FLUID POWER WORLD FEBRUARY 2024

Software-defined machines p. 26

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FLUIDLINES Mary C. Gannon • Editor-in-Chief

Proper conditioning isn’t just for athletes Last week, my 14-year-old daughter suffered what could be a season-ending injury during one of her basketball games. After doctor visits and an MRI, we learned she luckily only had a bruise to her AC joint — thankfully, no ligaments were involved so no surgery — but the pain is real, and I don’t imagine she’s getting back on the court anytime soon.

This is not her first sports-related injury. It got me thinking how frustrating it is that these kids don’t get the proper conditioning for most sports. It’s not her fault, nor her coaches but simply because there isn’t enough time scheduled between games to allow the players to fully warm up, stretch and prepare. If you watch a professional basketball player, they warm up and practice before the games, often live on TV. Most experts agree that 15 to 20 minutes of warm-up time is best to get your body ready for play and goes a long way in preventing injuries.

But with hundreds of games each weekend and only so many sites for games, there are usually only minutes between each game for the players to shoot some hoops and stretch properly. In elementary or middle schools, it’s not like there is room for the girls to run around elsewhere. So, they run out on the court without their bodies properly prepared. No wonder they’re dashing off the court grimacing more than they should be. A little stretching and warming up could go a long way to keeping kids healthy in youth sports.

You could draw a parallel here to on-the-job injuries. According to the U.S. Bureau of Labor Statistics, in the private manufacturing industry during 2020, there were 373,300 total recordable cases (TRC) of nonfatal injuries and illnesses. Of those, 135,900 had days away from work, 108,800 had days of job transfer or restriction, and 128,700 had other recordable cases. The total recordable case incidence rate per 100 fulltime equivalent workers was 3.1.

These injuries cost on average $40,000 based on the National Council on Compensation Insurance’s Workers Compensation Statistical Plan. And those are only the direct costs, indicates America Safe Group.

Once you add in wages during work stoppage, OSHA fines and actions, lost production, increase in workers’ compensation costs, and other staff time, you’re looking at more like $120,000, AmericaSafe Group calculates.

That’s a lot of money and much of it is preventable. Too often, machine operators in factories or on jobsites are not being educated on their machines the way they should be and are expected to operate machines as designed (then blamed for human error when operated outside of intended design parameters).

Like my daughter needs better conditioning, fluid power professionals need more consistent, on-thejob training along with better system designs featuring embedded safety that enable operators to prevent common failures or weaknesses. If you speak with anyone in the fluid power industry, whether on the user or manufacturer side, you’ll often hear the biggest complaint is the lack of qualified employees. But there’s no excuse for this. With several industry associations working to educate a skilled workforce and more qualified consultants and trainers than in other areas I’ve written about over the years, there is ample opportunity to find the proper training. If you need training or know someone working on hydraulic or pneumatic systems, contact the IFPS, NFPA, FPDA, or NAHAD for resources and help. The Milwaukee School of Engineering offers a variety of professional education classes as well. Or simply get on LinkedIn and start connecting with one of the many professional trainers that are on there, sharing their knowledge on a daily basis.

Most injuries are preventable through proper training and preparation. Let’s reduce those statistics in our industry.

FPW

Mary C. Gannon • Editor-in -Chief mgannon@wtwhmedia.com On Twitter @FPW_marygannon

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MOBILE HYDRAULICS

PNEUMATICS & AUTOMATION

Distributed electro-pneumatics streamline equipment designs Machinery builders and OEMs save space and improve functionality by applying electro-pneumatic I/O and solenoid systems throughout their equipment.

DIGITALIZATION

Making headway with digital integration Digital technologies allow for precise, highly responsive and efficient hydraulic control.

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F E AT U R E S

The growing wave of software-defined machines Data-driven off-road equipment will improve uptime and performance and reduce operating costs.

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D E PA R T M E N T S

04 FluidLines 08 Perspectives

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10

Design Notes

20

Fundamentals

22

Component Focus

24

Energy

Efficiency

44 Products 47

Ad Index

48

Troubleshooting Challenge

ON THE COVER

An autonomous excavator constructs dry stone walls by itself as part of a digitally planned and autonomously excavated landscape and park in Oberglatt, Switzerland.

Circularity Park in Oberglatt, Eberhard AG, 2021-2022 © Gramazio Kohler Research, ETH Zurich, Eberhard AG.

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PERSPECTIVES

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to repair my seven-year-old’s battlesmashing toy. Though it’s designed to withstand rough handling and abuse, one of the key features stopped functioning, which degraded the toy’s allure.

However, there was no way I would surrender my investment and chalk it up to, “Well, honey, that’s what happens when we play too rough.”

No, I decided to tackle the enigma of complex children’s toys and be a hero for my son. I wanted to teach him that we don’t just throw things away when they stop working. We think about the problem, brainstorm solutions, devise a plan, then give it a go and test the results.

Long story short, I figured out the problem but couldn’t fix it without breaking the only component still functioning. The mechanism causing the issue was inaccessible, and opening it up would likely result in irreversible damage. Being the sweet, understanding person he is, my son appreciated the lesson in manual actuators, gears, and springs and conceded that the remaining functionality was still worth playing battle-smashing games with his mom.

Many engineers I meet face similar conundrums. They first must decide whether an issue is worth investigating, and if so, then they have to figure out the problem and what to do about it. In some cases, problems can’t be fixed without creating brand-new ones, and maybe the remaining functionality or performance is enough. Technical feasibility aside, it usually boils down to ROI and whether solutions align with a company’s goals and trajectory.

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Over at our sibling publication, Design World, we’re hosting a new event to address just that. The inaugural Digital Transformation Forum will take place May 1 and 2 in Boston to help engineers and industry leaders discuss problems, align solutions, and accelerate time-to-value.

But one of the fundamental challenges is defining “value.” It starts with identifying and prioritizing who will receive value and establishing metrics to evaluate whether value has been realized. Each company must do this to strategically position itself in the market, but market viability and technical capabilities go hand-in-hand.

These days, it’s all about finding the right recipe for automation, electrification, and digitalization by leveraging AI, machine learning, IoT, big data, and other trends.

How much of each depends on the company’s objectives and willingness to contribute funds.

I firmly believe that given enough time and resources, engineers can create and fix almost anything. Give them the green light, and they’ll launch us into a new technological era. With our new event, we hope to help more engineers align designs with value and more leaders adopt value-based designs. Check your inbox for details or email me for more information. Hope to see you there! In the meantime, I’ll be tinkering with my son’s toys and showing him the value of problem-solving skills so he can learn how to defeat me in the battle-smashing game.

FPW

Rachael Pasini

Senior Editor rpasini@wtwhmedia.com

On Twitter @WTWH_Rachael

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DESIGN NOTES

By Racheal Pasini • Senior Editor

STONE WALLS MAKE A COMEBACK WITH AN AUTONOMOUS HYDRAULIC EXCAVATOR 10

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It’s no secret that the construction industry is a major contributor to greenhouse gas emissions. As such, engineers and researchers constantly explore new technologies that align with sustainability goals while increasing productivity and reducing manual labor.

Take dry stone wall construction, for example. This manually intensive task dates back thousands of years and was historically used for fortification, agricultural terracing, and boundary delineation. Castles and defensive structures were also built stone-bystone with precise placement for stability. In the 20th century, modern construction methods overshadowed such craftmanship and gave way to more timely built structures with less labor. However, interest has resurged in recent decades due to a growing appreciation for sustainable and traditional building practices.

The Menzi Muck picks and scans each boulder to

be placed in the correct position, Circularity Park in Oberglatt, Eberhard AG, 2021-2022 © Gramazio Kohler Research, ETH Zurich, Eberhard AG.

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DESIGN NOTES

Drone view of the

autonomous excavator HEAP, Circularity Park in Oberglatt, Eberhard AG, 2021-2022 © Gramazio Kohler Research, ETH Zurich, Eberhard AG.

Today, dry stone walls are valued for their aesthetic appeal and environmental friendliness. They are resource-efficient, as they use locally sourced materials low in embodied energy. And with advanced automation technology, builders can improve sustainability, reduce labor, and hasten projects — a dream of our ancient predecessors.

In the past two years, ETH Zurich researchers taught an autonomous excavator to construct dry stone walls by itself as part of a digitally planned and autonomously excavated landscape and park in Oberglatt, Switzerland. The multidisciplinary team deployed the excavator to build a wall 65 m long, 6 m tall at its apex, and consisting of 938 individual elements (boulders and concrete demolition debris, with an average mass of over 1000 kg each), placing it among the largest robotically fabricated structures in existence.

The research aims to autonomously construct masonry structures on an architectural scale, using found and readily available materials, such as waste concrete and stones. Building with locally sourced boulders and waste concrete has the potential to drastically reduce the environmental carbon footprint of construction for specific applications.

However, their production, calculation, and verification complexities make them less 12

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viable in modern construction. This project demonstrates that computational methods, machine vision approaches, and new control methods can be successfully integrated to handle the geometric variety of stone and rubble shapes in an adaptive building process that unfolds in an unstructured construction environment.

ETH Zurich’s Robotic Systems Lab developed the robotic excavator HEAP (Hydraulic Excavator for an Autonomous

Purpose), a customized Menzi Muck M545 12t walking excavator, as part of a broader research endeavor.

“Hydraulic excavators are quite different from the precise electronic manipulators more commonly used in robotics applications. These differences include coupling effects between cylinders, dead zones, and delays associated with controlling multi-stage hydraulics, variable friction, and joint slop. Thus, automating these machines requires a control policy that can adapt to these variations to allow the tool to move in the desired way,” said Ryan Luke Johns, project manager and researcher at the ETH Institute for Architecture and Digital Fabrication.

“Working in outdoor construction environments also introduces challenges,” he continued. “Like autonomous cars, autonomous excavators need to use sensors, such as cameras and LiDAR, to measure the world around them, giving them a real-time virtual survey that can be used for decisionmaking. However, unlike cars, excavators reshape the world they operate in.”

Using sensors, the excavator can autonomously draw a 3D map of the construction site and localize existing

Computational

planning and stone placement using the autonomous excavator HEAP, Circularity Park in Oberglatt, Eberhard AG, 2021-2022 © Gramazio Kohler Research, ETH Zurich, Eberhard AG.

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building blocks and stones for the wall’s construction. Specifically designed tools and machine vision enable the excavator to scan and grab large stones in its immediate environment. It can also register their approximate weight and centers of gravity.

An algorithm determines the best position for each stone, and the excavator places the stones in the desired location. The autonomous machine can place 20 to 30 stones in a single consignment — about as many as one delivery could supply.

“HEAP is a modified 12-ton Menzi Muck M545 ‘walking excavator’ equipped with multiple LiDAR sensors, cameras, IMUs (inertial measurement units), and GNSS receivers,” said Johns. “A combination of cabin and arm-mounted LiDAR sensors allows the machine to observe the full scene, including reaching over the inprogress wall to measure how stones are

placed on the backside. Cameras help isolate individual stones in the 3D map produced by these sensors, and detected stones are picked up and revolved in the gripper to produce a full 3D scan of each object.”

HEAP uses force-controllable cylinders and incorporates pressure and IMU feedback in the chassis. This allows for wheeled legs for automated load distribution and chassis balancing on irregular ground conditions.

“The large-scale retaining wall and landscape in Oberglatt, Switzerland, allowed us to demonstrate the capability of our system to perform incredibly complex tasks autonomously in a real construction environment,” said Johns.

“Given that experience, we are working now to commercialize that technology as an ETH spin-off company, Gravis Robotics.

At Gravis, we provide automation solutions

for generalized construction equipment, leveraging state-of-the-art machinelearning-based control.”

In addition to landscaping and stonewall building applications, HEAP has been used for trenching, tree harvesting, and teleoperation.

FPW

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DESIGN NOTES

One Cajun beef, please, but hold the air compressor oil No one wants air compressor oil contaminating production.

And in food processing applications, quality and safety are essential.

Oil-free compressed air

systems ensure food safety and quality during production and packaging. | Courtesy of ELGi

E2M Kitchen, a fresh and ready-to-eat meal provider, knows this all too well. The Charlotte-based company significantly evolved its food preparation and packaging process for creating gluten-free, dairy-free, and preservative-free meals. Every tool used in its production process was scrutinized to ensure food safety.

To meet growing demand, the company needed an automated system driven by compressed air — often dubbed “the fourth utility” in production plants. The air compressor powers the company’s conveyor belts and machines, including its: • • • • •

E2M Kitchen uses its ELGi AB37-125

for multiple machines that come in direct contact with food. | Courtesy of ELGi

A flexible packaging

company uses three ELGi OF170 compressors to remove downtime risks. | Courtesy of ELGi

Robotic arm that places food trays on the conveyor Pneumatic food depositor that portions food onto trays Vacuum sealer that packages trayed food Metal detector with piston-driven air to remove trays from production if metal is detected High-speed printer that labels the final product

The company worked with Pattons, a southeastern ELGi distributor, to install an ELGi AB37-125 as the heart of its food production system. The air compressor can provide 216 cfm of compressed air at 100 psi. This power output aligns with the requirements for maintaining consistent air quality throughout E2M Kitchen’s comprehensive food preparation and packaging processes. ELGi’s unique rotor design reduces pressure loss and increases stage efficiency, allowing the compressor to maintain peak operational efficiency. E2M Kitchen can produce approximately 10,000 meals daily during periods of maximum production.

“The ELGi oil-free air compressor has become the cornerstone of our manufacturing line, enabling a seamless transition from manual, hands-on food preparation to an automated system,” said Levi Barbee, president at E2M Kitchen.

“It has accelerated our production volumes, enabling us to cater to growing demand without compromising our strict standards of food quality and safety.”

The food production industry has seen a key shift in air compressor choices.

Historically, oil-flooded air compressors were the go-to, but they come with a builtin problem: oil contamination. Lubricating oil could end up in the compressed air, pushing tiny oil particles into the food, packaging, and production facilities. This oil contamination compromises product quality and introduces potential health threats to consumers.

In response, E2M Kitchen quickly embraced oil-free air compressors. The main benefit of such compressors is evident in their name: no oil. This means no risk of lubricants or oils tainting the food or the production site. However, the advantages extend beyond avoiding contamination.

The oil-free compressor also demands less maintenance than oil-flooded compressors, reducing the chances of oil spills and leaks — costly incidents that can halt production. Plus, it ensures pure air in the employee workspaces. With less required maintenance, there’s a reduced need for oil changes and filter

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swaps. Minimizing oil spill and leak risks and conserving time and resources align with the company’s environmentally friendly approach and sustainability goals. E2M Kitchen is also free to consider greener packaging alternatives since there is no concern about oil or moisture affecting food trays or packages.

In a similar story, an Iowa-based flexible packaging company serving North America’s food, beverage, and pharmaceutical industries went oil-free by replacing six oilflooded rotary screw air compressors with three ELGi oil-free air compressors.

For this company, downtime was a major concern. Oil-flooded air compressors use oil to seal, lubricate, and cool during the compression stage. Even with proper filtration, oil vapor can be passed downstream, build up in the system, and eventually jam components, leading to

facility shutdowns. Moreover, the oil vapor could reach the equipment from other factory areas and cause irreversible damage, significantly driving up costs.

To remove downtime risks, this company worked with Modern Compressed Air to create a redundant system with three ELGi OF170 compressors. Demand is met with two, and the third is used to take one offline without disrupting production.

ELGi is one of the few compressor companies to design and manufacture air ends for oil-free air compressors. The units are designed to provide class zero oil-free air and meet ISO8573-1 class zero oil standards.

The rotors and housing are coated with PTFE-based food-grade PP coating to resist corrosion and endure high temperatures up to 482° F. Another appreciated feature is the variable frequency drive (VFD). Unlike

quality matters.

traditional fixed-speed compressors, variable-speed compressors equipped with VFD can vary the speed of the motor and ensure that the compressor does not consume excess energy. This means compressors with VFD save up to 35% of energy costs compared with a fixedspeed unit. More importantly, VFD allows the facility to maintain stable pressure throughout.

“The equipment in the facility is from all over the world, and they all have different requirements in terms of energy.

So, when the processes turn on and off all over the plant, it becomes difficult to react and maintain a stable airflow plant,” said Tanner Hilton, sales manager at Modern Compressed Air. “The VFD enables us to smooth the process and keep the compressors in the idle mode without turning them off.”

In this and E2M Kitchen’s case — and any food, beverage, and pharmaceutical application relying on compressed air — going oil-free is a smart move that will benefit the companies and customers in the long run.

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DESIGN NOTES

Free pneumatic positioning optimizes gripping Pneumatic grippers are revered for being an economical, easy-to-

The PDD pre-positions

maintain solution with high force density.

the gripper fingers to avoid collisions with proximal workpieces.

However, force control and precision can prove challenging, especially when handling

| Courtesy of SCHUNK

delicate parts and parts of different sizes.

Sensory feedback is essential in such applications to measure parameters such as the force applied, object position, and speed.

Position sensing is especially important in dynamic environments. But determining position is just one piece of the automation puzzle. Adjusting position based on feedback is how pneumatic systems optimize operations and improve efficiency.

Specifically, free positioning increases flexibility and makes pneumatic grippers adaptable to changing or for use in less structured applications.

A new type of pneumatic positioning device (PPD) from SCHUNK allows such free pneumatic positioning with pneumatic grippers. The setup includes a gripper, sensor, and PPD. Prefabricated PLC function blocks simplify commissioning. The PPD was developed as an accessory and is controlled via IO-Link. Modifications or special variants of the gripper are unnecessary, making retrofitting existing processes easy. This is an optimal solution for any gripper application requiring flexibility, such as robot applications that move workpieces of different sizes or in close proximity.

This flexible control enables users to optimize cycle times, as the gripper fingers no longer need to move to their

end positions before and after each gripping operation. The device also avoids collisions with closely positioned workpieces by pre-positioning the gripper fingers. The gripping force can also be adapted by adjusting the output pressure,

The PPD provides free positioning,

gripping force, and speed adjustment. | Courtesy of SCHUNK

which provides clear advantages for gripping workpieces of varying sensitivity.

Even more gentle gripping is possible by adjusting the gripper jaw speed, which reduces the gripping impulse.

Inside the unit, four integrated highspeed 2/2 valves, integrated electronics, and the position sensor, which is installed on the gripper, ensure a closed control loop.

The sealed design with IP67 makes the PPD suited for industrial environments. The unit can be installed end-of-arm and, therefore, achieve precise positioning with short hose lengths. This ensures a positioning accuracy of up to 0.5 mm.

The PPD is available in three versions that differ in the flow rate of the internally installed valves. Size and weight always remain the same. An IO-Link sensor by SCHUNK or all common analog sensors from other suppliers can be used as sensors.

FPW

SCHUNK schunk.com

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FUNDAMENTALS Josh Cosford • Contributing Editor

How long should a hose last (and tips to extend service life) How long a hydraulic hose should last depends on many factors, not the least of which is who you ask. Some standards want to see hoses changed every few years, yet others are okay up to ten years (such as with the SAE). But do we even need to apply a death clock to hydraulic hoses if they’re properly cared for? The short answer is yes, but that doesn’t mean we must prematurely swap hoses based on counting full moons.

Let’s dig into the factors that affect hydraulic

Applications vary from cleanroom power units for testing NASA rockets to logging equipment trudging through cold mud, so to require the same hose maintenance schedule might not be prudent. You can combine industry recommendations with application and historical considerations.

Let’s start by saying you should probably change your hydraulic hoses within ten years max. Even a hydraulic hose sitting unused in your warehouse should be scrapped after ten years, as general ambient deterioration factors such as sunlight, moisture and ozone will degrade the hose over time.

When you factor in large temperature swings, such as with arctic machinery resting

overnight in frigid climates and then firing up the next morning for a day of operation, the expansion and contraction of the rubber accelerates aging. In such circumstances, a hose may swing across a hundred degrees of variability, fatiguing the structure of the inner tube and cover.

Combining pressure fluctuations or spikes within a deteriorating hose also reduces its lifespan. Imagine your already-weakened hose being subjected to pressure spikes as the machine operator slams his excavator’s hydraulic hammer into the side of a building he’s demolishing, for example. Conversely, an industrial conveyor using a hydraulic motor drive

hose life.

| Courtesy of Adobe Stock

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Next level hydraulic control seeing relatively constant ambient conditions while subjected to fewer of the pressure spikes of mobile machine will result in highly reliable hoses.

You can predict hose service life by factoring in specific machine and operation conditions. I’m never a fan of arbitrarily changing hydraulic parts that don’t need it, but unless you have your own crimper and stock of hose and fittings to create new hoses on the fly, it’s likely a failure will result in downtime.

Replacing a thousand dollars in hoses every three years on your production-critical machines is nothing compared to the thousands of dollars per hour you lose when your machine goes down. And try telling your customers you can’t deliver their order because your local hose shop has to bring in the 6-wire hose on your injection molding machine.

It’s always a good idea to track your maintenance activities, even from unexpected downtime. You need to understand how your own application and ambient environment affect the life of your hoses. Manufacturers and standardization bodies can’t know what you know, which is why they can only offer guidelines.

Knowing that your machine always seems to blow a pressure line every few years helps you stay on top of preventive maintenance, which avoids costly downtime.

Regardless of your machine or environment, you can put measures in place to increase the useful life of your hydraulic hoses. For one, only operate your machine within its design specifications. If your machine was designed to run at 2,500 psi, don’t push things to 3,000 psi just because you want more force.

The hoses selected may be rated for only 2,500 psi, and pushing higher will reduce reliability.

Additionally, using hose wrap not only protects from abrasion but the sleeve style also reduces exposure to ambient chemicals, industrial fallout or road film. And while protecting the outside of your hose, you should consider the health of its inside. Keeping your oil cool and dry will prevent oxidation, hardening and cracking of the inner tube. By cool, of course, I mean within the normal operating limits of hydraulic machinery (think 120°F [50°C], give or take). And you’d be surprised at the amount of water hydraulic oil can hold in solution without the obvious appearance of free water.

Most NBR hoses are okay with water, but your hydraulic oil isn’t. It can oxidize and sludge, which could result in the degrading of the nitrile tube.

If machine uptime is the most critical factor in deciding whether to change your hoses every five years, by all means, change them. Some factories, such as Tier 1 automotive suppliers, run at capacity with just-in-time production that prioritizes uptime.

You know your machine, and you WHAT know your production requirements, DO YOU so use the preceding information to THINK? schedule a hose changeout program Connect with thousands that works for you. And lastly, if your of engineering design hose looks like it requires changing; professionals online. absolutely change it!

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COMPONENT FOCUS Josh Cosford • Contributing Editor

A primer on pneumatic vacuum pumps

Vacuum technology is the quintessential method for safe and careful material handling in various industries, from packaging to glass manufacturing. Vacuum cups and pads are gentle and soft, lifting even the largest material while barely contacting the surface. By creating a vacuum inside the cup, the pressure differential draws the material towards the cup. With attraction force factored by both the area of the cup and the pressure differential, even minimal vacuum force is required to hold a fair-sized load, especially when many cups are added to the job.

We commonly use two methods to create a vacuum: generators and pumps. The terms are misleading since pumps also generate a vacuum. Nevertheless, how each option uses technology to create a vacuum comes through vastly different methods.

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The vacuum generator uses the venturi vacuum system as defined by Bernoulli’s Principle, whereby air blown through the generator creates a low-pressure area and subsequent suction. The downside to vacuum generators is their requirement for continuously flowing air during the gripping phase of their operation.

Vacuum pumps, on the other hand, create differential pressure by pumping air from a vessel, much like a compressor.

Vacuum pumps used to pull air molecules out of a vacuum chamber are often positivedisplacement types, such as rotary vane pumps, scroll or screw pumps. Although rarer than vacuum generators, centralized vacuum systems make material handling easy and efficient, mainly when such a system already exists in a factory for conveying raw materials, such as plastic pellets for injection molding.

Positive displacement vacuum pumps are offered in both dry and wet options. The wet type uses oil lubrication, which offers superior longevity and lower maintenance.

The oil in the pump’s crankcase lubricates the major moving components and bearings and is generally a bit quieter than dry pumps. However, in cases where oil or its vapor may contaminate downstream material such as food goods or microprocessors, a dry style pump should be selected, and air dryers added to the system. However, a dry pump may require greasing or oiling of bearings, gears or bushings, so be mindful of maintenance requirements when selecting your pump.

Although solenoid valves are used to turn vacuum generators on and off, systems with central vacuum pumps still need valves to open and close the vacuum path at the suction cups. A single valve may activate a single cup or bank of cups, depending on the material handling requirements. Highly versatile beds with a single valve per cup can use sophisticated vision systems to actuate only the suction cups required when handling various items or those with complicated shapes. The efficiency advantage lies with the vacuum pump circuit since only leakage flow requires replenishment from the pump during handling.

Whether for bulk material transfer, material handling or basic vacuum technology, a vacuum pump offers the most efficient method of creating pressure differential we observe as vacuum. Many manufacturers offer compact all-in-one units for low-duty use. At the same time, other system integrators can design, build and install central vacuum systems for even the largest factory.

FPW

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ENERGY EFFICIENCY Ron Marshall • Contributing Editor

Compressed air fail: Extra heat Most of the energy that goes into an air compressor comes out as heat, so it is always a good idea to direct the hot air produced to a location that needs heat — like into a plant in the winter season. The compressor in the photograph has a specially designed heat recovery system that takes care of this automatically, saving the customer money on their natural gas heating.

But it turns out this compressor is producing much more heat than desired. It is running in a mode called load/unload, where internal pressure switches load the compressor when the compressor needs to pump up the pressure in the plant and unloads the unit when the pressure is satisfied. If working normally, the compressor consumes full-rated power when loaded and reduces its power to around 25% when unloaded. This compressor, however, has internal problems that cause it to consume extra energy.

A compressed air auditor did an energy study of this facility and placed some measurement instruments on the power input. This revealed that the compressor consumed about 5% more energy than normal in the loaded state — and 50% more power in the unloaded state.

This significantly increased the annual operating cost of the compressor. What’s worse, it was causing it to overheat and trip off on occasion. Additional energy consumption amounted to $5,600 in annual electrical costs.

This compressor had never been measured by an auditor, so the plant manager had no idea of the extra costs being consumed.

A saving grace was that the additional energy reduced the plant heating costs by a small amount. However, this plant only needed the heat four months per year.

It pays to measure compressor operation on a regular basis to ensure internal circuitry is working. In this case, the failure of the internal sump blowdown circuitry and high pressure drop across the internal air/oil separator caused the problem. This was an easy fix that resulted in some excellent energy savings — that This compressor recovers both paid for the repair and the audit in a short period of time. heat to the plant; it turned out that much more heat was being produced than expected, due to internal mechanical problems.

FPW

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MOBILE HYDRAULICS

THE GROWING WAVE OF

SOFTWARE-

DEFINED MACHINES DATA-DRIVEN OFF-ROAD EQUIPMENT WILL IMPROVE UPTIME AND PERFORMANCE AND REDUCE OPERATING COSTS.

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Mobile

machine owners, fleet operators and rental companies increasingly want

equipment that offers more-exacting control, higher productivity and efficiency, and is more environmentally friendly. Add to that is the growing interest in electrification, automation, and autonomy.

In response, mobile OEMs and their suppliers are doubling down on efforts to embrace IoT and “intelligent” vehicle components that communicate with one another, make decisions, and pair with telematic systems to send data to the cloud.

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Such connectivity promises to: • Give companies a better understanding of how operators use their vehicles.

• Increase overall machine efficiency and productivity for substantial operational cost savings.

• Enable continuous system monitoring and diagnostics to reduce vehicle maintenance costs.

• Optimize vehicle usage and reduce fuel consumption of entire fleets.

• Improve machine security to protect against hacking and theft.

In a recent Technology Conference, “Fluid Power and the Drive Towards Connected Systems and Machines” sponsored by the Fluid Power Industrial Consortium (FPIC) and NFPA, several presenters delved into some important trends, including the growth in electrified devices like pumps and valves; how system architecture will change on next-generation connected vehicles; and collaborative efforts among suppliers and machine builders to ensure disparate systems seamlessly work together.

Building blocks

BY: KEN KORANE, TECHNOLOGY EDITOR www.fluidpowerworld.com

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Current on-board systems often rely on discrete input devices, controllers, actuators and pumps. An ongoing trend is the further integration of controllers and sensors into system components. As the cost of CAN chips and other electronics continues to fall, it’s becoming more cost-effective to put that intelligence on the devices themselves, said D.J. O’Konek, engineering manager at Nott Co. Integrating input devices and mobile controllers allows communication with other intelligent and non-intelligent components, rather than needing an independent primary controller. This creates a more compact system to control ancillary devices or even propulsion and steering on a machine.

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And as integrated controllers, sensors and other devices collect data, controller networks such as J1939 and other CANbased systems can team with telematics to transmit that data to the cloud for presentation, analysis, action, and storage.

This drive towards connectivity lets OEMs and users access far more data on devices than previously possible.

This creates a lot of advantages, said O’Konek. Among them: Develop streamlined systems to reduce wiring and eliminate a separate controller.

This provides distributed intelligence throughout the system which can reduce programming needs, simplify systems, reduce overall costs, and speed time to market.

Allow access to additional data that hadn’t been available previously, which permits closer monitoring of operating parameters and can lead to far more efficient systems.

Build additional safety into the system, with options like redundant supervisory controllers, error-checking of data, or monitoring for system faults.

“All major manufacturers are moving towards these intelligent devices. Everybody has their own suite of products that they have access to, and pretty much all manufacturers are moving towards this type of connectivity,” said O’Konek.

Examples include actuators like electrohydraulic cylinders and electric motors that now provide data that

previously required integrating a controller and sensor into the system. Now they can monitor and control parameters like speed, torque, displacement, current draw, and linear force. The same holds for pumps and valves, where it is fairly easy to integrate an onboard controller and provide data on the position of valve spools or the displacement angle on pumps.

Many sensors now have J1939, CANopen or other protocols on board.

This puts sensor data on the bus, rather than requiring conversion in a controller.

Likewise, user interfaces like displays and joysticks can now provide data directly into the system via CAN. Networks almost always require a primary controller, whether for supervisory functions, edge computing, or actual decision-making. The trend now is to integrate primary controllers into other devices, such as touchscreens or joysticks, resulting in more compact systems, said O’Konek.

Finally, virtually all gateways connect to a CAN or LIN network and provide data to the cloud. Most common is with a cellular network, but devices can also transmit data via Wi-Fi or Bluetooth. Some manufacturers are consolidating gateways into their displays, controllers, and other devices. Again, this eliminates additional components and wiring and allows over-theair updates of products.

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FLEETS OF MACHINES THAT EMBRACE SMART COMPONENTS, NEXT-GENERATION CONTROLS AND TELEMATICS CAN ENHANCE SAFETY, IMPROVE UTILIZATION, RAISE EFFICIENCY AND IMPROVE PRODUCTIVITY, ALL LEADING TO COST SAVINGS. COURTESY OF ADOBE STOCK Data overload

The expansion of “smart” components into most every vehicle system undoubtedly results in more data. Functions are electrified, the engine manages operations and emissions, and sensors drive automation and efficiency, said Matt Via, VP of sales and marketing, HED. Add to that, the equipment of tomorrow will incorporate AI and machine learning to understand real-time conditions, and automatically learn and make decisions based on the environment where they operate. This software-defined vehicle will also accelerate the pace at which data is created.

How much data are we talking about?

Estimates are that an electronicallycontrolled excavator produces approximately 15 GB/hr. In normal usage, an average machine produces 2.5 TB/ month, he said. As manufacturers add battery-management systems, high-accuracy radar, Lidar, high-resolution cameras and automation to support autonomy of a vehicle, data is expected to increase to about 5.4 TB/hr — approximately 200 times growth by about 2035.

“There is simply not enough bandwidth on today’s machines and the world of connectivity does not contain enough wireless or cloud capacity to try and consume all this data,” said Via. “As we process the stunning growth in the amount of data, it becomes clear that how we architect machines matters. Understanding what types of data, communication methods, and how machines will optimize edge processing versus cloud reliance to develop analytics will happen very quickly. The pure volume of software will demand connectivity of machines and, like your computer, updating the equipment will be normal,” he said.

Typical vehicles today are based on a domain architecture where controls are

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MOBILE HYDRAULICS

organized around functions. All inputs and outputs that are part of a function are wired back to a specific location. The average machine needs at least four CAN buses to move data, which can be replaced with a single, higher-bandwidth CAN-FD (CAN with Flexible Data-Rate) backbone. This offers a near-term solution, said Via. But future networks will require Ethernet to handle communications between vehicle systems, he said. As we implement items like functional safety and automation, machine builders need to reorganize how operations are distributed from functions to locations on the vehicle.

An Ethernet backbone set up around the vehicle lets controllers share data.

Within each zone, local networks collect data from sensors, while zonal gateways use the Ethernet backbone to transfer aggregated data back and forth for data processing.

Changes in the architecture of the vehicle also drive direct cost benefits for the manufacturer. Zonal configurations simplify and shorten wire harnesses, and software layers become more contained, allowing components to simply transfer raw data and remove multiple locations for software configurations, meaning fewer locations to maintain software.

The evolution from the domain to zonal architecture will start with power distribution and central computing. Over time, more and more domains around the vehicle are added, all using the same backbone. These features quickly start to use and leverage more data. This is why advanced automation and autonomy require a different approach to the vehicle system architecture, said Via. Telematics becomes essential

With the increase in data, telematics — the system to collect and transmit data to the cloud — also moves into a central role. Experts often tout next-generation controls and connected vehicles in terms of benefits like safety, predictive maintenance, productivity, user experience, and over-theair programming. But ultimately, the reason to embrace connectivity is for cost savings.

Fleets operate in an extremely competitive environment and are looking to

use data to improve their margins and enable better outcomes. Today, there are about 8.85 million subscriptions for data and telematics in non-trucking heavy vehicles, generating an average savings of around $6,400 — typically from machine utilization, operator efficiency, fuel, and reduced accident costs, said Via. OEMs also spend billions on warranty costs, great for their dealers but bad for customer satisfaction and OEM profitability.

By integrating telematic systems into their vehicles, OEMs can gain real-time insights into the performance condition of their vehicles and customer’s real use cases. This lets OEMs proactively identify and address potential issues before they become major problems, reduce the warranty pool size, provide real-time diagnostics and enable faster fixes, possibly avoiding the cost of a service call.

With software-defined vehicles, the ability to update features over the life of vehicle lets the OEM build constant value on existing vehicles that are in the field. The ability to fix with over-the-air programming provides more uptime, something that will be a key differentiator for early adopters. And telematics data can be used to improve product designs and manufacturing processes, leading to vehicles that are more reliable.

In addition, there are three impacts that’ll be very difficult or near impossible to implement without machine connectivity, said Via. First, software security. Equipment today is vulnerable to security attacks. Machines that are hacked could be rendered inoperable or cause damage and liability issues. Protection will require OEMs to implement encryption, security certificates, and hardware security devices. Connectivity will be required to keep these security systems up to date.

A second reason for connectivity in software-defined vehicles is software bugs.

Today, heavy-equipment software has about five to eight million lines of code, and Frost & Sullivan estimates about 100,000 bugs. In a decade, that’s estimated to be 150 to 225 million lines of code and three million bugs.

Without connectivity, software warranty costs for OEMs will be astronomical, if not unsustainable, he said.

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Third is advanced automation and autonomy. These technologies leverage learning models such as AI that are constantly learning, based on vehicle operations, the environment, and the vehicle pool. Connectivity is essential to share information, receive updates and continuously improve the models.

“Software is the future in vehicles,” continued Via. “It will drive changes to architectures and expand how connectivity is used in the vehicle. More data creates more opportunities.” Software-driven vehicles let OEMs build customer value in existing vehicles, increase customer satisfaction, and lower warranty rates. To push adoption and drive prescriptive analytics, however, OEMs need to deliver better outcomes. “Data does not equal value. Users want outcomes that produce better results, otherwise data is just noise and expense,” he said.

Collaborative future

For software-defined vehicles to succeed, however, commonality and standards become essential. As machines become more intelligent, with smart components and more connectivity, and as they advance toward electrification and autonomy, OEMs need more information and collaboration to design, service, and operate these machines.

“We’ve been in this game for about

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10 years now, doing telematics solutions for OEMs. Previously, one company would try to provide that whole solution,” said Adam Livesay, CRO of Elevāt Inc. The problem they’ve experienced: suppliers are very siloed within OEMs. One supplier might allow data to be shared on the CAN bus and the CAN network, but not allow a tie-in to their APIs (Application Programming Interfaces), to their back office, to their service centers or their databases. And they definitely are reluctant to share data between each other, or even with a thirdparty telematics company.

That’s been the case for years, but it has become increasingly difficult to go it alone. “The major shift we’ve seen in the last two or three years is companies are really coming together with their piece of the puzzle, rather than trying to provide the full solution. Now the suppliers, from the sensors to hardware, to gateways, to controllers, to the cloud, all have to work together in partnership with the OEMs to provide that unique solution,” he said.

Having all suppliers follow the same standards, such as the ability to provide common over-the-air software updates to all modules, or the ability to diagnose and implement common diagnostic messaging, represents saving opportunities for OEMs. For example, when equipment leaves the factory, OEMs often don’t know how those machines are operating in the field.

There’s not a rich and robust data feedback to the OEM, or to their dealers or service centers, said Livesay.

When a maintenance event occurs and the machine shuts down, average downtime for some major North American suppliers is eight days until the equipment is serviced and up and running again. On the other hand, if firms have a connected strategy that shares data with other suppliers and telematics companies, we start to connect these systems and provide better information across company boundaries to help solve these problems quicker — perhaps even eliminating the need for a costly on-site service call — and get the equipment up and running faster.

One impetus behind this transition was Covid-19 and the acceptance of work-

from-home, when companies were forced to embrace cloud-based solutions. Their IT teams had to develop security strategies, API strategies, cloud-based service strategies, and it really accelerated the telematics and connectivity industry. “When we meet with OEMs now, they already have their cloud service providers, API security, data-protection contracts all ready to go.

Now it’s about making those components and that infrastructure ready to be shared.

This is becoming more of the norm in the industry,” said Livesay.

Now, a connected machine or fleet can take that local data and connect it to the cloud, where an API might share that data not just to the OEM and the machine operator, but also the service centers, which can react to alerts and solve immediate issues. But as data is collected over years, OEMs build a history and can start making recommendations on predictive maintenance. And suppliers get information on how their components are being operated, how they’re holding up, and what kind of failures occur. Ultimately, it can lead to better components and better recommendations for system designs in the future.

“A shift is happening in the industry.

It’s happening fast. Companies are coming together, and they’re building these ecosystem partnerships that are really focused on delivering high value to the OEM and their customers,” said Livesay.

“So I think there’s two types of companies out there right now. You have the companies that are choosing not to do this, they’re choosing to stay siloed and provide their own solution. But I think the industry is really moving past that, and they’re expecting a lot more ecosystem cooperation and partnerships so that they can deliver their next generation of machines.”

FPW

Elevāt | elevat-iot.com HED Inc. | hedcontrols.com Nott Co. | nottco.com NFPA| nfpa.com

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PNEUMATICS & AUTOMATION

Figure 1. Equipment and machinery with a high density of I/O devices and pneumatics are suitable for incorporating distributed electropneumatic assemblies close to the field devices, minimizing wiring and tubing installation.

Courtesy of AutomationDirect

Distributed electro-pneumatics streamline equipment designs Machinery builders and OEMs save space and improve functionality by applying electro-pneumatic I/O and solenoid systems throughout their equipment. By: Chip McDaniel, AutomationDirect

For

machine builders and original equipment manufacturers (OEMs)

alike, there is an increasing push to deliver smarter, more modular, and physically compact systems. Among the many design choices required to make this approach a reality is a corresponding need to distribute automation intelligence, signaling, and control elements throughout the physical system arrangements, instead of following conventional design practices of mounting

requires new products that lend themselves to innovative installation.

Because so many types of equipment rely on pneumatics and electrical signals, it makes sense to look for solutions compatible with both and with standard industrial automation communication interfaces. For these and other reasons, electro-pneumatic input/output (I/O) and solenoid valve bank systems have become a preferred method for distributing signaling and pneumatic automation throughout equipment of any size.

all components in the main control panel.

Centralized versus distributed automation

Making OEM systems more intelligent calls for increased numbers of sensors and controlled elements. Modularity implies convenient options for both physical and logical connectivity, which can also lend itself to scalability, and compactness

Manufacturing machines and production equipment are commonly automated by programmable logic controllers (PLCs), which use I/O modules to monitor sensors throughout the equipment and control devices such as motor controls and solenoids. A traditional design approach has

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been to centralize all PLCs with local I/O into a main control panel or, in some cases, a few control panels.

While sensors and motor controls predominantly use electronic signaling, pneumatics controlled via solenoids are popular for operating mechanisms and actuators because they are simple, powerful, clean, and cost-effective. Because sensors and pneumatics are usually dispersed throughout the equipment — although there are often some localized concentrations of these elements — a corresponding amount of wiring and pneumatic plumbing is involved. Automating these components via one or more main control panels requires all this wiring and tubing to be routed from the field device to the control panel, entailing significant costs in materials and labor.

An elegant way to overcome these problems and simplify equipment designs is to use electro-pneumatic automation assemblies distributed throughout the equipment.

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PNEUMATICS & AUTOMATION

Electro-pneumatic assembly essentials

Electro-pneumatic assemblies incorporate subcomponents that accommodate a flexible variety of I/O and solenoid valve requirements (Figure 2). They are modular, so designers can configure just what they need from a catalog of standardized options.

Furthermore, some products are available in completely connectorized versions — using M8 and M12 quickdisconnect electrical connectors and push-to-connect pneumatic fittings — so they can be rapidly installed and easily maintained. In fact, once the assembly is physically mounted, users don’t even need a screwdriver to make wiring connections or a wrench to plumb air connections.

Field-wireable connectors are available, but most users prefer ready-made “patch cables” for the ultimate installation simplicity and speed. Connectorized and modular designs also greatly improve the

troubleshooting experience because users can rapidly swap cables and sensors to pinpoint where the problem is located.

Users should look for electro-pneumatic assemblies that are surface-mountable and IP65-rated to withstand dust and lightpressure water sprays, ensuring the assemblies can be mounted openly anywhere they are needed on equipment. The main control panel size is significantly reduced, as much or all of the I/O is located remotely, and the remote electro-pneumatic assemblies do not need any enclosures — although they can be installed within a control enclosure if it suits the design.

Connectorized I/O modules are

commonly available as 24 VDC discrete and analog inputs and outputs. Each I/O module supports a certain number of these points, and a complete assembly may have a maximum I/O count. Similarly, pushto-connect pneumatic valve modules are

Figure 2: Modular electro-pneumatics assemblies, such as the AutomationDirect Pneumatics Automation Link (PAL) shown here, are a compact and organized way to field install I/O signals and pneumatics outside of control panels, streamlining installations and improving equipment intelligence.

Courtesy of AutomationDirect

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PAL System Topologies

usually available as common 3/2, 5/2, and 5/3 center-closed variants, which connect to various base sizes. As with the I/O, there will be a limit to the number of modules supported by an assembly.

Another key point for electro-pneumatic assemblies is how they communicate so much concentrated I/O and solenoid data and commands with the host controller.

This is most efficiently accomplished using a standard industrial Ethernet communication protocol, such as EtherNet/IP. To do this, designers simply choose an EtherNet/IP master for the assembly and then ensure that the PLC controller is compatible, which is typically not an issue as this is a fairly common PLC capability today. An electronic data sheet (EDS) file defines how the EtherNet/IP device will interact with the host.

Depending on the electro-pneumatic system make or model, many installation topologies are possible, depending on equipment requirements (Figure 3).

Using an industrial communications bus means that basic on/off signals and commands are available, and other extended diagnostics can be transmitted to the main controller. Therefore, electro-pneumatic assemblies are a compact and organized way to improve the intelligence and capability of I/O and pneumatics on any machine.

Figure 3: Electro-pneumatics assemblies may have multi-conductor hardwiring options, but these components are even more effective for minimizing wiring and maximizing data transfer when implemented using an industrial Ethernet protocol, such as EtherNet/IP. Courtesy of AutomationDirect Making the connection

While modularity is generally considered a positive benefit, some designers are rightfully concerned about the difficulty of properly selecting and integrating from among too many options. For this reason, designers should look for suppliers offering configuration software to support this effort.

Effective configuration software will make selecting the communication controller, I/O signal modules, and solenoids easy. Furthermore, the software will identify the EtherNet/IP mapping for all signal, control, and diagnostics data, and provisions should be available for scanning and discovering any electro-pneumatic assemblies on the network and facilitating the configuration of these devices.

Availability of a flexible portfolio of components and easy-to-use software configuration tools accelerates the ability of designers to apply electro-pneumatic assemblies to any application. Small

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machines will realize space savings as control panels shrink in size because the I/O and solenoids are moved closer to target devices. Large machines can be fully shop-assembled, factory-tested, and rapidly broken into shipping splits. The splits can be quickly reconnected in the field — requiring only EtherNet/IP, power, and air supplies — with little risk of errors.

One company designed parts fabricating machines for the auto industry, including the automation aspects. They had embraced electro-pneumatic assemblies several years prior, using them to operate actuators for holding down parts, removing scraps, and similar operations. Designers could take advantage of the flexibility and expandability of using these EtherNet/IP devices and realize savings on troubleshooting. However, they struggled with specifying all needed components from a catalog and with supplier availability of parts, especially through the COVID-19 pandemic.

This situation improved significantly once they identified and standardized on a supplier with a comprehensive online method of selecting parts, which also showed the available stock levels and competitive pricing. Not only did these factors streamline the work, but they also served as a strong selling point for end-user customers.

Equipment designs evolve with electro-pneumatics

As machinery builders and OEMs look to deliver equipment more efficiently with greater intelligence, electro-pneumatic I/O and solenoid systems are leading methods for hitting these targets. By enabling more instrumentation and control points, simplifying installation and maintenance, and saving valuable space, these assemblies satisfy many design goals while providing overall cost savings. Modularity can increase the complexity of certain design aspects, but a flexible product portfolio and helpful configuration software will help designers effectively apply these systems.

FPW

AutomationDirect automationdirect.com

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DIGITALIZATION

Making headway WITH

DIGITAL INTEGRATION DIGITAL TECHNOLOGIES ALLOW FOR PRECISE, HIGHLY RESPONSIVE AND EFFICIENT HYDRAULIC CONTROL

BY JOSH COSFORD, CONTRIBUTING EDITOR

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In the era of

Industry 4.0, where the integration of digital technologies is transforming the manufacturing

landscape, on-board electronic controllers play a pivotal role in enhancing the efficiency and precision of hydraulic systems. These controllers, embedded within hydraulic valves and pumps, are ushering in a new wave of automation and intelligence, contributing significantly to the evolution of smart manufacturing.

Many hydraulic advancements in the past few decades are on the electronic control side rather than the fundamental nature of fluid power components.

On-board electronic controllers are sophisticated devices designed to manage and regulate the operation of hydraulic valves and pumps. However, pretty much any hydraulic component, from hose assemblies to cylinders, has benefited from electronic integration. These controllers utilize advanced sensors, actuators, and microprocessors to monitor and control various parameters, such as pressure, flow, and temperature, in real-time. By integrating these controllers directly into hydraulic components, manufacturers can achieve unprecedented precision, responsiveness, and adaptability in their industrial processes.

Electronic valve controls

Valves were among the first hydraulic components to realize the benefit of onboard electronics. Before I continue, let’s be clear: we’re differentiating between electric and electronic. Electric valves use raw ac or dc power to actuate the spool or poppet. However, electronic describes the use of electric components employing diodes, transistors, and integrated circuits. Even further, digital technology upgrades electronics to the level of computer control by processing binary codes.

Electronics are fascinating because of how closely their concepts resemble hydraulics, not only in the twin relationships between pressure and volts, and between flow and amps, but also in the functions and expression of its individual components. Look at the attached example schematic, which, although not entirely familiar to a hydraulic technician, is really just the electronic version of directional valves, check valves, orifices and pressure valves.

The schematic breakdown is for another article on another day, but understand that without any traditional computer control, an analog PWM valve driver can power and control a proportional valve using 1950s technology.

Early electronics were bulky, which is why a separate electronic valve driver card installed into the electrical cabinet was the standard for the day. Believe it or not, early electronic control hardware used vacuum tube amplifiers, much like the gear today’s audiophiles still covet. It took miniaturization of solid-state transistors and eventual computer chips to shrink the controls enough to fit on a valve, which led to on-board electronics.

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DIGITALIZATION

On-board electronic controllers enable proportional control of hydraulic valves, allowing for precise fluid flow and pressure adjustments. This level of control is essential in applications where accuracy is paramount, such as in the aerospace and automotive industries. Proportional valves, driven by on-board electronic controllers, precisely control pressure and flow while requiring only a power source and input signal from the PLC. Traditional hydraulic systems often suffer from lag and overshooting issues. On-board electronic controllers address these challenges by providing dynamic response capabilities, especially with the implementation of poppet or spool position feedback sensors. These controllers can quickly adjust valve settings to changing conditions, ensuring a more immediate and accurate system response. This is particularly advantageous in applications where rapid and precise movements are crucial, such as in motion control and robotics.

Proper digital control came when manufacturers added spool position transducers to the electronics, which use a PID (Proportional, Integral, Derivative) feedback and control system to exponentially improve the accuracy and repeatability of the valve. The PID controller uses a mathematical algorithm to regulate the valve based on inputs from the LDT (linear differential transducer) attached to the spool or poppet. In this case, the poppet is the slip-in cartridge valve since traditional poppets are difficult to modulate.

INNERCEPT DIGITAL PROPORTIONAL CONTROL FROM HYDRAFORCE IS A COMPACT PROPORTIONAL CARTRIDGE VALVE WITH AN INTEGRATED LVDT POSITION SENSOR AND ELECTRONIC VALVE DRIVER THAT DELIVERS HIGH LINEARITY AND REPEATABILITY.

Advanced pump technologies

On-board electronics aren’t just limited to valves, as hydraulic pumps also benefit significantly from on-board electronic controllers. However, the accoutrement of electronic and computer control can aid pumps and their systems in many more ways than what’s used on valves alone.

On-board electronic controllers facilitate variable speed control in hydraulic pumps, optimizing energy consumption and system efficiency. By adjusting the pump speed according to the actual demand of the system, these controllers contribute to substantial energy savings. This is particularly relevant in applications where the load varies, such as in material handling equipment and manufacturing processes.

The above example requires an asynchronous electric motor (servo) or variable frequency drive with an inverter duty motor so the motors may spin at speed outside a fixed rpm, which is typical of electric motors. The advantages are more than savings to your electricity bill, as the responsiveness is improved when both the variable pump and the motor contribute to the dynamic requirements of the actuators. Clever programming allows previously unheard-of features such as energy recovery, dynamic load holding and electronic flow sharing.

Load sensing is a crucial feature enabled by on-board electronic controllers in hydraulic pumps. The machine controllers continuously monitor the load on the system

SCHEMATIC SHOWS A PULSE WIDTH MODULATION (PWM) CONTROLLER

and adjust the pump output accordingly to suit the pressure and flow demand of the machine. This results in more efficient energy use, as the pump only delivers the required flow and pressure, reducing unnecessary power consumption. Load sensing is particularly beneficial in mobile hydraulic applications, such as construction equipment and agricultural machinery, and this method goes beyond the traditional hydraulic method. Instead of an arbitrary preset standby pressure applied to every valve and actuator, the digital version provides precisely the pressure and flow as required based on demand.

The integration of electronic controllers allows for remote monitoring and control of hydraulic pumps. Manufacturers can use Industrial Internet of Things (IIoT) technologies to access real-time data on pump performance, identify potential issues, and make adjustments remotely.

This capability enhances overall system reliability and enables a proactive approach to maintenance, reducing operational costs and downtime.

Adopting on-board electronic controllers aligns seamlessly with the principles of Industry 4.0, which emphasizes connectivity, data-driven decision-making, and automation.

These controllers serve as the bridge between the physical and digital realms, facilitating hydraulic systems integration into the broader industrial network.

Future opportunities

On-board electronic controllers generate a wealth of data related to the performance of hydraulic valves and pumps. When harnessed and analyzed, these data provide valuable 38

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insights into the hydraulic system’s efficiency, reliability, and overall health. Manufacturers can use this information to make informed decisions, optimize processes, and identify opportunities for improvement. With the proliferation of artificial intelligence, we can take this principle further and have the machine make its own optimization and improvement decisions.

On-board electronic controllers enable seamless communication between hydraulic components and other devices within the manufacturing environment.

This interconnectivity is vital for achieving a synchronized and coordinated operation of different systems. For example, in a production line, electronic controllers in hydraulic valves and pumps can communicate with controllers in other machinery, ensuring a harmonized workflow.

Many traditional controller area networks, such as CANopen and DeviceNet, continue to thrive in today’s market, but others, such as Time-Sensitive Networking (TSN), are gaining ground.

The advanced capabilities of onboard electronic controllers contribute to developing adaptive and autonomous systems. In an Industry 4.0 setting, hydraulic systems can autonomously adjust their parameters based on real-time data, environmental conditions, and production requirements. This level of adaptability enhances overall system performance and

responsiveness, contributing to the agility demanded by modern manufacturing.

While on-board electronic controllers offer significant benefits, their integration into hydraulic systems is not without challenges. Implementing on-board electronic controllers involves additional investment costs, including purchasing sensors, actuators, and advanced control systems. Small and medium-sized enterprises (SMEs) may find the initial investment challenging, although the longterm benefits in terms of efficiency and reliability can outweigh the upfront costs.

As hydraulic systems become more interconnected, there is an increased risk of cybersecurity threats. Manufacturers must prioritize implementing robust cybersecurity measures to protect sensitive data and ensure the secure operation of electronic controllers. This includes regular updates, encryption, and adherence to industryspecific cybersecurity standards. The postpandemic world has seen an exponential rise in cybersecurity threats, so risk aversion may keep many enterprises within the Industry 3.0 realm until the security solutions are more robust.

Besides the financial cost and security threats, we must also consider the challenges we face in growing and maintaining the technical personnel within fluid power. Integrating on-board electronic controllers necessitates a workforce with

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BOSCH REXROTH’S MODULAR CYTROFORCE IS BASED ON ENERGY-ON-DEMAND DRIVE SYTRONIX. CYTROFORCE FEATURES A MANIFOLD AND DIFFERENTIAL OR TANDEM CYLINDER CONNECTED TO THIS ENERGY-EFFICIENT UNIT. THE OUT-OF-THE-BOX SYSTEM CONSISTING OF FLOWOPTIMIZED STANDARD MODULES REPORTEDLY SETS NEW BENCHMARKS IN TERMS OF POWER DENSITY, ENERGY EFFICIENCY AND QUIET OPERATIONS. SYTRONIX SERVO VARIABLE PUMP HAS HYDRAULIC INTELLIGENCE BUILT INTO THE DRIVE THAT LETS USERS SIMPLY SEND A PROFILE FOR POSITION, VELOCITY AND FORCE TO THE DRIVE, WHICH CONVERTS THAT INFORMATION INTO COMMANDS NEEDED BY THE SERVOMOTOR TO CONTROL THE CYLINDER.

expertise in hydraulic systems and digital technologies. Training programs and educational initiatives are essential to equip professionals with the skills required to design, implement, and maintain these advanced systems.

On-board electronic controllers are at the forefront of the technological revolution shaping Industry 4.0. Their integration into hydraulic valves and pumps is transforming conventional hydraulic systems into intelligent, adaptive, and efficient components of modern manufacturing processes. The enhanced precision, dynamic response, and connectivity these controllers provide contribute to improved energy efficiency, reduced downtime, and overall optimization of industrial operations.

As the manufacturing landscape continues to evolve, the role of onboard electronic controllers will become increasingly prominent. Manufacturers must embrace these advancements, recognizing the long-term benefits they offer in terms of sustainability, competitiveness, and resilience in the ever-changing global market. The journey toward smart manufacturing fueled by on-board electronic controllers is a testament to the transformative power of technology in shaping the future of industry.

FPW

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OUTPERFORMING FILTRATION DEMANDS OF TODAY’S HYDRAULIC SYSTEM TECHNOLOGY

FMMX NEW High pressure in-line filter series, pressure to 6090 psi and flow to 40GPM. Patented MYclean filter element design assures original elements over machine life.

ELIXIR HFEX 508 psi in-line filters and flow to 80 gpm.

Spiral flow head design, and patented MYclean filter elements provide longer service life and assures original elements over machine life.

MPFX Series Tank mount return filters with working pressure up to 116 psi and flow to 238 gpm, multiport options, removable bowl and patented MYclean element with OEM specific design capabilities.

PASSION TO PERFORM

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ICM 4.0 WIFI capable sophisticated software suite monitors the status of your hydraulic filtration system in continuous real-time, with critical early warning detection.

LPA3 Portable optical and photodiode APC for fast and accurate particle monitoring of hydraulic fluids to identify risks before they impact the performance of the hydraulic system. www.mpfiltriusa.com (215) 529-1300 sales@mpfiltriusa.com

1/29/24 10:29 11/15/2023 10:40:14 AMAM

HANNOVER MESSE PREVIEW

Courtesy of Hannover Messe

NEW CONFERENCES AND IDEAS TAKE SHAPE AT

HANNOVER MESSE WITH THE THEME OF SUSTAINABILITY RUNNING THROUGHOUT, HANNOVER MESSE ORGANIZERS ADD AI, INDUSTRIAL SERVICES, R&D AND MORE TO THE 2024 EVENT. BY: MARY C. GANNON, EDITOR-IN-CHIEF

HANNOVER

Messe returns as one of the largest industrial trade

shows globally April 22 to 26, as show organizers shake up the event with several new conferences and themes throughout. This year’s theme will be “Energizing a Sustainable Industry.”

“Innovative technologies like those we see in April at Hannover Messe are paving the way to a climate-neutral, high-performance industry,” said Dr. Jochen Köckler, Chairman of the Managing Board, Deutsche Messe AG. “However, companies need advice and guidance on how to make sensible use of automation, artificial intelligence, renewable energies and hydrogen. Furthermore, bureaucracy and a shortage of skilled workers are limiting growth potential.”

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The event promotes close networking between government, industry and research to develop solutions and shape the necessary transformation process.

Mechanical and electrical engineering, digital industries, and energy sector companies will present solutions for a high-performance and sustainable industry. More than 4,000 companies will demonstrate how climate neutrality can be achieved through electrification, digitalization and automation. Köckler said, “The use of artificial intelligence in particular is leading to greater efficiency and product quality in industry.”

More than 170 exhibitors will be showcasing in the fluid power space, including Bosch Rexroth, Festo, Emerson, and more.

Sustainable and emission-free energy supply is increasingly coming into focus. This includes the use of renewable energies as well as their storage,

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HANNOVER MESSE PREVIEW

the implementation of a comprehensive energy management system and integration into an intelligent power grid. About 500 exhibitors from the green hydrogen and fuel cell industry will present their solutions.

Research and Innovation Summit moves to Hannover

The next Research and Innovation Summit will take place during Hannover Messe 2024.

Representatives from business and science as well as from politics and civil society will discuss the topic of innovations in Europe: catalysts, competencies and cooperation, based on the example of AI. Discussions will center on how industry and science should cooperate, how AI will change the future and other questions.

The Research and Innovation Summit is organized by the Stifterverband (Association for the Promotion of German Science), the German National Academy of Sciences Leopoldina and the Expert Commission for Research and Innovation. It is funded by the Volkswagen Foundation.

Also, after a one-day conference last month, “AI in Industry,” Hannover Messe will also feature artificial intelligence being presented and discussed both on the conference stages as well as at exhibitor stands throughout the event.

Industrial Services exhibition comes to Hannover Messe

Organizers are responding to changing market requirements with the new Industrial Services exhibition area. German industry is facing new challenges in the face of rising energy prices, a shortage of young talent, and increasing bureaucratic hurdles.

Thus, companies are outsourcing services so that they can devote their full attention to their own core activities and issues. This is where the new Industrial Services exhibition area comes into play, offering companies from the spheres of maintenance, assembly, recycling, cleaning, and industrial logistics the opportunity to showcase their service offerings and products in Hall 11.

This joint stand will be supported by VAIS (Association for Plant Engineering and Industrial Services). “Hannover Messe is the leading international trade fair and showcase for the industry. We are pleased that, with the new exhibition area, the importance and role of industrial services as enabler for the industrial transformation in Germany will become more visible,” said Dr. Dietmar Kestner, Managing Director of VAIS. Hermes Award entries still open

The Hermes Award and Hermes Startup Award will be presented by Germany’s

Minister of Education and Research, Bettina Stark-Watzinger, at the opening ceremony on April 21. Submission deadline is February 21.

The independent jury will be chaired for the first time by Prof. Dr.-Ing. Holger Hanselka, President of the FraunhoferGesellschaft. Jury members will nominate three products each for the Hermes Award and for the Startup Award from among submissions, and determine the respective winner from those nominees.

The degree of technological innovation, benefits for industry, the environment and society, as well as cost-effectiveness and implementation maturity are key criteria in assessing which entry merits the award.

Only those technology solutions which have already been proven in industrial practice are considered. Submit application at hermes-award.alpha-awards.com.

Bosch Rexroth was presented with the Hermes Award 2023. The Smart Flex Effector project consists of a sensor-based compensation module (end effector) for robots, featuring independent, precise kinematics in six degrees of freedom. It can be used in handling or joining processes with tight tolerances in automation technology or robotics, with loads of up to 6 kg. The position of workpieces or handling objects can be sensed by robots which are outfitted with the Smart Flex Effector.

The Hermes Startup Award 2023 went to MantiSpectra, which was awarded for its ChipSense product. It is a fully integrated near-infrared sensor – the smallest of its kind on the market, with a footprint of 1 mm2. The sensor enables rapid, highly accurate analysis and is used directly on the production line, from where it delivers real-time data. This makes it possible for defects to be detected as soon as they occur and for savings to be made through immediate quality control on the spot, on the production line.

FPW

Hannover Messe hannovermesse.de

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Don’t Compromise use MAIN Manufacturing The hydraulic flange you want, when you want it.

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PRODUCT WORLD

CFT flow meters with Deutsch, M20 conduit connector, and CAN-bus options DGD Fluid Power dgdfluidpower.com

In addition to the original M12 connection, Deutsch connectors and a standard M20 conduit style are now available for CFT flow meters. Deutsch style is the preferred connection for mobile equipment and M20 is destined for use in extremely harsh and hazardous conditions. These new electrical housings are threaded into the CFT cartridge body and use an O-ring seal to achieve complete isolation from the environment.

Testing is ongoing, but DGD anticipates a rating of IP67 or higher.

Designed for high IP ratings, the new Deutsch and M20 versions use heavy wall steel tubing to form the upper housing that threads into the cartridge body. An O-ring seal arrangement ensures complete isolation from the outside environment.

Tractor valve platform Danfoss danfoss.com Built on the PVG 32 proportional valve platform, the tractor valve offers a variety of components and features specific to agricultural applications. A range of valve modules — inlets, working modules for auxiliary functions, hitch modules, top-mounted modules, and endplates — enable customization for each specific application.

Zero-leak electrohydraulic PVBZ 16, 40, and 48 modules have been added to the platform, enabling the valve to cover flow rates of up to 170 lpm (44.9 gpm). The new sizes help customers to tailor the flow rate for each service more accurately. All PVBZ modules are based on the PVG 32 platform, eliminating the need for interface plates, and allowing them to be combined in numerous configurations to match customer needs.

The new modules are compatible with PVE electrohydraulic actuators.

DHPL long-stroke parallel gripper Festo Inc. festo.com The DHPL is a new generation of competitively priced long-stroke grippers that offers a host of advantages for high-load and torque applications. The grippers are interchangeable with competitive long-stroke grippers and provide the added benefits of lighter weight, higher precision, and no maintenance. The new long-stroke gripper is suitable for stacking boxes, gripping plates and shaped parts, and keeping bags open.

The long-stroke DHPL parallel gripper features ≤0.03 mm repetition accuracy due to three rugged guide rods and a rack and pinion design. Force ratings range from 40 to 750 N. Jaw stroke ranges from 20 to 200 mm.

Automatic hose-cutting machine UNIFLEX-Hydraulik GmbH uniflex-hydraulics.com The EMA 200 automatic hose-cutting machine comes with numerous sophisticated functions and its high-precision operation can achieve up to 450 1500-mm long hoses or 1,000 200-mm long hoses per hour.

It can be used for a small series or as part of a production line. The EMA 200 automatic hose-cutting machine helps increase productivity. All you must do is set up the machine and you can cut hoses up to DN 25 or 1 in.

The cutting machine pre-bends hose lines and cuts them with an adjustable cutting knife. The result is a perfect, square cut at a high cutting speed. If requirements change, the machine can be converted to a different hose size in just minutes.

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Mechanical hydraulic tester

Energy management system

Webtec webtec.com

Moog Inc. moog.com

The new RFIK270 mechanical hydraulic tester displays an increased flow capacity of 270 lpm (70 US gpm), while the pressure drop across the unit also sees a significant reduction. In addition to increased flow capacity, the tester features a modified load valve that significantly reduces pressure drop across the unit. According to tests completed using ISO32 mineral oil at 40° C (32cSt viscosity), the new tester reduces pressure drop by approximately 12 bar (174 psi) at maximum flow (270 lpm), equating to a reduction of circa 35%.

Like existing models in the series, the RFIK270 comprises a direct-acting reverse flow indicator (RFI), built-in thermometer, and a loading valve with pressure gauge. Calibrated from 20 to 270 lpm, the RFIK270’s substantial flow range ensures engineers can quickly, accurately, and easily service or commission hydraulic systems.

The 4-quadrant capability of the electrohydrostatic pump unit and servo drive used in electrohydrostatic actuation systems (EAS) technology, in combination with the new Moog Energy Management System (EMS), allows regenerative power flows generated during braking or pressure relief to be stored and reused.

The EMS, consisting of power supply and energy storage (ESU-C Storage Unit), also supports machine builders in the important goal of reducing the connected load in the EAS-based machine concept to a fraction of the peak power compared to the hydraulic concept by using actively or passively operating capacitors and/or kinetic storage.

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1/29/24 11:25 AM

ALA Industries Limited

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Co-Founder, Managing Partner Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson CFO Ken Gradman kgradman@wtwhmedia.com

Main Mfg.................................43

CONNECT WITH US! CHECK US OUT on ISSUU.COM!

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1/30/24 4:36 PM

TROUBLESHOOTING CHALLENGE Robert Sheaf • Founder of CFC Industrial Training

Cold, weak batteries impact tractor startup A student in one of our instructors’ hydraulic classes was having issues with his tractor upon startup. He said

Solution to December’s truck assembly line hydrostatic transmission overheating

that they would sometimes have a tough time starting their John Deere JD 4020 tractor when it was cold or if the battery was getting weak.

The John Deere dealer offered them a simple solution — he told them to move the steering wheel back and forth while turning the key. The student said it worked every time.

The JD 4020 has a hydraulic circuit with a closedcenter and pressure-compensating pump. Why would the tractor start easier when the steering wheel is constantly rotated back and forth, causing the steering wheels to turn?

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 in conjunction with our April 2024 issue.

FPW

The normal way hydrostatic systems work is having the charge pump pressure relief located in the charge pump housing or on the main pump set approximately 50 psi higher than the charge pump’s flushing/hot oil shuttle relief located on or close to the motor. Turning the adjustment screw “in/ CW” to increase its pressure didn’t change anything. But when the service technician backed it “out/CCW” to lower the pressure as low as it would go and then screwed it “in/CW” to increase the pressure it now read 225 psi as it did in the past.

Something must have been holding the relief open and the procedure the service man performed must have freed it, thus fixing the problem.

The only concern then would be that the contaminate made it back to the tank.

FPW

48

FLUID POWER WORLD

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2 • 2024

www.fluidpowerworld.com

1/29/24 11:08 AM

WE’RE YOUR SOURCE WE’RE YOUR SOURCE for Industrial and Mobile Fluid Power Solutions

for Industrial and Mobile Fluid Power Solutions

ALA Industries Limited ALA Industries Limited

ALA Industries Limited • 3410 Delta Drive • Portage, IN 46368 • Tel: (219) 762-2059 • Fax: (219) 762-2066 • www.alaindustrieslimited.com

ALA Industries Limited • 3410 Delta Drive • Portage, IN 46368 • Tel: (219) 762-2059 • Fax: (219) 762-2066 • www.alaindustrieslimited.com ALA 2-24_FPW.indd 49

1/29/24 10:30 AM

Precision

Control Solutions Designing efficient systems involves much more than simply understanding a few basic principles. There is a true art to balancing the specific requirements of an application in order to achieve the desired goals in the best possible way. Help us understand the unique needs of your application and together, we’ll develop something that surpasses what any of us could have done alone.

Contact your distributor to learn more, or visit clippard.com to request a free catalog and capabilities brochure.

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1/29/24 10:30 AM