plans to start with the series production of hydrogen motors by 2025.

“One of the big advantages of hydrogen is once you have the infrastructure, you can recharge this hydrogen quite fast compared to battery electric driven vehicles,” said Weitze. “We are not as fast as a diesel one, but we are much faster than battery electric vehicles. We see a big advantage if you use the machines, for example, in a two- or three-shift day. You can charge this vehicle without any problem between two shifts or even twice a shift without a problem.”

Weitze added that the hydrogen engine would be ideal for applications that require more power and density, while smaller machines will see the transition to battery electric.

“We’ve built up this prototype to prove that the technology works in hard

While many compact machines boast all-electric systems, several prototype designs feature alternative options to power larger, heavier-duty equipment.

C. Gannon, Editor-in-Chief

MOBILE MACHINERY ROUNDUP

Proterra battery packs leverage energy density and a customizable design to fit within a variety of vehicles. The packaging flexibility of Proterraʼs battery platform will further enable the optimal placement of the batteries within the middle-class excavator and replace the need for a normal counterweight used to balance the excavatorʼs hydraulic arm movements.

applications and that the recharge of the machine is no problem. We choose this 50ton excavator because it’s an excavator which is working in many different applications,” Weitze concluded. “So we can test them in normal road work and small mining applications. We see big advantages for these technologies in rough applications, high altitude, shocks, or dust. We are confident if it works in this excavator, it will work in all other machines we produce.”

Battery power packs a punch

A partnership between Komatsu and Proterra was launched at Bauma as well. Proterra’s battery technology is being used in the development of Komatsu’s first battery-electric middle class hydraulic excavator.

The collaboration represents Proterra’s entry into the offroad vehicle market and its first Proterra Powered battery-electric construction equipment.

The proof-of-concept electric excavator is expected to reach commercial production in 2023 to

Tadanoʼs E-Pack is an electrohydraulic system with an integrated 32 kW electric motor that provides low-noise and emission-free crane operation.

2024. The Proterra battery system powering the electric excavator will feature high energy density and fast charging technology.

This model of hydraulic excavator optimizes the entire body control system by capitalizing on Komatsu’s proprietary coordinating technology. It integrates Proterra’s lithium-ion battery technology with Komatsu’s components, such as the hydraulic pump, controller, and electric motor for work equipment operation. A robust cage structure provides additional protection onboard the vehicle for its battery packs. As a result, Komatsu has achieved digging performance and durability equivalent to those of engine-driven hydraulic excavators. In addition, the high energy onboard the excavator’s Proterra Powered battery system enables operation for up to 8 hours* when fully charged. (*In the PoC test, total operation time ranged from 5 to 9 hours, depending on the workload conditions.)

The electric power makes it possible to work comfortably in various work environments without worrying about noise

and exhaust emissions, and is expected to be used for work in urban areas and nighttime construction work. The zeroengine vibration will also help reduce operator fatigue.

Proterra battery packs are designed with safety and durability in mind. They undergo rigorous testing to ensure they can withstand the toughest conditions, making it an excellent choice for Komatsu and the offroad vehicle market.

Electrohydraulic system powers cranes

Japanese crane manufacturer

Tadano highlighted five of its AC cranes that are now available with its E-Pack electrohydraulic innovation. The E-Pack, an electrohydraulic system with integrated 32 kW electric motor, provides low-noise and emissionfree crane operation. This solution was presented at the last bauma in 2019.

Applications include indoor jobs, projects in urban areas, and residential nighttime work. The E-Pack can be used to carry out all crane functions maintaining the corresponding crane’s maximum lifting capacity. Other performance characteristics are comparable to those achieved with operation with a diesel engine in many work

areas. It is powered through the grid via a 400 V/63 A connection.

The E-Pack comes with significant cost advantages as well — the intelligent electro motor control system ensures that only the amount of electric power needed to carry out the required functions will be used. This results in lower operating costs compared to a diesel system and reduces the operating hours of the engine.

Cat pushing forward with electrification

Caterpillar highlighted four electric machine prototypes, including battery prototypes. They include the 301.9 mini excavator, 320 medium excavator, 950 GC medium wheel loader, and 906 compact wheel loader. The machines are powered by Caterpillar battery prototypes.

The Caterpillar-designed batteries will be available to power other industrial

applications. Built on proven Cat technology, the lithium-ion battery range features a modular design that offers flexible configurations.

The 301.9 and 906 are expected to be the first available models. The battery on the 301.9 is a Cat 48 V, 32 kWh, with run-time up to 8 hours on a single charge; up to 5 hours in continuous trenching. The 906 battery is a Cat 300 V, 64 kWh, with run-time up to 6 hours on a single charge.

On the hydraulics side, the Cat 336 Hydraulic Excavator includes a powerful hydraulic system that delivers strong digging forces and swing torque to boost production in demanding applications.

The Cat C7.1 engine features three engine modes to match excavator power to the demands of the job while saving fuel. Power mode delivers maximum power; Smart mode automatically matches engine and hydraulic power to digging conditions

to lower fuel consumption. Reducing engine speed to a constant 1,500 rpm, Eco mode minimizes fuel consumption.

Auto hydraulic warmup in cold temperatures gets the machine to work faster and prolongs component life. The air intake filter with pre-cleaner features high dust capacity, and a high-efficiency hydraulic fan offers optional automatic reverse to keep cores free from debris. FPW

Catʼs new 336 Hydraulic Excavator features a powerful hydraulic system that delivers strong digging forces and swing torque to boost production in the most demanding applications.

For over 50+ years, Yates has set the bar for quality hydraulic and pneumatic cylinders. Offering world-class customer service and cutting-edge technology, Yates has the capabilities to manufacture and repair all of your custom cylinder needs from NFPA Tie Rod, Welded type, and Mill duty. Equipped with one of the largest and most complete repair facilities in the midwest United States, with four locations, 330,000 sq. ft. of manufacturing space, in-house engineering, CNC machining, welding, assembly, and testing, there is no job Yates can't handle.

Booth #S81817

Efficient fluid maintenance

is core to sustainability

IFPE conference

ASnoted in my FluidLines column on page 2, both IFPE and CONEXPO-CON/AGG have a special focus on sustainability throughout the show floor and conference program. Several sessions will take looks at digitalization, electrification, and autonomy as solutions to creating more carbon-neutral mobile machinery. But all these efforts would be wasted if the hydraulic fluids in those machines are not selected with care and maintained regularly to ensure long life.

Therefore, three sessions in the IFPE conference program will cover the importance of hydraulic fluid contamination prevention and how clean fluids promote efficiency and sustainability. Two will be led by Paul Michael, one of the industry’s leading fluids expert. Another will be a panel discussion as part of the NFPA’s Fluid Power Forum series.

Prior to the show kicking off on Tuesday, IFPE will hold a day of Fluid Power Workshops, with Paul Michael, Research Chemist and Director of the Milwaukee School of Engineering Fluid Power Institute, hosting a seminar on “Examining Fluid Efficiency and Contamination Control Effects in Hydraulic Motors,” from 1 to 4 p.m. on Monday, March 13.

Attendees of the workshop session will learn how to:

• Figure out the sources, symptoms, effects, and best practices to avoid various types of contamination.

• Recognize the different types of hydraulic fluids, their properties, and their standard test methods.

• Perform hydraulic fluid sampling and analysis and how to interpret the analysis report.

• Understand filter performance ratings.

By Mary C. Gannon, Editor-in-Chief

programming will take in-depth looks at fluid cleanliness and life to ensure sustainable, efficient systems.

“All the information will be presented in a combination of case studies and traditional training strategy,” noted Michael in an article IFPE published about fluid efficiency and contamination control effects in hydraulic motors.

Fluid power directly impacts machine reliability, productivity, and energy consumption. “For working machines, reliability, productivity, and energy consumption not only affect the total cost of ownership, but they also flow right to the bottom line,” Michael said.

There has been continual research and upgrades in the quality and life of oils, lubricants, and hydraulic fluids. “The Holy Grail, if you will, for oils, lubricants, and hydraulic fluids is to be able to use them forever without having to change them. Organizations are continuously researching different ways to improve the performance of oils, lubricants, and hydraulic fluids so they can be used longer and require less maintenance.”

Having a solid understanding of contamination control and filtration is essential for getting the maximum life out of oils, lubricants, and hydraulic fluids and this benefits the entire system over time, said Michael.

“The limiting factor in fluid life oftentimes is the contamination that can occur to the fluid. If a fluid becomes contaminated, either with water, dirt, or wear debris, it may be necessary to change the fluid and refresh the system with new fluid.

“Contamination is one of the potential drivers for the end of life for a hydraulic fluid,” pointed out Michael. “In a hydraulic system, the fluid transmits the power. For the power transmission to take place, the fluid must be maintained within what is called a pressure envelope the pumps, hoses, valves, cylinders, etc., that are actually transmitting power and doing the work of the machine. To keep the fluid contained in the pressure envelope, it is necessary to have very tight gap control in the moving components within the hydraulic system.”

By way of example, the gaps between the cylinder, pistons, and cylinder bore in a pump, or between the spool and the manifold in a valve, must be maintained very tightly, otherwise, there is gap flow that occurs, he said. Gap flows are undesirable because they diminish productivity and generate heat. To maintain these critical gaps in the moving areas of the hydraulic system, the fluid must be very clean.

“In most other lubricating systems, the lubricant is not transmitting the power and is not

encapsulated within a pressure envelope,” he said. “The cleanliness requirements for gear oils, engine oils, automatic transmission fluids, and compressor oils are relatively lenient because these applications operate at lower pressures and control of gap flow is less.”

Michael said there are several ways to determine when it is time to change oil. Commonly, the change interval is based on time, miles, season, or condition-based monitoring.

Additionally, Michael will be holding a 45-minute session on Tuesday, March 14 from 9:30 to 10:15 a.m., Contamination Control and Filtration, where he will discuss how to evaluate fluid cleanliness and implement strategies to ensure that hydraulic fluid starts out and stays clean.

Finally, on the last conference day, Eric Lanke, CEO of The NFPA, will be joined by Barry Verdegan, a consultant on filtration standards for 11171 Solutions LLC, and Ivan N. Sheffield, Director of Filtration, Des-Case, for a final discussion on the importance of contamination prevention.

The panel discussion, “Fluid Power Forum Presents: Contamination Standards Prevent Machine Failure and Boost Cost Savings,” is brought to the IFPE audience by Fluid Power Forum, a podcast that features interesting and innovative applications of fluid power (hydraulics and pneumatics).

“Machine failures are costly. Contamination is the root cause of 80% of hydraulic failures. 90% of these failures are preventable,” said Lanke. “Standards, such as those created by ISO or national standards bodies, establish a level playing field to allow manufacturers, suppliers, and users to speak a common language and use best practices to develop and implement contamination control programs. Standards developed by ISO TC131/SC6 and other technical committees allow you to measure particulate contamination in fluids, set required cleanliness levels, choose appropriate filters for your application, compare products and identify false claims, and monitor the success of contamination control efforts.”

The speakers will use real world examples to demonstrate the financial benefits of standardsbased contamination control programs.

For more information or to register for conference programming, visit ifpe.com/visit/ education. Fluid Power World readers can receive at 30% discount on show admission through January 6 by using the code PR30. Education sessions and workshops incur additional fees. FPW

Paul Michael, director of the Fluid Power Institute at Milwaukee School of Engineering, will present two educational programs at IFPE on the importance of hydraulic fluid contamination control.

The #1 Trade Show & Conference for Fluid Power, Power Transmission,

and Motion Control

CO-LOCATED WITH CONEXPO-CON/AGG

(two shows, one price)

The International Fluid Power Exposition (IFPE) is the place where engineers meet to:

Spark new ideas with in-depth technical conversations with other engineers.

Discover solutions current suppliers can offer to your unique challenges.

Find new partners among suppliers pushing the envelope on what fluid power can do.

CONNECT WITH TOP MANUFACTURERS

Including Bosch Rexroth , Danfoss Power Solutions , Parker Hannifin , Poclain , IFM Efector , Hawe Hydraulik , Husco , and 375+ more!

Join your peers from these OEMs:

∙ Caterpillar Inc

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∙ LBX Company

“ There’s no other show in the world I think that brings the OEM machine manufacturers and the suppliers as close together as this show. It’s a good place to meet and learn about what’s going on. In the Americas, in the Western Hemisphere, this is the show for fluid power.”

KEN ROSENBECKER SALES MANAGER NORTH AMERICA | WIPRO INFRASTRUCTURE ENGINEERING

IFPE only happens once every three years!

REGISTRATION OPENS EARLY AUGUST

See why IFPE is the can’t-miss fluid power event of 2023! Learn more at IFPE.com

INTERNATIONAL FLUID POWER EXPO

MARCH 14-18, 2023

LAS VEGAS, NV, USA

The new

Las Vegas is ready for IFPE

Three years is a long time to go between events, but Las Vegas’ fast paced building and turnover — combined with the unique weirdness of the last few years — mean that some things have changed for visitors who haven’t been to Sin City since early 2020 (or even 2017). Here’s a look at the afterhours aspect of IFPE 2023 … what’s changed and what’s new in the city, from hotels to attractions to restaurants.

New lodging options

There are some major changes in and around the Strip, headlined with the opening of the huge Resorts World Las Vegas complex, located on the north end of the Strip. Resorts World opened in June 2021 and features three hotels: Hilton (1,774 rooms), Conrads (1,496 rooms), and Crockfords (332 rooms). This is only the fifth location in the world for the luxury Crockfords brand. The complex also boasts more than a dozen bars and restaurants, including an Asian-inspired food hall, a sushi bar, a modern Mexican concept, wine bar with more than 8,000 labels, and a 66th floor lounge. Guests will also find a 5,000seat theater onsite, a 117,000 sq-ft casino (of

course!), a spa, and an expansive outdoor pool deck that features seven different pools.

In March 2021, the former Hard Rock Hotel was taken over and rebranded as the Virgin Hotel Las Vegas. It features a dozen bars and restaurants on site, three pools, a spa and fitness center, casino, and three guestroom towers. The Canyon Tower gives guests speedy access to the Mohegan Casino and features sweeping mountain views and overlooks the five-acre desert pool oasis. The Opal Tower is focused on rooms with style and sophistication with a cool desert twist. And the all-suite Ruby Tower has large accommodations, an exclusive check-in area, and a dedicated valet. Some rooms in the Ruby Tower offer views of the Las Vegas Strip.

Circa Las Vegas is an interesting casino property that’s unique in the city. Located amidst the more historic hotels of downtown’s Fremont Strip, it’s part of the area’s remaking of itself. The site formerly held the Las Vegas Club and Mermaids Casino; they were demolished in 2017 and a tall gleaming 500room tower (of the type more commonly see on the Strip) was built in their place. Circa opened its doors in late 2020. One of the property’s big attractions is its extensive pool area, known as Stadium Swim. This

A lot has changed in the Nevada desert since the last show took place in March 2020 — here’s what to expect for 2023 visitors.

area is three levels and includes six pools, all overlooking a 143-foot-high HD television screen, perfect for broadcasting sporting events. The area holds an incredible 4,000 guests, making it truly feel like you’re attending the big game.

Attractions galore

Maybe the most noticeable new addition to the Las Vegas skyline is the new Allegiant Stadium, the new home of the NFL’s Oakland Raiders. Opened in September 2020, the 65,000 seat, state-of-the-art stadium also hosts major sporting and entertainment events. In the first quarter of 2023, the stadium is primed to host the East-West Shrine Bowl, the NFL’s Pro Bowl, and Taylor Swift ’s The Eras Tour.

And in 2024, it will be the site of Super Bowl LVIII. Las Vegas has always been a destination with plenty of shows, from residencies for music superstars like Celine Dion, Britney Spears, and Mariah Carey to more unique performances. A trend in recent years has seen smaller, sexier shows proliferate, such as the Atomic Saloon Show at the Venetian resort — a romp full of comedy, acrobatics and barely clad male and female performers — in an intimate space that only seats a couple hundred attendees.

Other interesting news in Sin City includes:

• Escape IT, inspired by one of the most horrifying film franchises of all time, “IT,” launches in Las Vegas this month. Spanning more than 30,000 square feet, Escape IT is a new take on the traditional escape room experiences, offering fans two multi-room escape adventures that bring to life IT, and its blockbuster sequel, IT Chapter Two. The attraction will include more than 20 interactive rooms, state-of-the-art special FX, lighting, animatronics, and live actors to create a fully immersive and terrifying experience.

• Mad Apple, the newest Las Vegas production from Cirque

du Soleil, opened this summer at New York-New York Hotel & Casino. Mad Apple is a highenergy cocktail of comedy, music, dance, and high-flying acrobatics that delivers New York’s wildest night out under the Vegas lights. Featuring stand-up comedy, a first in a Cirque du Soleil show, the headlining comedians Brad Williams and Harrison Greenbaum, and freestyle comedy rapper Chris Turner entertain guests with on-thespot, often rowdy improvs.

• The award-winning hit production Bat Out of Hell –The Musical announced a Las Vegas Residency several months ago. The musical, featuring Jim Steinman and Meat Loaf’s greatest hits, is set at Paris Las Vegas Hotel & Casino. For the stage musical, Steinman incorporated iconic songs from the Bat Out of Hell albums.

• Princess Diana: A Tribute Exhibition is a 10,000-squarefoot royal exhibit that has begun a long-term residency inside The Shops at Crystals on the Las Vegas Strip. The exhibition transports visitors into the life of world-famous royalty through the designer fashions, personal effects, and historic items of the “People’s Princess” and family and friends important in her life.

• Perception Las Vegas, a new museum for immersive and high-tech digital art installations recently debuted on the Las Vegas Strip with the world premiere of Leonardo: The Universal Man. Chronicling the life and works of Leonardo da Vinci, one of history’s greatest thinkers, the hour-long, threepart journey will transport guests into the mind of the Renaissance master. da Vinci changed the perception of humankind through his visionary ideas, science, and art. Three 360° gallery exhibits will envelop guests in da Vinci’s works, studies, and findings as an architect, engineer, alchemist, artist, philosopher, and sculptor.

• The beloved Ghostbar at Palms Casino Resort reopened in September. Originally debuting in 2001, this widely popular bar and lounge is perched high atop the 55th floor has spectacular views of The Strip.

• The D Las Vegas has brought bacon downtown with the launch of Bacon Nation. Located on the newly renovated second floor of the Fremont Street Experience hotspot, the 24/7 menu will be centered around a love for all things bacon. The sizzling concept features 14 variations of house-cured bacon with flavors ranging from lemon pepper to chocolate-dipped. FPW

Return to IFPE

Robby Shell, Permco's COO, recaps COVID and maps out fl uid power's future.

In 2019, we were operating at a world-record revenue pace. And for seven years, we had the luxury of orchestrating a plan to educate and train our people without compromising production. Of course, COVID disrupted all that, and we didn’t want to fall backward. We still wanted to educate our people, but we didn’t want to put them at risk.

As we iterated our COVID protocols and best practices, we researched the question: What industry has the most to lose if it can’t open or operate? NFL football was a big one. The NFL can withstand a season without fans in the seats because of its television revenue. But what happens when it can’t field a team? How do managers keep the team safe in close quarters and have enough players to maintain revenue?

We watched the NFL intently and drilled in further by analyzing casinos. We discovered that the Hard Rock Casino hired a consulting group called the Global Biorisk Advisory Council (GBAC). This group provided detailed training on how to prevent and reduce spread, protect people, assess airflow, and how many times a day surfaces must be wiped down — all the factors for operating during COVID. So, I sent five of my young operators

to become GBAC warriors, as they’re called. We trained them in transmission, prevention, and identification, wiped down lights, knobs — any surface that would be touched — at least four times a day, and sprayed and disinfected all buildings at least twice a week.

Meanwhile, we learned that Case Western Reserve University was using robots we’ve been experimenting with in our virtual reality (VR) program. We sat down with them and helped underwrite the cost of putting telepresence robots into the Weatherhead School of

Management so that we could train our people remotely and safely. But at the end of the day, we identified an opportunity for advanced education for people who may not be able to travel to a class, regardless of COVID.

We had such big plans for 2020, coming off a record year, a record pace, with new clients and products and on a trajectory we had been executing for years. As we look to 2023, we hope we see a little return to normalcy in the marketplace — a market reawakening.

Robby Shell, Permco’s Chief Operating O cer, carries his grandfather’s vision for the company forward, continuously adapting and innovating as the market changes.

We’re excited to see our friends at IFPE 2023. We’re a family business, as are many of our clients. And if they’re not a family business, they now understand a family business dynamic by working with us. I’ve known many of these people for more than 40 years, and some worked with my grandparents. It’s always neat when a random person walks up to the booth and tells me a story about my grandfather driving an RV through Arizona for a visit in 1971.

IFPE is an opportunity to bring everybody together and loosen up a bit. We’ve all been so tightly wound that I’m looking forward to a gigantic cocktail party with new and familiar faces.

Permco will be a 110-year-old family business at IFPE 2023. We’ve been doing this for a while and have had much time for introspection on what we want to be when we grow up. As we move forward, we take the fundamental strength of our product design and add some new gadgets

that work quieter and at higher pressures and speeds. We also have new electrical controls that people will get to see.

But we’re not only in the blood and guts of the hydraulic world — hardcore dump trucks, construction equipment, and garbage trucks. We’re also working on some sexy applications, such as windmills. People don’t necessarily equate an old hydraulic system used on dump trucks and mining machinery to a windmill, but that windmill is a gigantic gearbox that needs lubrication. And our big pumps provide lubrication circuits on those windmills. Also, commercial solar panels use hydraulics to move with the sun and position themselves at the best angles. So, we’re looking at energy and where the market’s going. We want to be part of the blood and guts. We want to be part of the sexy side. And we’re really excited to showcase all that at IFPE 2023.

Permco permco.com

had such big plans for 2020, coming o a record year, a record pace, with new clients

on a

Permco employees feel a sense of relief as they return to normal operations post-COVID.

We

and products and

trajectory we had been executing for years. As we look to 2023, we hope we see a little return to normalcy in the marketplace — a market reawakening.

Technician training goes virtual

Fluid power manufacturers got creative during COVID to embrace the “new normal,” and many brave companies saw opportunities within the uncertainty.

Permco is one such company that partitioned its attention to innovation and people development while filling backorders and managing employee safety. In 2021, Permco partnered with Case Western Reserve University in Cleveland to implement a new virtual learning program with telepresence robots. The robots serve as proxy students so employees can attend class from home and feel immersed in the experience.

But why would a hydraulic pump manufacturer branch out into the virtual reality (VR) and robotics business in the middle of a pandemic?

Like every manufacturer, Permco faced COVID-related hurdles and needed to adapt quickly to new safety standards while keeping production afloat. Management filled in for absent staff by taking calls, running machines, and doing engineering work over the phone. Everyone needed to cross-train quickly while working remotely and caring for their families. Several employees suffered COVID health complications, including a lead trainer eager to teach the next generation and secure the company’s future.

How proxy robots and haptic gloves arrived in fl uid power technician training.

Permco’s VR program simulates the real-life pump assembly environment.

Permco has trained 2,500 technicians over the past 25 years at its in-person hydraulic school. The team also developed an “under 30” plan about eight years ago to develop younger talent and place them in strategic training programs. During COVID, the company shut down inperson instruction for employees and customers and felt pressured to accelerate its talent development plan. But without their lead trainer, they needed alternatives.

“Most people don’t have the discipline to divert labor from production to a project that will provide future efficiency,” said Robby Shell, Permco’s Chief Operating Officer. “But we must lay the seeds and the groundwork for the next generation.”

Proxy robots create immersive distance learning

During COVID, Permco wanted to send a few employees to Case’s Weatherhead School of Management to receive their Master of Business Administration (MBA) degrees. However, no one could abandon their daily responsibilities during a pandemic, and they couldn’t take classes in person.

Permco learned that Weatherhead was using alternative methods for remote instruction. Unlike signing into virtual conferencing software and using webinar-style learning, Case students could experience a live classroom with proxy robots.

The robots were positioned in classrooms where instructors moved about in front of a hybrid human-robot audience. Proxy students were immersed in the classroom and could rotate their “heads” 360° to look at other human or proxy students and participate in discussions. They could also break out into groups and physically move to different rooms without changing screens or instructor intervention.

Permco saw such robots as an opportunity to experiment with proxy learning and propel its next-generation training plans forward despite the pandemic.

As a result, the fluid power system manufacturer supplied Weatherhead with eight telepresence robots at no cost so that Permco employees and other Case students could receive immersed education remotely.

Technicians can grab parts from shelves to learn how production is organized before setting foot in the facility.

But why would a hydraulic pump manufacturer branch out into the virtual reality (VR) and robotics business in the middle of a pandemic?

“It was a huge benefit for our young people who have families and were working extremely difficult hours,” said Shell. “One Case student was pregnant and couldn’t attend classes or afford a robot, so we lent the student one of ours. We are proud to help Weatherhead accelerate their program and provide education for people all over the world without being physically present.”

Virtual fluid power training improves competency

Permco is a family-owned business with roots in the mining industry. It started out designing and manufacturing replacement parts and continues developing hydraulic systems and components for various applications. It consistently hires and retains bright minds and hard workers who share a passion for precision and dedication to the industry.

With the overwhelming increase in orders during COVID, Permco desperately needed technicians, but the learning curve was so steep that they couldn’t train people fast enough. Technicians need three to seven years to learn Permco’s assembly procedures, equivalent to the time doctors or Ph.D. students need to develop expertise in their fields.

Previously, standard Permco training consisted of shadowing assembly experts and learning little pieces of the process over a long period. However, during COVID, there was strict social distancing, transparent plastic sheets hanging from each workstation, and locked facilities

requiring vaccination for access. So, when the team discovered virtual training opportunities, they immediately saw the value in developing expertise in less time without a physical presence.

“The virtual program allowed us to train people by building a pump a hundred times virtually before they ever touch the physical part, which shortens the learning curve immensely,” said Shell. “With the virtual training environment, technicians already know what the gears look like, what they’re supposed to do with them, and how they fit. The VR program builds competency faster and really came into fruition as we moved to continuous improvement.”

The system Permco developed to make their pumps virtual can be used for almost any object in a specific engineering format.

For example, if a company needs to build pens, they can run the pen and parts through Permco’s software and present identical parts lying virtually on an assembly table. The VR program then guides a technician through the entire pen assembly process.

While developing the VR program, one major challenge they faced was capturing the physical feel that technicians rely on during real-life assembly. For instance, the feeling of tightness or resistance in moving parts is lost in a virtual environment.

In response, they turned to haptic technology that Kent State University’s mechatronics engineers developed. Haptic technology provides kinesthetic communication to users in a virtual environment to simulate a sense of touch. This technology is widely explored

Permco’s technicians need three to seven years of training. The VR program reduces time to competency and provides hands-on experience before technicians physically interact with parts.

Permco saw such robots as an opportunity to experiment with proxy learning and propel its next-generation training plans forward despite the pandemic.

for medical applications, such as inserting needles, performing surgery, and limb rehabilitating, and it’s shown to reduce time to competency. With the close tolerances in manufactured parts, Permco saw a parallel need for sensory feedback in assembly precision to shorten the learning curve. As a result, the fluid power system manufacturer decided to incorporate Kent State’s haptic glove technology into its VR training program.

The haptic glove allows a technician to open a virtual cabinet and grab a steel gear off a shelf. Before inserting the gear into a pump, the technician can physically inspect the gear’s quality by running an index finger across the surface. During real-life assembly, if the steel gear has a burr on its surface and is mated to a bronze plate, the burr will create a groove in the plate, which will cause leaks and decrease pump efficiency. The technician must feel for burrs, smooth them out, then feel again to ensure they’re removed. During VR assembly, the haptic

glove can create a burr-like sensation that the technician-in-training can detect and remove, giving employees a virtual hands-on approach to learning.

VR entices young talent and expands service offerings

With the new VR program, Permco can offer remote training for employees and help educate young talent before they start their careers. The team currently works with junior high and high school STEM and vo-tech programs to make VR learning more available.

“When we go to job fairs or career day events at these vo-tech schools, there’s a long line in front of the Permco booth because everybody wants to put that headset on,” said Shell. “Since we’re addressing a younger demographic accustomed to gaming, we want to take virtual training further. For instance, we want to create competitions and tournaments to see who’s the best pump builder. We

even want to give our clients some friendly competition and test their knowledge by leaving out parts to see if they catch mistakes. We’re going have all kinds of fun with this technology as we go forward.”

Permco also plans to use the VR program in other business areas, such as customer service and training, maintenance, and troubleshooting. It also welcomes new opportunities to develop virtual training programs for any external organization.

“It was a big challenge for us to divert labor from production, but the VR and robotics programs spawned because of it,” said Shell. “Now, we believe that we can take individual training actions on any product that exists in digital engineering software, run it through our program, and develop training on any assembly, inspection, or process.”

Technicians rely on their sense of touch during production, so the VR program will introduce haptic gloves to simulate sensations that technicians experience in real life.

Customer-focused innovation without reinventing the wheel

It’s no secret that hydraulic systems are the workhorses of dirty environments and gear pumps are at the back of the herd. Fluid power manufacturers know they’re not in production for the glamor, yet they’re passionate about the industry and providing the best quality for their customers.

While some industries want to reinvent the wheel just to get noticed, hydraulic pumps haven’t changed much over the years. The fundamental concepts and machines have persisted, and customers don’t seem to desire cutting-edge components just because they’re new. They’re looking for reliable products and custom solutions to specific problems.

For instance, Permco’s American Champ series is one of the most widely used dump pumps on dump trucks in the U.S. The series is hand-crafted and hand-tested in Streetsboro, Ohio, and includes different configurations

Though Permco refines its products to meet changing customer needs, it continues to produce legacy pumps that remain favorable for certain applications.

While some organizations chase industry trends in fear of obsolescence, others look intrinsically for innovation opportunities that bring the best to their customers.

for light-, medium-, and heavy-duty trucks and trailers. The tried-and-true design concept has been around for more than 50 years, and Permco continues evolving its series to meet customer needs and application requirements.

One notable development is the Gemini DG-20/RG-20, designed for dual use, such as switching a tractor from a truck to a trailer with a walking floor. With dual-purpose valves, operators can easily adjust pressure settings depending on the application.

Another product with a dual-pressure option is the MVP, which is designed for hard-to-fit class 8 automatic transmissions. With these transmissions,

Permco found that there wasn’t enough space for their existing pumps, and the pumps even interfered. In response, engineers incorporated a remotely mounted tipping valve block rotated on its side so that customers could install a smaller pump and all the parts fit better.

“We don’t expect anything to come out that makes people stop and think they’ve been doing it wrong all these years,” said Ryan Crosby, Warranty Manager at Permco. “Our designs are working, but we’re always thinking of the future and constantly brainstorming and innovating.”

Many experienced technicians start out as customers or in the field with boots on the ground. Their first-hand experience allows

Many experienced technicians start out as customers or in the field with boots on the ground. Their first-hand experience allows them to see how innovations can help or hinder applications, whether a process, procedure, or design enhancement.

Permco hand-builds and tests each pump for quality.

them to see how innovations can help or hinder applications, whether a process, procedure, or design enhancement.

For example, roller bearings dominated pump designs thirty years ago. Mining and similar environments still use roller bearings because they can tolerate contamination. However, roller bearings have a finite life, which is unfavorable in many applications. Therefore, like many manufacturers, Permco created new pumps with bushings as an alternative solution for customers.

“With each rotation, a little bit of life is taken from the roller bearings, whereas the bushings ride on a hydrodynamic film of oil, so you don’t have that metal-to-metal contact,” said Joel Auckerman, Permco’s Engineering Manager. “You can run higher pressures with the bushings, and they provide a more durable product as long as you keep the oil clean.”

Permco builds a range of bushing pumps for small-sized applications, such as fan motors and bed hoists, and large applications, such as cranes and mobile crushers. And as solution designs increasingly require compact footprints, customers are asking for smaller components with more power. Permco’s smallest bushing pump is the 124 series, with displacements from 0.62 through 2.48 in. 3 and working pressure up to 3,500 psi.

Though the market shifted toward bushings, Permco still produces roller-bearing designs for customers with high-contamination environments. So long as customers request legacy designs, Permco will manufacture them by hand to fulfill each customer’s need.

“We’re always striving and exploring alternatives that help cut costs for our customers without compromising the quality or integrity of our products,” said Crosby. “And we’re always available for onsite evaluations to test equipment and help fine-tune solutions.”

As manufacturers such as Permco demonstrate, innovation isn’t always about reinventing the wheel but reconfiguring existing products to fit specific customer requirements. It’s about improving service, product training, and support so that customers can maintain their investments effectively and reap long-lasting benefits. It’s also about looking inward at production processes, suppliers, employee development, and management to ensure that customers receive the highest quality, cost-effective products to build their machines and systems.

However, make no mistake. The great minds of each organization are constantly tinkering with something substantial in the background. Of course, they can’t tell us what they’re working on, but their brainstorming board is always full of ideas and strategies.

“Permco is very unique to have so many bright employees with multiple years of combined experience and to be located in northeast Ohio in an area where everyone wants to work hard and love life,” said Crosby. Permco

Though the market shifted toward bushings, Permco still produces roller-bearing designs for customers with high-contamination environments. So long as customers request legacy designs, Permco will manufacture them by hand to fulfi ll each customer’s need.

A tale of two facilities

Adapting global production in anticipation of market demand.

Permco’s no stranger to thinking outside of the box — nor outside of the country. It started doing business in China in the 1980s with intentions that differed from other manufacturers at the time. Today, its partner facilities in the Sichuan province embody the heart and soul of Permco’s dedication to quality products for its customers and quality of life for its employees.

“My grandfather, who started this company, was a Georgia Tech mechanical engineer,” said Robby Shell, Permco’s Chief Operating Officer. “When he joined the military, he was stationed in the Pacific for part of his tour and spent time in Chengdu, the capital of China’s Sichuan province, from 1943 to 1945. When he returned to the U.S., he brought home something inside of him that created a spiritual connection between the Shell family and Chengdu’s people.”

This special connection was passed down to Shell’s father, who became an avid stamp collector specializing in stamps from China. In 1980, Shell’s father visited China for the first time to learn more about the people and economy in hopes of establishing business overseas. Over the next eight years, Permco managers traveled to various provinces and met with government leaders until they found the right province to work with.

But instead of setting up a new hydraulic pump facility, they got into the hotel business.

“When my father traveled over there in the eighties, he noticed that most of the reputable hotels didn’t have Western-style commodes, showers, bathtubs, sinks, and things like that,” said Shell. “He felt like China was a sleeping giant and that there’d be an explosion in tourism once the country opened up.”

Like all manufacturers, Permco was forced to think outside of the box during COVID to ensure consistent quality despite supply chain issues.

Shell’s father predicted that China would quickly feel pressured to upgrade its hospitality to accommodate Westernstyle preferences. And he was right.

As new hotels sprung up in the mid1980s, cultured marble was favored for bathroom surfaces, such as sinks, counters, and even wainscotted walls. Shell’s father responded by opening a plant in Huntington, West Virginia, to create cultured marble products and sell them to China’s hotels. Once the business gained competency, Shell’s father moved the plant to China so that local workers could learn the trade and start making products for their own market. He then started a bigger system with more capacity, established the business, and moved that one to China as well.

Building businesses unrelated to fluid power gave Permco time to understand the opportunities available for hydraulics. Looking back, Permco is the leading cast iron roller bearing gear manufacturer in China.

“Our philosophy is that we want to be part of that domestic economy,” said Shell. “We didn’t go there to find cheap parts and bootleg them back to the U.S. We wanted to develop the business for China’s domestic market, and if we could do some trading back and forth as well, that’d be a bonus.”

In 2008, the Sichuan province had a horrible earthquake that killed more than 87,000 people. The earthquake was so strong, it changed landscapes, created

new lakes, and swallowed old lakes into the earth. Shell’s family was a large U.S. donor to Chengdu’s relief and recovery efforts. “Some companies say they fuel your technology. Some say they drive your innovation. At Permco, we say ‘it’s personal.’ And that thread gets woven through the fabric of everything we do and makes us different,” said Shell.

Like other businesses, Permco’s challenges come from areas not under their direct control. The hydraulic pump manufacturer relies on foundries to pour cast iron, make steel, and provide parts such as bearings, nuts, bolts, gaskets, and seals. Tariffs also create hurdles and force management to think differently about supply chains and productivity. And of course, COVID revealed vulnerabilities and reinforced the importance of trusted relationships.

“In the U.S., we’re set up to build larger products for larger applications,” said Ryan Crosby, Warranty Manager at Permco. “But in conjunction with our China facilities, we can also provide compact solutions for customers who need smaller pumps. Permco’s global footprint and product availability is really a game-changer for its customers.” Permco

Before opening gear and shaft manufacturing facilities in China, Permco entered the hotel business to learn about the people and industry opportunities.

Hydraulic flow monitor with CAN-bus interface

The compact, rugged, and resilient design of the new Webtec CTA series flow monitor makes it suitable for permanent installation on both on- and off-highway vehicles, where it can monitor, record, and transmit data about oil flow rates and temperature through a J1939 CAN-bus interface. This innovative device is perfect for use in predictive maintenance/IoT systems. By communicating directly with the vehicle’s control and monitoring network, it is possible to transmit performance data to the cloud or IoT system with subsequent download and analysis in real time. Further uses include the enablement of autonomous vehicle operation, closed-loop control, real-time diagnostics, and safety interlocks. The units are fully EMC-compliant, resistant to water spray and steam cleaning (IP69K protection rating), and unaffected by heavy vibration, making them an extremely useful addition to many vehicle applications.

Counterbalance

valve for H1B bent-axis motor

Energy-efficient controls for press brakes

Specifically designed for the H1B bent-axis motor, the counterbalance valve enables original equipment manufacturers to harness the benefits of the variable-speed H1B motor, including compact design and efficiency, in high-power drivetrain and winching applications while preventing overspeed and cavitation. In comparison to competitive offerings, the counterbalance valve for H1B reduces pressure drop, improving system efficiency, and features integrated pressure relief valves, simplifying system integration and reducing time to market. The valve also offers a broad range of options to optimize performance through damping and overall behavior of the main spool, as well as an optional charge port for external charging or system heat-up.

The motors are suitable for wheeled and crawler excavators, crawler and truck cranes, and drilling and pipe handling applications. The DN32 counterbalance valve, available in two versions, fits H1B motors with displacements ranging from 160 to 250 cm3. A DN25 valve, to be introduced in 2023, will fit H1B motors with displacements ranging from 80 to 110 cc.

Using servomotor designs such as ePRAX drives versus asynchronous motors in valvecontrolled press brake systems, allows for energy savings of up to 80% compared to conventional press controls. These are available for all sizes of a press brake. A servomotor takes over the dynamic adjustment of the conveying volume and the pressure to the actual demand. Due to the very short reaction time of the servomotors, the pressurization in the hydraulics takes place very quickly, which enables a significant reduction in cycle times compared to conventional systems. With the speed-controlled ePRAX modular control system, the required tank volume and thus the oil requirement can be significantly reduced.

Miniature pinch valve

Beswick miniature pinch valves are now available for 1/8-in. OD and 1/4-in. OD tubing. The PV series miniature pinch valve is designed to control fluid when it is advantageous to avoid fluid contact with mechanical components and elastomeric seals.

Pinch valves achieve fluid control by clamping down on the outside diameter of the tubing in order to limit or stop flow. The PV has a port for pneumatic actuation as well as a manual knurled knob for extra flexibility.

Threaded flat-face couplings

The new couplings of the QRC-FG series include additional customer requirements and can be coupled under residual pressure on both sides. With these couplings, the flow rate is higher, and the coupling forces are lower. Threaded flat-face couplings are mainly used in large demolition excavators. The booms of the excavators are multi-part and reduced in size piece-by-piece as demolition progresses. Coupling and uncoupling the hydraulic lines must therefore be uncomplicated and safe for the user. Flatface screw couplings also have advantages in other heavy-duty construction and agricultural machinery. While the predecessor series could only be coupled on the plug side at up to 250 bar, the sleeve can now also be easily coupled by hand under residual pressure. The company’s designers have developed a particularly reliable second valve for this purpose. There are also design features inside the sleeve that enable the QRC-FG series to be coupled under pressure on the female side. For this purpose, the pressurized surface of the valve was kept as small as possible to press the valve open against a low force during the coupling process.

AISI 316L (A4) stainless steel plugs

The stainless-steel fluid fill/drain plugs are available for threads from M14 to M33 and G¼ to G1 and are intended for especially corrosive environments, such as offshore applications or situations with heavy exposure to salt or brine. The screws have an embedded seal of fluorine rubber that is secured against loss or overloading. To minimize errors, they also have icons on the front side that clearly indicate whether the opening is for filling or draining. The magnetic plugs GN 738.5 look quite similar, except they have an integrated bar magnet that extends into the fluid to reliably capture any iron particles that could damage gears or the like. The fluid glass sight glasses GN 7440 are inserted into the stainless-steel body using a special thermal process. During cooling, the glass shrinks to create a hermetic and tight seal. The level of pretensioning makes it almost indestructible. This allows the oil sight glass to withstand even high pressures. Burst tests have shown that, depending on the temperature, the parts only fail at pressures above 400 bar. Thanks to the FPM seal, temperatures up to 356° F (180° C) are no problem; with a copper seal, even temperatures as high as 572° F (300° C) are withstood.

Series 6700 diaphragm valve

Manufactured in an allbrass form, the series 6700 provides superior flow rate for typical applications of twoway control of inert gasses, water, and compatible fluids. The valve comes in both 3/4 in. and 1.0 in. NPT port configuration to meet your system requirements. Offered with FKM seals as standard, this valve will accommodate a large percentage of media requirements. At 120 psi, the series 6700 delivers a reliable maximum flow rate of 53.3 gpm. To provide a comprehensive solution for a variety of systems, the series 6700 not only provides multiple port sizes, but also different options for coil options and types.

Multi-stage vacuum pump

Coval coval.com

The new CMS HD multi-stage vacuum pumps have been jointly developed with system integrators and industrial customers. They improve the performance of previous-generation models in three key areas: power, robustness, and modularity. The pumps are specified to handle flow rates up to 1300 Nl/min. The IP65 rated pumps are designed for a service life of 50 million cycles. Finally, thanks to their modular design, the pump can be configured with a selectable flow rate, with or without piloting, and with three configurable exhaust solutions, depending on the application requirements. The modularity allows each of its sub-assemblies to be accessed individually for servicing. This also improves the repairability rate.

Shuttles improve hydraulic efficiency

Innas BV innas.com

Innas shuttles can save up to 2,000 l of fuel in an average off-road machine by increasing hydrostatic pump and motor efficiency. When applied in a conventional slipper type machine, peak overall efficiency increased from 91.4% to 96.4%. At speeds below 1,000 rpm, efficiency at some points increased by more than 30%-points. The technology can be implemented in all piston-type pumps and motors. Shuttles do not demand a completely design. Only a rather small adaptation is needed. The cylinder block or barrel needs to have some extra connections between the cylinders, allowing the small ceramic shuttle balls to be installed. The valve plate design becomes more simplified, eliminating any silencing grooves or pressure relief grooves. Shuttles can be applied in both fixed and variable displacement pumps and motors.

One Fluid Solution For Your Hydraulic Needs.

We offer high-quality hydraulic hoses, fittings, and accessories with unmatched customer service to keep your business Ahead Of The Curve.

We offer high-quality hydraulic hoses, fittings, and accessories with unmatched customer service to keep your business Ahead Of The Curve.

Your Partner For Over 40 Years

Rely on Texcel’s experienced and knowledgeable team for sales, technical support, customer service, and more.

Your Partner For Over 40 Years

Rely on Texcel’s experienced and knowledgeable team for sales, technical support, customer service, and more.

Extensive & Premium Product Range

Our broad range of high-performing hydraulic hoses and fittings are designed to exceed your toughest applications.

Extensive & Premium Product Range

Our broad range of high-performing hydraulic hoses and fittings are designed to exceed your toughest applications.

Swift Service & Exceptional Inventory

Explore our U.S. hydraulic inventory, and buy everything you need on one Purchase Order with a 99.9% error-free rating.

Swift Service & Exceptional Inventory

Explore our U.S. hydraulic inventory, and buy everything you need on one Purchase Order with a 99.9% error-free rating.

By Josh Cosford • Contributing Editor

When should you use SAE flanges?

Permanent plumbing connections, such as those piped or welded, offer the most reliable form of connection for your hydraulic system. But, of course, when the connection is neither flexible (like a hose) nor detachable (like a weld), you have little reason ever to remove the plumbing until you change the circuit or decommission the machine entirely.

Most of the challenges in hydraulic connection types revolve around producing an effective seal in a removable package. Early removable fittings, such as NPT and JIC, counted on metal-to-metal sealing surfaces to reliably transmit fluid under pressure. Unfortunately, the deformation of NPT threads makes them a one-hit wonder, which works best when installed once and left to do its job. The JIC flare fitting is a

common and practical choice for tubes and hoses with frequently removed and replaced connections (think test stands or training systems). However, the flat metalto-metal sealing surfaces do little in offering long-term reliability.

Most modern sealing systems use polymer technology to contain your expensive hydraulic fluid effectively, from the various O-ring boss technologies (ORB, BSPP and Metric) to the end-face connections such as SAE O-Ring Face. The ORF hose end enjoys the current standard as the go-to hydraulic hose connection, offering an effective seal with zero leakage and an easy and cheap replacement O-ring. However, another O-ring face technology provides a popular intermediate connection with myriad possible options — the SAE flange. Defined under SAE standard J518, the system uses four bolts to fix a flat flange against the also-flat work port on a pump, motor, cylinder or valve. The ported surface offers an entirely flat area to accept the O-ring situated inside a machined groove on the flange. Four bolts inserted

through holes on the flange provide the means to compress the polymer seal, providing legendary high-pressure capacity.

Two pressure capacity ratings are defined under the SAE J518 standard. The Code 61 flange provides a connection suitable for everything 3,000 psi or less, while the Code 62 flange provides a leakfree connection up to 6,000 psi. Although the pressure capacity varies — as you would expect — with port size, only the 2-1/2 in. and larger size Code 61 flanges cannot hold 3,000 psi. Code 62 flanges offer 6,000 psi across the board, but most manufacturers offer only up to 2 in. ports. If you need more than a couple of hundred gpm capacity, you may need to double up the plumbing or find custom flanges.

Code 61 and 62 flanges differ more than by their pressure capacity. Instead, the flange’s size and general beefiness are reflected by its pressure rating. Taking the 2 in. flanges as an example, Code 61 uses 1/2 in. bolts spaced about 3 x 1.7 in. in a 7/8 in. thick flange. Conversely, the Code 62 unit upgrades to massive 3/4 in. bolts across 3.8 x 1.75 in. respectively.

SAE flanges offer two methods of attaching plumbing: split flange concept or standard port adapters. The split flange traps the O-ring face hose end against the mounting surface, allowing quick and leak-free connection to a hose. In addition, the split flanges allow the technician to rotate the hose end in any direction before tightening, avoiding the need for any swivel despite individual plumbing requirements.

Flanges are easily integrated with traditional and existing hydraulic plumbing packages as well. Stand-alone flanges threaded with female ports such as NPT, ORB or BSPP provide versatility, allowing any newer flange-equipped pump, motor or cylinder to adapt quickly to the hoses and fittings already on the machine. The exceptional, leak-free pressure capacity of SAE J518 flanges, combined with their various configurations, makes it the current king of high-pressure plumbing. FPW

| Courtesy of Stauff

Solutions for E-Vehicles

Move from manual to electrical control with minimal design changes and maximum return!

• The HYDAC FLKS-SC series has been specially developed for cooling in mobile applications for electrical drives, inverters, chargers and batteries. In proven design, it is routinely used as a semi-closed cooling circuit in vehicle construction.

• The HYDAC HLT 1300 detects linear position and measures pressure and temperature in a single device.

• Our “In pin” angle sensor stays safe and sound on your machine - it’s designed to be integrated inside a hollow pin assembly in the joint of the machine, not externally.

• Keeping track of it all, our controllers are available in a wide variety of I/O options for differing levels of complexity.

• HYDAC TTControl Displays are characterized by low reflectivity and high color saturations for optimal readability in a variety of conditions.

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