FLUID POWER WORLD JUNE 2021

Pulsed air boosts efficiency p. 28

Distributed electro-pneumatics for automation p. 34

Precision in agricultural machinery p. 38

www.fluidpowerworld.com

June 2021

The roof wing opening system of the

UAE Pavilion PAGE 42

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FLUIDLINES Mary C. Gannon • Editor

Strength ahead, but still some uncertainty Over the last few months, I’ve chatted with several fluid power manufacturers who have stated that their business is busier than normal in any type of recovery mode. It’s an all-hands-on-deck situation, where every employee is pitching in and hiring has become a challenge.

These were all just passing conversations. NFPA data also indicate that shipments of fluid power products for April 2021 increased 35.4% when compared to April 2020, but decreased 9.5% when compared to last month. Mobile hydraulic, industrial hydraulic and pneumatic shipments all jumped between 25% and 35% in April 2021 when compared to April 2020, when indexes dropped sharply with the onset of the Covid crisis. All of the April 2021 shipment indexes dropped back about 12% from the high levels of March 2021. This comes from data collected from more than 80 manufacturers by NFPA’s Confidential Shipment Statistics (CSS) program.

I reached out to Peter Alles, VP of Member Services and Marketing for the NFPA to gain some insight into what these numbers mean for both users and manufacturers of fluid power technologies.

“The fluid power industry, and many industries that are customers to fluid power, are experiencing an exceptionally sudden and steep bounce back from an exceptional event. And many of us are seeing numbers we aren’t used to seeing. This is unlike a ‘normal’ recession in which there’s often a more lengthy recovery curve. So, supply chains weren’t ready. Labor wasn’t always in place, and is hard to put in place,” Alles said.

As a result, there has been some speculation of panic ordering. Alles said in usual circumstances, you may see supply chain purchasers add a 5-10% cushion to orders, but indications show maybe 20 to 25% more demand than actually exists downstream in the marketplace. Alles said the drop down in April numbers are closer to historically normal levels.

Forecasts are showing a strong 2021 overall. “But a strong 2021 is probably going to feel more hectic, and hard to keep up with than if we had a more gradual return to these levels of activity,” Alles said.

“The new normal we see for a while could be some 2

FLUID POWER WORLD

6 • 2021

continuation of the heightened level of uncertainty, supply chain difficulty and labor market disruption we have now.”

The pandemic and concerns about supply chain capabilities significantly increased talk about reshoring.

Alles said that the start of tariffs helped kick this into gear, as an annual reshoring report and index from AT Kearney shows the import percent peaked at 13% in 2018, and dropped back to 12% in 2019, the lowest level since 2014. AT Kearney attributes that drop in import impact to the trade war.

Imports of fluid power products from China peaked in 2018, and dropped by 12% in 2019, prior to the industry decline in 2020. That would be consistent with AT Kearney’s findings. “You would have to go back a long time to find the last downturn in imports from China. During that same time period, from 2018 to 2019, imports from Canada (+20%), Mexico (+8%), Germany and Japan continued to trend upward. Again, this is seemingly consistent with at least the idea that China is becoming less of a source for fluid power products, with companies based in countries such as Canada and Mexico picking up that business.”

“Looking at the first four months of 2021, and comparing to the more normal year of 2019, imports of fluid power from Canada and Mexico are keeping pace, but China is lagging its 2019 pace, which was already behind the 2018 pace,” Alles continued. “This could be evidence of significant shifts in where fluid power products are imported from.”

The NFPA IEOC will provide more insight into these numbers with two more months to report. The conference is slated for August 17 and 18, at the Hilton Chicago/Oak Brook Hills Resort & Conference Center.

Registration is open; see page 12 for details.

www.fluidpowerworld.com

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Mary C. Gannon • Editor mgannon@wtwhmedia.com On Twitter @DW_marygannon

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FROM THE FIELD Paul J. Heney • VP, Editorial Director

Online training and learning is still hot In this pandemic, we’ve definitely learned to use online learning, networking and training to the fullest. And even with a gradual return to in-person events in sight, we’re continuing to offer plenty of online opportunities to get new insights on fluid power technology.

Last year, we launched a series of eight YouTube Live sessions with our longtime collaborator, writer, and trainer, Carl Dyke, of CD Industrial Group Inc. Dyke has taught mobile hydraulics maintenance for years across Canada and the U.S. — and even at times north of the Arctic Circle. There, extreme conditions make the operation of mobile hydraulics a challenge, to say the least. He and his team are natural teachers, and the feedback we’ve gotten has been fantastic. We’re currently planning four summertime sessions, tentatively on these topics: • • • •

Load holding and motion controls (check valves and counterbalance valves) Extra pressure and extra flow (intensifiers and accumulators) Hydrostatic systems (closed-loop hydraulics) Sensors and electronics in hydraulics

efficiencies, the IoT, electro-pneumatics, failure analysis simulation tools, prototyping, accumulator design, and more. Based on feedback from readers, we plan to keep the Virtual Series going, even as we keep our eye on eventually bringing back the in-person FPTC. We’re looking at Detroit and Minneapolis/St. Paul for upcoming FPTC events, but we’d also like to hear from you, as to what locations you’d prefer to travel to, once business travel becomes more normal.

Past events have been held in Milwaukee and Cleveland, and we are also open to returning to those cities for future events. Drop me an email at the address below and let me know where you’re interested in, what your attitude is toward business travel right now, and what topics you’d like to see in our Virtual Series in the near future.

Lastly, our sister publication, Design World, also has been producing more online events. There, the live monthly Women in Engineering chats and the fantastic Future of Design Engineering Series webinars have been drawing huge numbers of attendees.

These are all free of charge, and I welcome you to check them out (designworldonline.com).

I look forward to seeing you soon, either on screen or in person!

Turn to our Training department on page 24 to learn more.

Also, we have been continuing our very popular Fluid Power Technology Conference Virtual Series (fluidpowertechconference.com), with a variety of speakers covering sizing of seals, pump and motor

FPW

Paul J. Heney

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JUNE 2021

C ontents |

vol 8 no 3

|

fluidpowerworld.com

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6

•

2021

F E AT U R E S PNEUMATICS

Pulsed air boosts pneumatic efficiency The AirFlowSaver supplies energy- and cost-optimized compressed air based on unique SmartValve technology.

Distributed electro-pneumatics maximize machine automation options Distributed automation options have been improving for many years. Networked electro-pneumatic solenoid banks give machine builders smart and convenient choices.

MOBILE HYDRAULICS

Precision is key in agricultural machinery The use of GPS technology, coupled with the power and precision of hydraulics, ensures modern farming success.

INDUSTRIAL HYDRAULICS The roof wing opening system of the UAE Pavilion Far-reaching hydraulics power a show-stopping display

28 34

38

D E PA R T M E N T S

42

ON THE COVER

02

FluidLines

04

From The Field

10

Korane’s Outlook

12

Association Watch

14

Design Notes

20

Fundamentals

24

Training

26

Energy Efficiency

48

Products

54

Component Focus

56

Ad Index

The UAE Pavilion at Expo 2020 has 28 massive carbon and glass-fiber movable wings that are controlled by a sophisticated hydraulic system including 46 cylinders. | courtesy of Santiago Calatrava LLC

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6 • 2021

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FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Noncommissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

IN UNCERTAIN TIMES, WE HAVE NEVER BEEN MORE RELIABLE.

FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2021 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

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FLUID POWER WORLD (ISSN 2375-3641) is published seven times a year: in February, April, June, July, August, October, and December by WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Fluid Power World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

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FLUID POWER WORLD

6 • 2021

KORANE’S OUTLOOK Ken Korane • Contributing Editor

Sustainability is good for business Many companies talk a good game when it comes to climate change but for most, it’s not a top priority. Pneumatics manufacturer SMC, in contrast, is incorporating sustainability across its entire business, from the products it makes and how they are manufactured to reorganizing production facilities to minimize waste and CO2 emissions. According to Global Manager Tony Hutchinson, speaking at the company’s National Pneumatics Day event, “We’ve taken the scientific evidence seriously, and we’re trying to reduce our company’s carbon footprint while helping our customers reduce theirs.”

The United Nations has established sustainable development goals to end extreme poverty, reduce inequality and protect the planet by 2030. According to Hutchinson, “The U.N. has said that the private sector is realizing that transitioning from a high carbon economy to one built on low carbon activities is not only essential to limit dangerous climate change, but also it’s good for business.”

With strong support from upper management, SMC is aligning with the U.N. goals, in particular by developing technologies to reduce carbon emissions in the pneumatic marketplace. One well-established undertaking they’re championing is the energy audit, where technicians assess a total system from compressor to actuator and recommend

changes that improve performance and save money. Intelligent products and software can now pinpoint inefficiencies and calculate the effects on total cost of ownership. At one large multinational food processor, SMC found $2.5 million in savings just by changing processes, eliminating leaks, upgrading components and optimizing pressure levels.

Company engineers have identified numerous products that could be improved to promote energy efficiency, he continued.

They’re embracing “topology optimized design,” an approach that permits downsizing via techniques that use less or alternative materials while generating the least amount of CO2 during production and use. It ultimately reduces product weight, important in, say, end-of-arm tooling, letting robots carry higher loads or move faster.

“We also use out-of-the-box thinking.

We’ve been constrained for many years by established ISO, JIS or NFPA standards,” he said. For example, the norms may dictate a two-in. bore cylinder where the actual application doesn’t need those exact dimensions. SMC now offers products like non-standard 57 mm bore cylinders that match the force of a standard 63 mm cylinder in the space of a 50 mm unit. “We use less material with 50% more force. It’s a more ecological design that gives customers electrical and pneumatic energy saving.”

Some new-generation products use upwards of 90% less compressed air than in the past. They’ve revamped valve spools and physical specifications to permit the same

| Courtesy of Adobe Stock

10

FLUID POWER WORLD

6 • 2021

www.fluidpowerworld.com

flow in half the space, reducing footprint and weight by nearly 80%. Solenoid coils with energy-saving circuits keep wattage low. Air blow guns are often the worst consumers of energy in an entire plant, so new versions rely on short-duration impacts to slash air usage.

The list goes on. Suction-cup vacuum ejectors monitor pressure and switch off when unneeded. And better, they alert technicians if a dirty or worn cup needs cleaning or replacement. Finally, new pneumatic boosters are 40% more efficient, work faster, and run quieter than previous options. For many customers, it’s now practical and advantageous to lower total plant air pressure and use boosters in the few applications that truly need higher pressure. All told, such products can mean fewer or smaller compressors with less wear and tear.

Hutchinson recommends that users formulate a sustainability plan. Take advantage of software like SMC’s eTools to calculate baseline air consumption, then set goals like lowering plant pressure, eliminating leaks, or making equipment lighter or more efficient.

And once implemented, verify the results and identify where additional improvements are feasible. This straightforward process will lower air consumption, save energy and cut carbon emissions — and result in substantial cost savings.

FPW

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6/21/21 9:47 AM

ASSOCIATION WATCH Edited by Mike Santora • Editor

Registration now National Fluid open for NFPA’s 2021 Power Association IEOC in Chicago awards 15 fluid power scholarships 2021 Industry & Economic Outlook Conference (IEOC) August 16 – 18 Hilton Chicago/Oak Brook Hills Resort Oak Brook, Ill.

The NFPA Education and Technology Foundation has awarded $2,000 scholarships to fifteen students pursuing fluid power technology fields of study.

A minimum GPA of 3.0 out of 4.0, a 500-word essay, and a letter of recommendation were required from each applicant. The Foundation’s goal is to help individuals enrolled in technical schools and universities pursue their interests in fluid power.

The following students were each selected to receive a $2,000 scholarship: • • • • • • • • • • • • • • •

Ashleigh Creeger, Spokane Community College Ben Quade, Iowa State University (Raymond F. Hanley Memorial Award) Brendan McCluskey, Georgia Institute of Technology Dana Nestrick, Triton College Elizabeth Lincoln, University Of Missouri – Columbia Evan Bartelsen, University of Wisconsin – Milwaukee Joleen Nush, Spokane Community College (Robert Mackey Memorial Award) Luke Wille, Iowa State University Max Kolesnikov, Moraine Valley Community College Michael Glochowsky, Triton College Natalie Pecaro, Triton College Reagan Lawson, California Polytechnic State University Sawyer Newman, Purdue University Northwest Seth Leighton, Spokane Community College Zoe Kulphongpatana, University of Kansas

The Industry & Economic Outlook Conference (IEOC) is NFPA’s highly anticipated economic event for everyone in the fluid power supply chain – NFPA members and nonmembers alike are invited to attend. The 2021 event will return to an in-person format at the Hilton Chicago/Oak Brook Hills Resort from August 16 – 18.

As always, the event will focus on the opportunities and threats associated with the economy as they relate specifically to the fluid power industry. Industry experts will share the analyses, hard data, and critical insights fluid power business leaders need to translate economic trends into competitive intelligence and successfully plan for the future.

The conference will feature networking in a digital world, the U.S. market outlook, and the fluid power industry forecast. There will also be several options for breakout sessions that focus on mobile and industrial markets like metalworking, construction machinery, and cybersecurity — plus more.

The IEOC is also an excellent opportunity for fluid power professionals to connect in and out of the sessions. The IEOC Invitational Golf Tournament, exclusive Future Leader activities, networking receptions/meals, and committee meetings all provide unique opportunities to make the right connections for your company to get ahead.

For further information on the scholarships, contact Amy Zignego, Workforce Program Manager, at azignego@nfpa.com FPW

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6 • 2021

www.fluidpowerworld.com

FPW

IFPS announces several upcoming projects The International Fluid Power Society (IFPS) is excited to announce several projects on the horizon.

•

•

•

Just released - Upgraded Mobile Hydraulic Mechanic Certification — The Upgraded Mobile Hydraulic Mechanic (MHM) Certification Study Manual reflects the knowledge and skills needed for today’s mobile hydraulic mechanic.

Visit ifps.org/updated-mhm-certification for more information.

Just Released - Fluid Power Symbols Guide — This 30-page guide presents fluid power symbols commonly used within ISO 1219-1 and 2 standards and illustrates the component function applied within fluid power systems. Visit ifps.org/fluid-powersymbology-guide-2 to order the guide.

Mentorship Program – A pilot program is underway matching experienced leaders with

•

•

emerging professionals to build a relationship based on trust, experience exchange, support, and guidance.

Beginners Guide to Fluid Power – The Youth & Outreach Education committee is in the final stages of developing a Beginners Guide to Fluid Power to aid middle-school teachers and students involved with the NFPA Fluid Power Action Challenge.

Fluid Power Associate Certification – A Certification subcommittee is developing a new certification geared towards nontechnical fluid power professionals. Likely candidates will be administrative assistants, HR Personnel, and customer service representatives who can enhance their roles with a greater fluid power base.

Visit ifps.org for more details.

FPW

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6/21/21 9:48 AM

DESIGN NOTES Edited by Mike Santora • Editor

The project required a total of 68

hydraulic cylinders of varying sizes, with the largest stroke length being 17.2 m. As these cylinders will be exposed to the elements, and used regularly, Bosch Rexroth needed to ensure that each one was engineered to last.

Helping to keep saltwater at bay

S

Saltwater can be a challenge for farms as it limits the amount of land used to grow crops and cannot be used for any kind of irrigation. For some farms in Vietnam, this is a serious issue, especially for those between the Cái Bé and Cái Lớn rivers. Rice farms in this area have been struggling with the ingress of seawater for a long time, so the Vietnamese government decided to build a barrier system to control flows. They chose Bosch Rexroth to provide the many hydraulic cylinders required.

Once complete, the two barriers will open and close based on tidal patterns, and the idea is that they will help local farms ensure more consistent access to freshwater while limiting their exposure to saltwater.

“If you irrigate land with saltwater, not much will grow,” said Khoa Nguyen Bach, Senior Sales Manager in Vietnam. “With the new barriers, they will be able to expand the area where they can farm.

This is better for the local community and better for the economy in general as it allows for bigger crops and better yields. The barriers are big and open and close using hydraulic technology. For this project, we provided the hydraulic cylinders which move the barriers.”

Bosch Rexroth was chosen as the supplier for the hydraulic cylinders as it had already worked with the Vietnamese government on another barrier on the Mekong Delta, which is meeting the performance levels required.

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6 • 2021

www.fluidpowerworld.com

The project required a total of 68 hydraulic cylinders of varying sizes to move both of the barriers — the largest cylinder’s stroke length being 17.2m. As these cylinders will be exposed to the elements, and used regularly, Bosch Rexroth needed to ensure that each one was engineered to last.

“With cylinders like this, the rod coating is important,” explained Frank Maas, Sales Manager for Large Hydraulic Cylinders at Bosch Rexroth in the Netherlands. “We use the latest Enduroq 2200 technology, which is designed for the best possible performance and durability. We also used this on the cylinders used in the Ho Chi Minh City Flood protection project, and this is one of the reasons they came back to us.”

Bosch Rexroth is one of the few businesses capable of a delivery like this, but it was made even more demanding with a strict time frame. The request came near the end of 2019, and over a year later, all cylinders had been delivered to the site. This is a quick turnaround, especially when considering the size of the cylinders combined with the logistical challenges.

“I’m happy with the way we handled this project,” Maas said. “It’s not often that we’re asked for cylinders of this size, and to be able to deliver them in such a short time frame was impressive. The rest of the infrastructure was already in place and that shows how efficient the customer has been in building these barriers, as everything has happened so quickly. There were hundreds of people working on the project in shifts — things were happening 24 hours a day.”

Although Bosch Rexroth provided some consultancy on the hydraulic systems for this project, the main part of the delivery was the 68 cylinders, and each one of these is built to perform over many years.

Reliability is essential for technology used in these projects, as it impacts local communities and businesses, so having proven expertise and solutions, alongside confidence in the final product, was essential.

In addition to this project, there are many opportunities for Bosch and Bosch Rexroth in the future.

“It’s great to work with projects like this,” Khoa Nguyen Bach concluded. “It’s something that really will contribute to the local environment and will help people on a local level as well. It’s something that will make a big difference, and it was special to be a part of this.”

FPW

The barriers are large and open and close using hydraulic technology.

Bosch Rexroth boschrexroth.com

www.fluidpowerworld.com

6 • 2021

FLUID POWER WORLD

15

DESIGN NOTES Edited by Mike Santora • Editor

With the Renishaw RenAM 500Q,

a four-laser AM system designed for serial production applications, Domin increased its productivity and reduced its overall cost-per-part.

3D printed servovalves saves one ton of CO2 Recent decades have seen swathes of technology introduced across all industries. However, UK-based company Domin believes that there has not yet been an innovation that has caused a significant change in the fluid power market. The company’s engineers set out to develop a competitive range of servovalves and are now setting out to showcase how engineering start-ups can drive value for UK industry.

Supported by metal additive manufacturing technology from global engineering company Renishaw, the

16

FLUID POWER WORLD

Design Notes 6-21_FPW_Vs3.indd 16

6 • 2021

company has produced a first-of-its-kind product — a high-performance servovalve. The servovalve represents the company’s first step towards drastically reducing CO2 emissions from the fluid power industry — every valve can save one ton of CO2.

For Domin, metal additive manufacturing (AM) was the missing piece of the puzzle, and it turned to this technology to design its product range. This technique, where products are built up layer-by-layer from metal powder, is used across various industry sectors, including aerospace, automotive, and medical.

By using the Renishaw RenAM 500Q, a four-laser AM system designed for serial production applications, Domin increased its productivity, achieved design freedom, and reduce cost per part in such a way that 3D printing presented a compelling case for use in hydraulic manufacturing.

“There is a pressing reason disruption is needed — sustainability. In the US, the fluid power sector alone wastes about 300 million tons of CO2 per year through system inefficiencies,” said Marcus Pont, Chief Executive Officer of Domin. “To put this into context, this is about the same as the total output for all CO2 emissions in the UK. More efficient technology could make a real difference to global emissions.”

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4001 FP

Domin’s electrohydraulic valves are designed for the most demanding servo applications and are marketed as small, light, affordable, and high-performance products that are easy to configure online, offering good power density and dynamic performance. Pont sees this product range as just the first step in creating change in fluid power systems across the UK; “every valve saves over one ton of CO2 per year compared with alternative products”.

Long term, Domin plans to start manufacturing and selling complete systems. It is already working on some high-profile projects, which Pont says includes developing a new suspension system with Aston Martin Lagonda.

FPW

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DESIGN NOTES Edited by Mike Santora • Editor

Vacuum handling systems for industrial applications Vacuum handling systems in industry must respond to very diverse requirements, gripping parts of different weights or materials, integration on machines and robots, and high-speed operation. Coval’s GVMAX HD series of heavy-duty vacuum pumps combine robustness, power, modularity, and

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Coval’s GVMAX HD series of heavy-

communication, allowing them to adapt

duty vacuum pumps combine robustness, power, modularity, and communication, allowing them to adapt to multiple applications.

to multiple applications. With IO-Link

FLUID POWER WORLD

technology, they are fully plugged in to the Industry of the future.

IO-Link and NFC ease communication

The IO-Link communication interface of the Coval GVMAX HD vacuum pumps makes installation fast and economical, supports continuous diagnostics, centralized parametrization, and efficient communication with higher-level protocols (Ethernet/IP, PROFINET, EtherCAT).

With the NFC technology integrated into the GVMAX HD vacuum pumps, all parametrization and diagnostic functions are accessible and can be modified in the dedicated COVAL Vacuum Manager app on an Android or IOS mobile device. The NFC interface combined with the app makes it possible to copy parameters from one pump to another easily and can store up to five different parameter configurations.

Product ergonomics have been centered on the operator, with a Human Machine Interface (HMI) that makes the operating, diagnostic, and maintenance information easy to read and allows parameters to be set up rapidly. The 1.54-in. color LCD display is intuitive, with explicit messages in 5 languages. The pump status is highly-visible thanks to a 3-color status light.

With the GVMAX HD vacuum pumps, the user can benefit from technical assistance thanks to the data sent by the application to the Coval engineering team.

The new GVMAX HD vacuum pump is designed to permanently communicate with its environment, ready to play its part to the full in Industry 4.0.

Equipped with a single-stage venturi, the GVMAX HD vacuum pump delivers powerful suction rates and reduced

emptying times for gripping, transferring or clamping parts of various sizes and weights. For example, maximum vacuum is 85%, suction flow rate up to 230 Nl/min and 0.4 s to empty a volume of 1 litre at 75% vacuum. Each component has been designed and tested in real-life situations to meet the toughest environmental conditions. As such, the pumps are IP65 and guaranteed for more than 50 million cycles.

The performance of the vacuum pumps comes along with reduced energy consumption. The ASC (Air Saving Control) technology, which provides intelligent vacuum regulation by stopping air consumption when the set vacuum level is reached, offers up to 90% energy savings.

The GVMAX HD series is designed to allow quick and easy maintenance while minimizing the impact on production. The Smart Swap system, a Coval innovation, allows pumps to be replaced while under pressure and without needing tools. Also, the modular design of the GVMAX HD makes it possible to make targeted interventions on each pump element, simultaneously lowering costs and intervention time.

It is possible to install each pump as a stand-alone assembly or as an island assembly of up to 4 pumps with an internal pressure common.

FPW

COVAL coval-international.com

With the NFC technology

integrated into the GVMAX HD vacuum pumps, all parametrization and diagnostic functions are accessible and can be modified in the dedicated COVAL Vacuum Manager app on an Android or IOS mobile device.

FLUID POWER WORLD

21

FUNDAMENTALS Josh Cosford • Contributing Editor

Symbology 401 – Logic Elements Logic elements are fantastic little creatures. Sometimes call DIN valves or slip-in cartridge valves, they are the most basic valve design capable of controlling direction, flow and pressure. Their simple poppet construction nearly guarantees reliability while flowing upwards of a thousand gallons per minute or more. Unlike most of the Symbology series, this one requires some primer to grasp fully.

The ISO symbol depicts a 2/2 directional valve’s traditional dual box, which I show normally-closed with a spring offset. Following the pilot lines from either A or B to the left, they both push against the operator side with different forces. Typically, the A-side area offers half the area to push against as the B-side. The A-side’s smaller cone resides at the bottom of the seat and blocks the A-port (sometimes called Port 1), while the annular B-side spans the diameter of the poppet minus the diameter of the A-side.

Logic elements (Figure 1) are machined steel poppet valves traditionally ranging from 16 to 125 mm, as defined by the valves “B-port” diameter. The two-way poppet valve resides within the fixed sleeve or bush, installed into a large, machined and ported manifold block. Sitting atop every logic element is a cover not only to hold the spring-loaded cartridge valve in place but also to provide a method to control the valve’s operation. This directional, pressure or flow control valve atop the cover acts upon the logic element with pilot passage to produce one of the three primary hydraulic functions.

Moving along to the symbology used for a single logic element, as shown in Figure 2, I show two different versions of the same symbol.

The first is the ISO 1219 symbol, which should be your first choice when designing logic element schematics. However, my personal preference lies with the DIN symbol of the same valve. I find the DIN symbol better expresses what is happening inside the valve.

Figure 1. Slip in cartridge valves 20

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Figure 2. A comparison of basic logic elements as ISO 1219 and DIN symbols

Opposing both the A- and B-side, the spring side area equals the combined area of A+B and benefits from the strength of the spring to help keep the poppet seated. What’s not shown in the basic symbols of Figure 2 is the cover, and its method of controlling the X pilot port, which I will discuss shortly.

Reading the previous two paragraphs while now inspecting the DIN symbol for the same valve likely provides more clarity. The symbol itself more accurately represents a poppet valve, where you can see the A-side and its smaller area relative to the B-side. So long as pilot pressure is minimal across the X-side area, any pressure at A or B will lift the poppet off its seat. The B-side requires half the pressure as A-side to directly open the valve, allowing flow to occur.

Moving along to Figure 3, you can see I’ve constructed what appears to be an overly complex circuit controlling just one cylinder.

Valve 1 on the left is the ISO version of the symbol, while the remaining three use the DIN symbology to make things confusing. However, as mentioned, I prefer the DIN symbol, which indicates the actual valve construction, providing a more intuitive sense of operation.

Logic elements are useless without pilot control, so each valve gets its marching orders from the pilot valve above. Tracing the orange pilot line from where it tees off from the main pump line, you’ll find it travels up and around to each of the pilot valves. The

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pilot valves are discreet functions that either transmit full pilot pressure into the poppet’s spring side or open the same chamber to the tank. When the spring chamber is open to the tank, the poppet is at the mercy of any pressure from the A and B ports. The poppet opens any time A and B pressure exceeds the force of the spring.

I’ve drawn the circuit showing the cylinder retracting under pressure, and each of the four valves reflects what must occur when four pairs of valves are used to mimic a single 4/3 valve. Valves 1 and 2 handle the cylinder’s cap port via their B-ports, while valves 3 and 4 take care of the rod side action. Below the logic elements, the A-port paths from valves 1 and 3 connect to the primary pump pressure, while the A-ports of 2 and 4 run parallel with the tank line.

Pilot pressure keeps valves 1 and 4 locked in place, while the pilot valves 2a and 3a have opened the spring chamber of their respective main stage valves directly to tank. The pressure acting on valve 3’s A-side easily overcomes the spring force, opening the poppet where the extra force on the B-area keeps the valve wide open. However, the pressure at the B-area of valve 4 cannot overcome the larger X-side surface area above, so valve 4 remains locked.

Flow continues through valve 3, subsequently flowing into the rod port of the cylinder. Force against the rod side means force is also created on the piston side, which in turn flows down into the B-side chamber of valve 2. The backpressure created during retraction forces open the B-area poppet, providing a path to tank. Essentially, just opening valves 2 and 3 can retract the cylinder.

Conversely, opening only logic elements 1 and 4 extend the cylinder.

Besides the advantage of high flow, there are clever tricks possible with logic elements. Using this same circuit, for example, opening valves 3 and 4 unloads the pump, which is essential for open circuit systems. Also, simply opening valve 1 puts the cylinder into regeneration mode, sending rod side fluid to pass through valve 3 to join pump flow in speeding up the cylinder.

Logic elements, as mentioned earlier, also operate in these circuits as pressure and flow valves. I’ve shown a relief valve example and displayed a group of symbols missing from the directional valves. The enclosure surrounding the relief valve represents the cover, as shown sandwiched between the pilot valves and the

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FUNDAMENTALS

manifold in Figure 1. This cover houses a pilot relief valve and two orifices.

The pilot source is the X-line teed in from the pressure line, itself in parallel with the pump’s pressure line and the A-Port of the slip-in relief valve. The first orifice on the supply side limits pilot flow into the pilot valve, preventing it from being over-saturated at any given time. The second orifice dampens the main-stage relief valve’s action, preventing some pressure spikes that may quickly open and close the pilot valve from doing the same to the main stage.

This relief valve symbol is the basis for many other valve functions using logic elements: counterbalance valves, sequence valves, flow controls and even proportional valves.

All logic elements use pilot control of the spring chamber to mimic a hydraulic system’s traditional valves. Imagine, for example, a proportional pressure reducing valve instead of the relief valve pilot. Electrohydraulically controlling the spring chamber in effect controls the flow rate possible through ports A and B of the poppet.

This example is elementary, and real-life examples of logic element circuits reach dizzying proportions, with myriad possible combinations of valves, pilots and controls. If you can study logic element schematics, you will appreciate the ingenuity and creativity possible.

Figure 3. Logic element circuit

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FLUID POWER TRAINING

GOES LIVE NEW LIVE STREAM TR AINING SERIES

brought to you by Carl Dyke from LunchBoxSessions.com June 24 Hydrostatic Drives Get ready for some hydrostatic fun as Carl takes you around a closed-loop, hydrostatic system in real life and in simulation mode. You’ll want to keep your system from overheating this summer and pose a question or two about function and maintenance in this interactive YouTube Live event on June 24.

July 22 Load Holding and Motion Control Valves

ADDITIONAL SESSIONS September 2, 2021 Electronic Controls & Sensors for Hydraulic Systems September 28, 2021 Extra Pressure & Extra Flow Intensifiers & Accumulators

SIGN UP TODAY AT

Don’t go into freefall! Keep control of load lowering and load holding with counterbalance valves, pilot-operated check valves and other types of load control valves.

Carl is looking forward to a conversation with you during this YouTube Live event on July 22.

www.lunchboxsessions.com/live to be notified of these training sessions and also get a reminder 1 hour before each session goes live!

Presented in partnership with:

For past and future fluid power training sessions, go to: www.lunchboxsessions.com/live

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www.lunchboxsessions.com/live

TRAINING Mary C. Gannon • Editor

LunchBox Sessions and FPW take to YouTube Live again Last year, Fluid Power World partnered with the experts at Lunchbox Sessions to promote special, free YouTube Live training sessions to bring accessible fluid power training to the world during lockdown. And although many people are back at work, there is always a need for quality education on hydraulic systems, so we are continuing this partnership. LunchBox Sessions YouTube Live will return four times this summer and fall, on Tuesdays June 24, July 22 and September 2 and Thursday, September 28 at 12 p.m. EDT, in which Carl Dyke will use operating cutaways and his popular Live Schematics to bring hydraulic technologies to life.

Tune in for the summer sessions listed below:

June 24

Hydrostatic Drives — Get ready for some hydrostatic fun as Carl takes you around a closed-loop, hydrostatic system in real life and in simulation mode. You’ll want to keep your system from overheating this summer and pose a question or two about function and maintenance in this interactive YouTube Live event on June 24.

July 22

Load Holding and Motion Control Valves — Don’t go into freefall! Keep control of load lowering and load holding with counterbalance valves, pilot operated check valves and other types of load control valves. Carl is looking forward to a conversation with you during this YouTube Live event on July 22.

After a break in August, Dyke will return with two Live presentations on September 2, with Electronic Controls and Sensors for Hydraulic Systems and September 28, with Extra Pressure and Extra Flow (Intensifiers and Accumulators).

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www.fluidpowerworld.com

Attendees can interact throughout the live video by logging into their Google or YouTube account. Questions and comments can be posed to Dyke this way.

To see all the live sessions from 2020, search or subscribe to LunchBox Sessions’ YouTube channel. The following topics were discussed: • • • • • • • • •

Pilot Pressure Control: Manual Joysticks to Electronics Proportional Directional Valves: Fun With Electro-Hydraulics Pilot Operated Pressure Relief Valves Piston Pumps: Displacement & Pressure Cutoff Particle Contamination: Seeing Is Believing Servo Valves: Live and in 3D Slip-in Cartridge Valves: Simply Logical Flow Load Sensing Systems: Pump Control & Valve Bank Mysteries Piston Pumps: Displacement & Pressure Cutoff

Visit lunchboxsessions.com/live on the day before the live sessions to obtain the live video link.

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6/21/21 9:49 AM

ENERGY EFFICIENCY Ron Marshall • Contributing Editor

The “MBWA” compressed air strategy The old concept of MBWA — management by walking around — applies both to people, and surprisingly, to compressed air systems. Let’s take a look at a specific example that saved one company a whole lot of money.

A measurement system was recently installed as part of a compressed air improvement project at a home products company. New, more efficient air compressors and dryers were installed, and significant leakage repair done to reduce system energy consumption. The measurement system monitored the pressure, power, and flow of the air compressors. This was done both before and after the system upgrade in order to verify that the project was meeting the energy savings goals.

Early into the monitoring of the final results, the monitoring system detected an abnormally high air flow during nonproduction hours. An automatic email alert was sent to local system operators who were always onsite, 24 hours a day, supervising the site boiler system. Based on this information, the operators started a walk-around of the very large plant to try to find any problems.

Within an hour, the shift operator responded that an obvious, large “leak” was found by ear within the enclosure of a piece of processing equipment. Due to the high ambient noise during the normal production hours, this air demand could not typically be heard. The air demand turned out to be a large air knife that had been left to flow continuously, due to a failed solenoid valve. If this 160-cfm air demand had not been detected, it would have contributed $24,000 per year in compressed air system electrical costs.

It pays to monitor compressed air systems — and to occasionally investigate by simply walking around your equipment!

FPW

| Courtesy of Adobe Stock

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P N E U M A T I C S

Pulsed air boosts

pneumatic efficiency The AirFlowSaver supplies energy- and cost-optimized compressed air based on unique SmartValve technology.

Wolfgang Teichmann, CEO and Markus Koenig, CSO, KTW Technology, Wehr, Germany Andy Pott, Vice President, PHIR Technologies, Hartland, Wisconsin

For well over a century, compressed air has been commonly used across many industries because it is a simple, flexible and often indispensable source of energy.

Unfortunately, it’s also expensive — in some cases up to ten times more so than electricity.

With growing regulatory and societal pressures to sustainably use resources and mitigate climate change, many companies are looking to reduce the energy consumption in their compressed air systems. Minimizing leaks is one obvious target. And projects to modernize systems and cut costs tend to focus on the generation side, usually by adding new high-efficiency compressors.

Often overlooked but even more important are efforts to optimize consumption at the point of use. Reducing the demand for compressed air in existing applications lets engineers downsize the entire compressed air system, eliminating costly and wasteful over capacities and unnecessary capital investments.

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KTW’s AirFlowSaver does just that. It saves energy by reducing the amount of compressed air required by 60 to 90% across a broad range of industrial applications. At the same time, it maintains or improves overall system performance.

Operating principle

The AirFlowSaver (AFS) is an integrated system that cuts air consumption while increasing the output force by converting continuous air flows into sharp and powerful pulses that can last only milliseconds if, for example, a product passes a sensor.

In typical compressed-air systems, initial start-up generates a momentary high-force impulse that quickly decreases as it reaches steady-state conditions. The AirFlowSaver exploits this characteristic by quickly and repeatedly generating high-frequency compressed air blasts.

Thus, it maintains a greater force output and lets equipment do more work with faster process times, significantly improving effectiveness in blowoff, cooling, cleaning and drying operations.

At the same time, because the air stream is pulsating and not flowing continuously and blowing only if needed, it significantly reduces the amount of compressed air required, cutting costs. The AirFlowSaver is suited for more than 70% of all compressed air applications.

Some previous attempts have been made at pulsing control in compressed air systems, with limited success. For example, in the past few years valves with modified solenoids have been promoted as using pulsing to save on compressed air. These devices claim energy savings of almost 50%, but savings are more realistically around 25%. Otherwise, outlet force drops too low to be advantageous in most installations. The units are also highly sensitive to back pressure in the airline, so reliability becomes an issue. And these pulsing systems are limited to about 15 Hz frequency and, thus, too slow to adequately clean or dry parts traveling along fast-moving production lines.

The AirFlowSaver is well suited for scrubbing and drying packaged goods, beverage containers and countless other products.

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P N E U M A T I C S

SmartValve in action

The basis for the AirFlowSaver system is KTW’s SmartValve, a new type of flow-control valve that relies on a magnetized ball as the fluid-control element. In addition to use with compressed air, the ultrafast switching valve can handle other gases and liquids in dosing systems, sprayers, injectors and many other applications that demand better control and sizable energy savings.

SmartValve technology was originally developed by the German Aerospace Center (DLR) for the European space mission Rosetta, as a cold gas control valve for the Philae lander – the craft which made the first-ever soft landing on a comet nucleus. Over the last few years KTW engineers have further refined the valve design for industrial applications, produced a range of sizes, and developed the power electronics that provides closed-loop control.

The SmartValve features a simple, robust and reliable design. The only moving internal part is a ball that opens and closes the valve. No other components like springs or membranes are necessary.

At rest, a pressure differential between the valve inlet and outlet keeps the ball on the valve seat. To actuate the valve, electric current energizes a solenoid coil in the valve housing. The resulting magnetic field force laterally pulls the ball off the seat — permitting flow.

Shutting off power eliminates the magnetic field, flow forces return the ball back to the seat, and the valve closes. Extremely fast (1 msec), direct and stochastic switching allows for real-time applications. The fail-safe valve closes automatically in case of power loss.

SmartValves typically operate with pressure differentials of between 1 and 10 bar (14.5 to 145 psi), and system pressures can range up to 1,000 bar. Customized versions address special customer requirements. KTW has developed valves to work at pressure differentials of approximately 600 bar and at temperatures as low as -200° C (-328° F) and as high as 400° C (752° F).

Ball and valve seat diameters, and the magnetic system, determine operating characteristics like opening force and switching speed. Varying these parameters lets engineers easily adapt the valve to suit different requirements and applications.

For example, applying higher current opens the valve faster, although actual switching speed depends on the fluid and pressure differential. Accuracy depends on the size of the valve and the fluid forces but, in general, pulse-to-pulse repeatability is extremely high, provided that the pressure differential is fairly constant.

The ball, seat and other parts in contact with media are made of stainless steel, and working surfaces are polished. However,

Closed

SmartValves rely on a magnetized ball as the fluid-control element. With no power to the solenoid, a pressure differential holds the ball on the seat and the valve remains closed.

Energizing the solenoid coil generates a magnetic field force that laterally pulls the ball off the seat, permitting flow.

Open

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SmartValve technology

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Flow rate

Potential energy and air consumption savings

Pulsed flow

Pulsing frequency

Continuous flow

(fixed or variable)

Force

Less air, more force High-frequency pulsing

Increased effective force Pulsed flow

Time

certain plastics, such as PEEK, can be used for the valve seat if required. Thanks to the low-friction, low-wear design and minimal mechanical load, the valve has an extremely long service life of more than three billion switching cycles.

The valve resists corrosion and KTW engineers recommend use with particle-free media or installing proper filtration to extract solid contaminants. Unchecked, dirt and debris could lodge between ball and seat and lead to leakage past the valve. Maintenance technicians can remove troublesome contamination by opening the valve and cleaning the seat. Damaged balls and seats are easily replaced.

System considerations

AirFlowSaver performance can be scaled as needed thanks to four standard valve sizes. The smallest offers maximum flow rate of about 14 m3/hr (8.24 cfm); the largest approximately 75 m3/hr (44.14 cfm). Also, a three-ball version produces maximum flow of 85 m3/hr (50.03 cfm).

In addition to the SmartValve, other essential AirFlowSaver components include the valve controller, power supply, and sensors that initiate start/stop actions (trigger event). Also critical to overall system performance are application-specific output nozzles and air knives that come in numerous shapes, types and sizes. They optimize flow output, reduce noise and direct the pulsating compressed airstream to the desired target.

Time

All the components are functionally fine-tuned to match the system’s flow, force and efficiency strategy and offer maximum benefits in each specific application.

The AirFlowSaver has three operating modes: • • •

Continuous flow

Continuous pulsing at a predetermined frequency over a fixed time.

Continuous pulsing with a frequency that varies over time.

Event-controlled, for example initiated by a sensor signal.

High-performance applications in terms of frequency and flow need closed-loop current control to ensure precise and repeatable valve behavior. KTW’s proprietary Controller Output Stage operates SmartValves at high speeds (reaction time from trigger input to switch of valve = 1 msec) and short switching cycles (from fully closed to fully open to fully closed within 1.5 to 2.0 msec). Depending on the size and media, customized valves can run at frequencies of up to 3,000 Hz. Duration and frequency of the pulses can be adjusted via parameters in the Output Stage, and pulse-width modulation can control flow linearly. Between fully closed (zero flow) and fully open (maximum flow) every flow rate value can be adjusted by varying the pulsing length and frequency – which means the unit can serve as a proportional valve.

Fast opening and closing of the valve requires a high operating voltage. The Output www.fluidpowerworld.com

The AirFlowSaver is an integrated system that cuts air consumption while increasing output force by converting continuous air flows into sharp and powerful pulses that can last only milliseconds.

Stage combines an operating voltage of up to 48 V with closed-loop current control of up to 12 A per channel. Alternatively, it supplies 24 V for lower performance/lower speed applications (two valves per output stage). The Output Stage incorporates the latest MosFET technology to guarantee high output power of over 2 × 500 W. However, actual power consumption is relatively low (≈20 Whr at 10 Hz) because maximum power is only required for the very short duration needed to overcome pressure forces and lift the ball off the seat.

The current control loops also rely on Hall-effect current sensors and FPGA-based state machine logic. A 32-bit microcontroller enables customizable parametrization to match a customer’s individual needs.

Communication with the system is via intuitive software (USB interface) or a CANbus network. Thus, users can manipulate valve/ pulsing parameters in real time.

Application benefits

Experience at customer installations shows that the AirFlowSaver reduces compressed air-consumption by 60% to 90% — resulting in significant energy savings along with a 6 • 2021

FLUID POWER WORLD

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P N E U M A T I C S

This automated CNC production line takes advantage of an AirFlowSaver. The pulsed air stream removes coolant and chips, cleaning and drying the workpieces.

Networked to a sensor, it only runs when a part is present, significantly reducing air consumption.

corresponding reduction in CO2 emissions. Just as important, it improves process quality, as the pulsed beam generates about 15 to 20% higher impulse force compared to a continuous flow. That, in turn, can speed processes and improve productivity.

Depending on the installation, it lets users downsize the compressed air system and avoid unnecessary capital spending. Long service life of the solenoid valve (>3 billion switching cycles), high reliability and a maintenance-friendly design equate to increased equipment and plant availability. And energy efficiency upgrades may qualify for tax benefits.

All told, investments in the AirFlowSaver show payback (ROI) in less than one year.

The AirFlowSaver can operate as a standalone unit or as part of an integrated system.

The modular design permits distributed mounting of individual components and, thus, can be easily configured and adapted to almost any application and any orientation. And the system is readily scalable in throughput and force via the number and size of valves.

It is suitable for a wide variety of uses, such as for blow-off, drying, degreasing, cleaning, material handling and certain pneumatic control tasks. Specific applications where the new pulse system shows tremendous promise include: • •

• •

Drying packaged products or beverage containers. Because they are often discretely moving on conveying lines and spaced apart, an on-off system is of great benefit.

Removing unwanted matter. The inherent scrubbing action can remove sticky material from parts with an oily residue. Or similarly, cleaning rough surfaces like wood, where pulsing action helps dislodge hard-to-remove debris.

Part ejection. The amplified force action can move heavier parts on conveying systems.

Cleaning parts. Combining the pulse system with air knives and static eliminators produces cleaner parts in the semiconductor industry. The same holds in painting operations, in particular those involving plastic auto bumpers, door panels and instrument clusters.

Engineers should consider the AirFlowSaver in any industry that is plagued by high consumption of compressed air. That includes metalworking, packaging and beverage bottling, electronics production, painting, and paper, wood and furniture manufacturing, just to name a few.

FPW

PHIR Technologies, Hartland, Wis., represents KTW Technology GmbH in North America.

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MOST

automated machines and systems incorporate some number of enclosures and panels for housing controls components. However, these centralized

devices typically must interconnect with many more field sensors and other equipment which could be some distance away. Many years ago, hardware designers knew it made good sense to push some of the control elements out of main control panels and closer to the field devices they connect to, minimizing field wiring and installation costs.

This concept of distributed control for industrial automation has been around for some time, developing just a while after the programmable logic controller (PLC) was invented.

Available distributed control options have expanded greatly over the years, with many new device types and other capabilities, such as advanced networking and fieldbus protocols.

One example is intelligent electro-pneumatic solenoid manifolds, which can be distributed throughout a machine or system, and networked to a controller. But before we examine these solutions, let’s take a look at how we arrived at these advances.

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Going the distance

Distributed control started as input/output (I/O) blocks located remotely from the controller, allowing automation to reach relatively distant areas that might only need a small number of I/O. Each location where an I/O block was located was sometimes called a drop.

These first I/O blocks came in a few fixed sizes, point counts, and signal types (discrete or analog), giving engineers and designers some flexibility as systems and I/O counts grew larger and more dispersed.

One initial problem was a lack of modularity and a one-sizefits-all mentality. It was great to reach remote areas using a single communications cable, instead of needing an electrician to install multiple wires and cables to something 400 feet away. However, if only a few I/O points were needed, or if the point count did not conveniently match available modules, then there would be excessive spare points, which made remote I/O less economical. So sometimes remote I/O was a little wasteful, but this was what was available at the time.

Another problem with these older I/O blocks was the simple serial networks they supported. Modbus RTU was common with many vendors, but quite a few used proprietary serial networks.

Serial networks of any type could be very reliable, but also experienced or required: • • • • •

Noise and grounding issues, which slowed or disrupted communications.

Specific topology layouts and termination requirements.

Low limitations on the number of nodes.

Architectures which could constrain convenient future expansion.

Non-compliant installations that could run for many years, then unexpectedly fail.

Modularity modernization

PLCs and automation distributed control went through some growth and evolution as manufacturers saw the need for modularity. PLCs were already becoming more modular — with remote racks, CPU cards, and separate communication adapter cards — providing more flexibility to mix-and-match configurations.

Soon manufacturers developed products specifically designed for distributed field I/O, and then smarter and more modern networks and protocols to support these devices. CANbus for DeviceNet was one example, but today the most popular choice is Ethernet media for distributed I/O, with protocols such as Modbus TCP and EtherNet/IP.

Eventually, field I/O systems became more compact and affordable, reinforcing the benefit of installing remote I/O devices closer to field equipment. Today, these distributed I/O systems are scalable, affordable, and supported by many different industrial communications networks and vendors. Small, low-density I/O modules — often known as point I/O or slice I/O — are ideal for locations like a start/stop pushbutton station with just a few I/O points. Other high-density options might use a larger rack configuration and handle large amounts of I/O.

Another advancement was improved environmental ratings, which enabled I/O components to be installed outside of control panels as direct machine-mounted devices, even in washdown environments. This can save even more design and installation costs, while making it easier to maintain equipment.

Enlightened electro-pneumatics

One need not spend much time around industrial machinery or automation to learn that pneumatics go hand in hand with control systems. Pneumatics are one of the most common ways to perform physical actions and movements with automated equipment.

Whether it is performing a press action, lifting, indexing, or diverting with a pneumatic cylinder or airbag — pneumatics are everywhere on automated equipment.

Standard solenoids are individual devices, each requiring air tubing connections and wiring. Many solenoids could be grouped into a single manifold, called a modular pneumatic valve bank, to simplify the air supply tubing somewhat, but each still needed hardwiring (Figure 1).

Therefore, just as with I/O, there was a growing need for better ways to install distributed pneumatic solenoid valves, especially for small to medium quantities of actuators in more remote areas. As

All figures courtesy of AutomationDirect

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P N E U M A T I C S

with I/O, the best case would be a system needing just one network connection.

Of course, pneumatic modularity remains important, both for the number of solenoids at a drop and the ability to choose among 3-, 4-, and 5-way, and 2- or 3-position configurations. The system also needs to accept one or more air supplies for each drop, and each solenoid must offer a high enough Cv rating to support the flow needed to operate the equipment.

The solution is known as a modular electro-pneumatic valve bank, which allows multiple individual valve modules to be installed in one manifold assembly. This assembly will typically need only one air input, although additional inputs may be optional if other pressures and flows are needed. All of the electrical wiring is concentrated at this location, simplifying installation, reducing wiring errors, and making the system much easier to troubleshoot.

Distributing multiple valve manifolds around a machine can also simplify tubing runs and shorten airlines to cylinders and actuators, resulting in simpler integration and faster actuator response. Some manifolds are available with environmental rating options so they can be installed away from electrical panel hazards and right on machines, even in washdown environments.

Not only do these modular valve manifolds work with popular Ethernet industrial protocols, but some provide the

Figure 1: Pneumatic valve banks are a compact way to simplify plumbing, but they still require many hardwired signals.

Figure 2: Electro-pneumatic systems, like this AutomationDirect PAL assembly, combine modular pneumatics, flexible I/O, network communications, and IP65 surface-mount capability.

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option to add I/O modules in conjunction with pneumatic modules. Pneumatics and instrumentation exist together on machines, so the ability to group solenoids and I/O in one drop is a great benefit. A single assembly combines various solenoid valve types, digital and/or analog I/O, and common power sources for all of the above. Many different configurations can be created using a limited variety of basic components, with the I/O providing local control and monitoring.

Flexible fit

Electro-pneumatic systems are very versatile as they can be used for just field I/O or pneumatic solenoids, or a combination in one unit (Figure 2). This comes in handy for OEM machine builders and system integrators, who can standardize on designs, vendors, protocols, parts ordering, and products to meet all their automation needs.

The field I/O side of electro-pneumatic systems are comparable to other remote I/O systems in terms of scalability, footprint, and cost. The same can be said for the solenoid valve side of these systems when compared to hardwired modular pneumatic valve banks.

Valves are compact, yet they have high flow ratings (Cv) and good performance.

Environmental ratings for modular electro-pneumatic systems also align with the other types of individual devices. Some require installation in an enclosure, while others can be machine mounted, with suitable environmental ratings.

Electro-mechanical systems can usually be split into separate physical subsystems while still using only one network connection.

Designers can take advantage of this modularity feature for best operational performance and installation simplicity. This especially makes sense where systems are organized into zones or cells, and each section should have localized automation components. These production lines can be shop-assembled and tested as a whole, and then broken down into convenient sections for shipping and field installation.

Only minimal network and pneumatic connections are required in the field when this approach is used (Figure 3).

Some installations — such as packaging lines and the associated box forming, conveying, filling, labelling, and palletizing equipment — are organized through a spread-out area with relatively low I/O densities and pneumatics needs.

These applications are ideal candidates for applying electro-pneumatics precisely where they are needed.

Electro-pneumatic manifolds deliver choices

Electro-pneumatic systems are a versatile solution for providing I/O connections and pneumatic solenoid valves in a modular form factor at remote locations. This gives designers far more options for building effective automation systems. Intelligent manifolds also save space and reduce the need for control enclosures, while minimizing the effort and cost of wiring and plumbing.

Electro-pneumatic systems are easier to maintain, and they deliver more information to and from supervisory automation systems for better control and diagnostics. Installations using this approach are very neat and clean, with future expansions easy to implement.

For these and other reasons, designers should work with suppliers of electro-pneumatic manifolds to see how they can improve their machine automation systems.

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AutomationDirect | automationdirect.com

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Figure 3: AutomationDirect PAL modular electro-pneumatic installations provide many options for OEMs and system designers to distribute pneumatics and I/O in an organized way throughout an automated machine or system.

M O B I L E

H Y D R A U L I C S

Precision is key in agricultural machinery BY: Josh Cosford, Contributing Editor

The use of GPS technology, coupled with the power and precision of hydraulics, ensures modern farming success.

The Fendt Momentum planter from AGCO is the most agronomically advanced planter available worldwide and is designed to consistently place every seed at the optimum depth and spacing while minimizing compaction and eliminating pinch rows. Seeding machines like these rely on the power and precision of fluid power.

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It's challenging to find an industry older than agriculture.

Humans have been farming for over twelve millennia based on current estimates, making agriculture easily more mature than all other industries outside of carpentry. Civilization’s need for nourishment is unlikely to wane, all but guaranteeing our agriculture industry receives the latest technology to keep up with population growth.

The tools at the farmer’s disposal continue to expand in leaps, where particular technologies reshape the industry as a whole. The scythe, cotton gin, and combine harvester were responsible for marked improvements in crop yields and processing. Technology offers us exponentially higher productivity, so it’s no surprise that the past few decades realized advancements to improve agricultural machinery as well.

Mega-machines need big power

Many people are entirely blind to the scope of technology offered to the Ag industry. The small farm you pass on a country drive does little to represent the scope of advanced farming, especially concerning machinery. The hobby tractor pulling a single-bottom plow hardy represents the state of machinery exploited by vast farms spanning thousands of acres.

In fact, the purchase price of a single large tractor may surpass the cost of purchasing a small farm. If a hobby tractor offers little more than a hitch, PTO and one or two hydraulic remotes, what does a fully specced, modern tractor the price of a hypercar offer? A whole lot, as it turns out.

Much of what you get in a million-dollar tractor is neither specific to hydraulic nor related to advanced technology. You get very large diesel powerplants to the tune of 13 liters or more of displacement, perhaps with B20 biodiesel capability. Expect 500 or 600 hp, 4WD and Tier 4 Final compliance. The technology to provide a high-horsepower tractor with Tier 4 Final compliance could quickly fill the space of this entire article. But know that off-highway engines are just as technologically advanced as those in light vehicles.

The mega-tractor employs an impressive array of hydraulic power and sophistication. Expect well over a hundred gallons per minute of flow from their pressure-compensated, loading-sensing piston pumps. Flow may be shared with up to eight pairs of hydraulic outputs, providing powerful and accurate control of attachments. Sophisticated electrohydraulic draft control ensures attachment depth remains constant with no operator interaction.

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GPS and elaborate machine control hardware allow a tractor to follow intricately mapped, hands-free routes through a field. | courtesy of Adobe Stock

Sophisticated controls

Speaking of control; the days of directional control valves, or even pilot joysticks, taking up valuable operating room in the cab are long gone. Expect fully electro-proportional control with programmable user profiles. Nearly all tractor operations lay at the operator’s fingertips, making even the most difficult ISOBUS-compliant implement easy to control.

ISOBUS is a communication protocol standardized for Ag equipment. The ISOBUS system permits the computer systems in tractors and implements to speak to each other regardless of the machine manufacturer.

ISOBUS provides freedom to the farmer, no

longer married to a specific manufacturer with proprietary control systems.

The modern tractor offers display systems rivalling your iPad (in fact, some tractors indeed use actual Apple iPads). With ISOBUS, the implement or machine sends the same user interface to the display, which works and appears as it would on any other machine. Implement manufacturers now offer sophisticated control entirely customizable on the fly from the tractor’s touchscreen.

Monitoring and then changing the boom geometry of your sprayer, for example, is easily accomplished by the operator when sensors detect poor geopositioning after a turn.

The Sunflower 9830NT Series air drill from AGCO is a fieldproven, single-rank, single-disc opener system that delivers the precise, high-speed seeding performance farmers need to plant more acres in less time. The 9830NT provides a large capacity, two-compartment seed tank and a narrow, 11.5-foot transport width to give it exceptional versatility and performance.

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Some of the most demanding hydraulic applications are large air seeders, the largest of which span more than 100 ft wide and weigh upwards of 35 tons. Able to plant over a hundred seed rows at once with hydraulic cylinders automatically controlling seed and fertilizer depth, the entire control system links to the ISOBUS interface inside the tractor. The operator can monitor and change seed depth and spacing, even mapping where seed skips or multiples occur. The air seeder tank scales employ load cells to measure the mass of the seeds left in the tank, and the controller extrapolates the overall application rate.

GPS and sensors enable machine control

Autoguidance systems proudly stand atop the stage with previous technological advancements in agriculture. Using global positioning and elaborate machine control hardware, a tractor may follow intricately mapped, hands-free routes through a field.

The farmer will pre-route the guidance via computer using high-resolution satellite maps. Further, personnel back at the office may upload new maps or guidance on the fly when field conditions change, such as changing weather or field conditions.

Field mapping grows upon the GPS autoguidance systems that offer accurate maps of fields and combines those maps with real-world data on crop yields. During harvesting, sensors measure and track crop yield in real-time and maps are uploaded to show the farmer current and historical field performance.

Areas with low yield get flagged as a concern, so the farmer may sample soil after to

M O B I L E

see if it’s a soil concern. There may be a drain tile line or other reason for the poor yield. However, weeds, insects and diseases are more than likely the concern. Satellite imagery allows in-season expression of poor performing areas, which allows the farmer to inspect for problems.

Maps may be overlayed to cross-reference previous seasons. Springtime applications of herbicide, fertilizer, cation exchange capacity etc., can be compared to see how yields were affected by changes in the application. Although field mapping is nearly as old as global positioning systems, today’s systems offer precision and ease of implementation for even the smallest farms.

Hydraulics is the cornerstone

to improve the accuracy of seed, fertilizer and other treatments.

Imagine combining field mapping with fertilizer application rates accurate to a quarter of an inch, then using that data in the following seasons to improve yields exponentially. If you’re skeptical of this technology, ask a farm employing these methods the scope of their yield improvements.

The future of technology in agriculture will continue to expand at the same rate as other industries, including but not limited to, Industry 4.0. In some ways, agriculture has exploited big data with better results than many other industries. Combined with the wave of technologies such as augmented reality to help farmers

The current technological summit enjoyed in the agricultural industry could not have been realized without hydraulics. The power density and reliability that made the farm a perfect home to hydraulics for so long continues to offer those same benefits despite electrification. The dozens of hydraulic cylinders used in the previously mentioned seeders run high pressure to maintain their compact size while also reducing the mass that is best enjoyed by the payload.

Furthermore, the addition of inexpensive linear and pressure transducers used in conjunction with high-pressure actuators offers force and positioning feedback

H Y D R A U L I C S

or untrained technicians diagnose and repair complicated hydraulic control systems, the combination of electronics and powerful hydraulics offers solutions to ensure the next hundred years of farming will continue to increase its rate of productivity faster than us humans can populate.

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I N D U S T R I A L

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THE ROOF WING OPENING SYSTEM OF THE UAE PAVILION FAR-REACHING HYDRAULICS POWERS A SHOW-STOPPING DISPLAY

PAOLO LEUTENEGGER, GENERAL MANAGER • DUPLOMATIC MOTION SOLUTIONS, PARABIAGO, ITALY

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EXPO 2020, DELAYED BY THE COVID-19 PANDEMIC, opens October 1 in Dubai. The world’s fair, set to welcome 190 participating countries with an estimated 25 million visitors from across the globe, aspires to increase awareness about the technology and environmental challenges humanity faces in the coming years.

The UAE Pavilion will be a major attraction at Expo 2020. The building, designed by Spanish architect Santiago Calatrava, is shaped like a falcon in flight — the official symbol of the UAE. The pavilion roof consists of 28 carbon and glass-fiber movable wings having masses ranging from 5 to 18 tons and total lengths from 30 to 65 m, all actuated and controlled by a sophisticated hydraulic system.

This unique project faced challenges well beyond those of typical industrial applications.

A functional design was not enough, the final aim was to delight and astonish visitors. At the highest level, we had to provide a system that met client expectations in terms of outstanding performance and unrivalled aesthetics, all aligned with Expo 2020’s sustainability goals.

In practical terms, it means all wings must open and close in a synchronized harmonic fashion, absolutely silently, with smooth and stable motion, along with the highest reliability and power efficiency.

One major challenge is control of the wings.

Some of them, due to their large size and weight, are actuated using two or three hydraulic cylinders that must be properly synchronized to avoid excessive stresses on the wing’s mechanical structure. Given the nature of the project, final validation of the control algorithms can be done only at the system level during commissioning. Therefore, particular care was devoted to the verification strategy, to identify and head off critical problems early on and reduce the overall risk.

The UAE Pavilion at Expo 2020 has 28 carbon and glass-fiber movable wings as long as 65 m and weighing up to 18 tons. All are actuated and controlled by a sophisticated hydraulic system. | courtesy of Santiago Calatrava LLC

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INDUSTRIAL HYDRAULICS

Roof Wing Opening System

The hydraulic system for the Roof Wing Opening System (RWOS) is massive. It includes an approximately 1 MW hydraulic power unit (HPU), 2 km of piping, 46 hydraulic cylinders each weighing 1.5 tons, 46 valve stands to independently control each hydraulic actuator, and a complete automation and control subsystem that includes nine PLCs, dedicated software, 2,000 sensors and control points, and over 20 km of wiring harnesses.

The basic design idea is to control flow and system pressure independently to address every working condition. For this reason, fixed-displacement pumps controlled by inverter-driven electrical motors have been used. This allows an almost instantaneous setting of system pressure according to specific load requests.

Maximum oil flow rate is based on the time requirements specified for wing opening and closing sequences. It takes into consideration the kinematic characteristics and acceleration and deceleration profiles of every individual actuator.

System pressure must satisfy the dynamic load requirements for all actuators.

That considers movements at given angular positions of each wing under worst-case load conditions due to the effects of gravity and wind-generated forces. (Relevant wind-load data have been derived from wind-tunnel testing of a scale-model pavilion, including all surrounding buildings, using an array of approximately 900 pressure sensors.)

To minimize power consumption, flow rate and system pressure are regulated according to the work cycle. For example, maximum pressure is needed at the start of opening movements, where flow demands are minimal. After acceleration, pressure decreases while flow rate increases. This trade-off between pressure and flow helps optimize power consumption.

Another essential requirement is silent operation. This led us to choose internal gear pumps which, among high-pressure pumps, have the lowest noise emission. Additionally, two pumps mount on each pump unit.

The twin pumps are installed such that 44

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Despite working in an active construction site, Duplomatic engineers successfully finalized commissioning by tweaking control algorithms to ensure proper wing synchronization. | courtesy of Duplomatic Motion Solutions

pulsation is in counter-phase, thus reducing pressure ripple on the pressure line and, consequently, noise generation. Likewise, the start-up sequence is designed to minimize the possibility of vibration.

System piping

System piping must take into account several different constraints. The main requirement is to guarantee high-pressure hydraulic fluid flow rates despite the sizeable distance and height between the HPU and actuators. Unpainted 316L stainless steel was selected as the piping material, considered the most reliable option to guarantee functionality with limited maintenance over the pavilion’s lifetime.

The HPU provides more than 2,000 lpm flow rate at a constant 210 bar working pressure. The HPU is located in the basement, 5 m below ground level, 45 m from the point where pipes reach the roof and approximately 100 m from the mostdistant wing actuator. To minimize pressure losses and withstand design and test pressure 1.5 times the working pressure, engineers selected a 5 in. size main pipe for the highpressure line to the roof and an 8 in. size low-pressure pipe for return flow.

The riser, the vertical section of pipes reaching the roof, is 15 m long. This represents a real challenge considering that the high-pressure line weighs about 50 kg/m for bare steel without fluid inside. Special supports are each designed to carry more than a half metric ton. The supports must also compensate for structural movements of the building, such as for extreme temperature www.fluidpowerworld.com

swings typical in the desert climate.

Another concern is that the steel roof and concrete building expand and contract at different rates, due to thermal changes.

Thus, flexible hoses connect the riser to the roof piping.

On the roof, the two pipes form loops, called ring pipes, which ensure fluid distribution to each wing. The ring topology lets fluid take the easiest path to the actuators. Each ring is composed of numerous curved sections connected by flanges, forming a segmented loop that allows deformation induced by thermal loads. Pressure lines range between 4 and 3 in. in diameter, and 6 to 4 in. for the return lines. Overall length of each loop is approximately 550 m for the pressure line and 590 m for the return.

Smaller lines, called wing pipes, branch off the ring pipes and supply the actuators. They are sized according to flow requirements and run along the steel wing ribs to the valve manifolds. Flexible hoses between ring and wing pipes allow independent movement with respect to each other.

Particular attention was devoted to the pipe supports. The pipe network must expand as oil temperature rises and allow for roof movements due to thermal effects and wind loads. Special supports let the pipes slide and accommodate any deformation. In essence, the entire pipe ring “floats” on these supports.

Finally, because the roof steel structure could amplify system vibrations

and generate noise inside the pavilion, elastic elements were added at connection points between the hydraulic system and supports.

Actuators and motion control

The motion control system follows Duplomatic’s standard philosophy in controlling the speed of a hydraulic axis by piloting a compensated proportional flow valve and using a position-transducer signal as feedback.

Movement of each hydraulic actuator is independently controlled by one dedicated proportional control valve. Additional valves manage lock-in position, emergency closing and direction of movement. Valves mount on a block located on the back of each actuator, a compact design that ensures fast response.

For safety, relief and lock valves are installed directly on the cylinder.

Each axis has a dedicated motion control card (CAC) and, in multi-axis wings, an additional control card acts as synchronism supervisor (SSC). All cards communicate internally via a dedicated CAN bus and connect to the automation and control subsystem through a PROFINET interface.

Wing control electronics manages

the valves, as well as pressure and stroke transducers and temperature sensors, and executes commands to operate the wing.

The angular speed profile in terms of travel distance and acceleration and deceleration times is defined according to hydraulic circuit characteristics and power management requirements. Standard full-stroke opening/ closing movements are performed in 180 ±2 sec. Fast closing in 120 sec is permitted in critical weather conditions.

Due to the project’s unusual characteristics and the difficulty in predicting

dynamic behavior of each wing, a special open-loop algorithm was implemented for controlling the angular speed of a wing based on cylinder stroke feedback. Kinematic parameters of each actuator depend on the wing geometry and position. Consequently, each cylinder has a unique set that is stored in the firmware.

The system calculates output to the proportional flow valve based on the actual position and angular profile. Due to the openloop control, tracking quality of the kinematic profile is strictly linked to the behavior of the specially designed proportional flow valve. To compensate for deviations induced by external influences and tolerances in mechanical and hydraulic components, a Speed Adaptive Control (SAC) algorithm looks at a number of checkpoints as a supervisor and forces speed corrections at each checkpoint. This minimizes the cumulated positioning error in the remaining part of the stroke.

Synchronism control, managed by the SSC,

is required for wings with two or three axes.

A closed-loop PI control based on a MasterSlave concept is implemented in the motion controllers, using synchronization set points

from the SSC. It’s active only for slave axes. The aim is to minimize synchronism error under the maximum acceptable limit of ±10 mm.

The main advantage with this concept is that disturbances and oscillations on a slave axis do not influence the entire controller. The Master is controlled in open-loop avoiding the complexity arising from the system’s low natural frequency, and it makes tuning of the synchro controller independent from the wing control. SSC, being the fastest observer, also immediately stops wing movement if synchronization error exceeds an acceptable threshold limit.

A central Building Management System networked to the main PLC commands roof opening and closing. The control and automation subsystem manages the RWOS. Ten wing automation cabinets located on the roof house remote PLCs and electronics for actuator control and synchronization. Parametrization of any device can be performed remotely. Thus, no direct roof access is required, simplifying maintenance. Three UPS subsystems, which supply the main PLC and all control subsystems, allow 10 minutes of operation to secure the RWOS in case of main power loss.

Duplomatic supplied all the valves, cylinders and pumps, and the proportional flow control valves were specifically designed and manufactured for the Expo 2020 project.

The company’s engineers also developed the motion control cards and motion algorithms.

Siemens provided the asynchronous electric motors, inverters, PLCs and Profinet network. | courtesy of Duplomatic Motion Solutions

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I N D U S T R I A L

H Y D R A U L I C S

The hydraulic system controlling the Roof Wing Opening System includes a 1 MW hydraulic power unit, 2 km of piping and 46 hydraulic cylinders. | courtesy of Santiago Calatrava LLC

System verification and testing

The main verification challenge relates to the system’s size and to the difficulty of performing representative tests before final commissioning on site. The aim was to identify risks during the development phase, combining system modelling, simulations and tests at the subsystem level.

System modeling and simulations analyzed two critical aspects: System pressure losses throughout the entire operating sequence and the actuators’ power demands during movements. They answer to the basic question: Can the cylinders move under any possible load condition? Analysis also determines pressure reserve available under worst-case operating conditions.

Design data include the pipe system model; pipe elements that consider hydraulic capacity, inductance and losses; cylinder flow and physical behavior; as well as different temperatures and oil types.

Results showed the need to modify system pressure at the beginning of the opening cycle, to overcome high loads, and during the closing process where some pressures were insufficient. Increasing system pressure from 140 to 160 bar resulted in ample design margin during all operating conditions.

Hardware-in-the-Loop simulation is a common technique for system-level testing of embedded systems. Here, the control hardware links to a virtual environment that includes the cylinder subsystem.

The HiL test bench simulates virtual movements of the wings, which are controlled by the motion control cards (CAC and SAC) and the corresponding hydraulic valves.

The main objective was to test the motion control algorithms to ensure performance specifications are met and all software bugs identified. HiL simulations show that the Speed Adaptive Control algorithm holds position error within specified limits during both 46

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opening and closing, for all wings, under worst-case load conditions, and opening/closing time requirements are met. Complying with time tolerances is a precondition to ensure the synchronous movement of all wings on the roof. Likewise, the SSC controller for multi-axis wings meets angular-deviation tolerances during all test cases. This guarantees low bending moments and damage-free wing movements.

The wing test bench is a versatile hardware replica of a wing subsystem, built at DMS. Although downscaled to limit space and energy consumption, it accurately replicates the properties of both single-and multi-axis wings. It includes three hydraulic cylinders (stroke 1,000 mm, bore 50 mm, rod 28 mm) including SSI linear transducers, related control-axes boards and valve blocks; a hydraulic power unit running at 120 bar and constant flow; a PLC acting as the wing controller; and ancillary sensors, remote I/O modules and HMI.

The main objectives were to validate firmware in the motion control boards; and debug and validate the automation software. To thoroughly test the robustness of the motion algorithms, the hydraulic circuit was equipped with additional proportional pressure valves that inject external disturbances to simulate wind loads.

Results confirmed that external forces do not affect the overall opening time. In Master-Slave controlled mode, the synchronism control loop acting on each slave is unaffected by the other slave axes. This demonstrates that the synchronization algorithm holds synchronization error on the slave axes to well below the acceptable threshold of ±10 mm.

Commissioning on site

Simulations, HiL and test bench results confirm the feasibility and reliability of Duplomatic’s technical solution. However, some simplifications in the model and behaviors not fully validated in the

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simulations required additional analysis of the real system on site.

Once equipment was installed, several tuning activities had to be performed. On the HPU, particular care had to be devoted to determine the correct delays for switching the valves in order to avoid abrupt pressure build-ups/losses and vibrations or noise.

The kinematic parameters of each hydraulic actuator had to be verified due to differences between the design data and actual construction of the wing structures. In the majority of cases, the original parameters were almost identical to the measured ones.

However, on some of the longer wings, major discrepancies were identified with the manufacturing tolerances, which had to be corrected to prevent out-of-synchronization errors.

The procedure we identified to overcome this hurdle was meticulous and time-consuming: Each problem wing was actuated separately using a modified version of the software where synchronization between master and slave cylinders was deactivated. The wing moved only with the master cylinder, while slave cylinders followed movements that prevent wing deflections. The relationship between the cylinders as wing angle changes was recorded through temporary sensors and cylinder stroke transducers. This allowed us to verify the revised kinematic profile, including calculations of each parameter used within the axis control cards.

The other major difficulty involved the coordination of activities on the roof among many different subcontractors.

Any delay in one activity impacted the work of all the other companies, which made planning almost impossible and required a redefinition of priorities on a daily basis.

Moreover, the difficulty in accessing areas of the roof, due to the complexity of the steelwork and slope of the roof — in some areas on the order of 45° — and the large number of workers led to uncontrolled walkways and regular damage to the equipment installed.

The most important milestone was achieved in December 2020, where all 28 wings on the roof were moved perfectly synchronously for the first time, confirming system behavior in full accordance with simulations and laboratory testing activities. Installation is now complete. Presently, commissioning activities involve the final alignment of wings with respect to the stationary roof structure, to ensure the best aesthetic effect.

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EDA duplex change-over filters for continuous operation

The Filtration Division of Eaton has redesigned its EDA series of duplex pressure filters to be up to 30% smaller and lighter than its predecessor while maintaining the same performance level.

Available in five different sizes from EDA 106, 256, 406, and 636 to 1006 with flow capacities up to 265 gpm (1,000 lpm), the in-line mounted stainless-steel filters have a maximum working pressure of 580 psi (40 bar) and operate from 14 to 212 °F (-10 to 100 °C). In a Siberian application, Eaton even modified the EDA filters for temperatures as low as -58 °F (-50 °C).

They are suitable for petroleum-based fluids, HW-emulsions, and most synthetic hydraulic fluids and lubrication oils. Fitted with Eaton’s ISO-tested filter elements, high intrinsic stability, excellent filtration capability, high dirt-holding capacity, and long service life are assured. Available as fine as 5 µm, they increase fluid cleanliness and lifetime, reducing replacement, repair, and disposal costs. Visual differential pressure (DP) indicators, SAE-counter flanges, and drain- and bleeder connection are also available.

Diaphragm seals

New standard filtration products

A diaphragm seal (commonly referred to as a chemical seal) separates and protects a pressure sensing instrument from the process media.

One of the most common uses is separating the sensing element from a corrosive or caustic process media. If allowed to come into direct contact with the sensing element of a gauge, the corrosive media would damage the unit. Adding the diagram seal protects the gauge and significantly extends its life cycle.

The M&G line of diaphragm seals is available in various materials, including Hastelloy C276, Inconel 600, Monel 400, and Titanium, giving them a solution to fit almost any application. The seals combine the latest technology of material compatibility and many years of practical expertise in designing solutions to meet the most demanding environments.

The initial investment of a diaphragm seal may be recovered by reducing production downtime, extending the service life of instrumentation, lowering the cost of repetitive instrument installation, and reducing or eliminating maintenance costs.

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Ohio Fabricators Company (OFCO) has added several new standard filtration products to its stock inventory.

To reduce lead time and continue prompt delivery of its products to both distributors and end-users, OFCO has decided to create and maintain increased inventory levels on 16 products, including suction strainers, screens, and filler breathers.

Each of the 16 new products are available in various configurations and options, including screen size, port size, dimensions, and finish, to fit any hydraulic power application. OFCO says that most of its standard products ship from its Central Ohio facility within 10 days of order, exceeding most other suppliers’ delivery capabilities.

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Pre-compensated valve platform for mobile machines

Multifunction handle for right-hand operation

Bosch Rexroth boschrexroth-us.com/pcvp

APEM apem.com

Flexible and adaptable, the Pre-Compensated Valve Platform makes it easier for mobile machine builders to selectively combine a range of hydraulic control valves into a single, integrated, multifunctional control solution to match specific operational and performance requirements.

With the Pre-Compensated Valve Platform, Bosch Rexroth has engineered a solution that combines multiple valves with minimal need for adapter plates or custom fittings. All the valves in the platform support pre-compensated loadsensing capabilities that ensure that the proper hydraulic flow is delivered to each function, independent of the overall loads on the hydraulic systems.

The Pre-Compensated Valve Platform incorporates load-sensing capabilities that improve efficiency, freeing more hydraulic power to the implement while enabling better machine designs. The load-sensing valves can also help reduce hydraulic cooling system size and costs, and potentially lower engine horsepower requirements.

In a load-sensing system, the control block of the valve senses how much flow needs to be delivered to individual cylinders on different parts of the machine as work is being done. It provides feedback to the pump, so less energy is wasted to support all the machine’s functions.

The new RT handle has an ergonomic grip, offering a comprehensive combination of pushbutton and Hall effect thumbwheel combinations.

Designed exclusively for APEM’s XD series joystick, the RT grip provides IP67 above panel sealing and is well-suited for vehicle applications requiring dedicated righthand operation.

Using detailed “voice of the customer” studies, engineers ergonomically designed the RT handle for optimal right-hand operation.

With both front and rear-facing configuration plates, the handle allows users to easily reach all forward-facing functions with an easy sweep of the thumb. Rear-mounting functions can be actuated by the user’s index trigger without strain.

The front-facing plate may be specified with up to two HR series thumbwheels and six IX series pushbuttons.

Using Hall effect technology, the HR series provides linear outputs for over five million lifecycles. The IX series is a momentary pushbutton with a protective membrane to provide IP67 panel sealing for over 1M actuations. The Rear-facing plate may be configured with up to one momentary pushbutton in addition to APEM’s FNR series.

Hose sleeve for distinguishing hose bundles Python Protective Sleeve + Covers pythoncovers.com Python Protective Sleeve + Covers has announced the release of its Sidewinder Signal Sleeve for distinguishing hose bundles. Offered in five colors with custom logo options available, Signal Sleeve can serve as both a product for operator safety and company branding.

The sleeve is designed using high tenacity textured nylon with a light coating of polyurethane to offer abrasion resistance and a water-repellent finish. The military-grade hook & loop-style fastener reduces installation by up to 70% when compared to alternative options. It is lightweight, flexible, and provides a clean and professional look to the application.

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DELAWARE MANUFACTURING INDUSTRIES CORPORATION

Solutions Under Pressure

Ball Valves

ISO 9001 Certified Flow Control Needle Valves

Check Valves

Check Valves

Gauge Valves

Flow Control Valves Needle Valves High Pressure Valves

Medium Pressure Valves

Flanges & Adapters

SAE Port Flanges

Bar & Custom Manifolds Pressure Gauges & Snubbers SSW Power Unit Systems

Low Pressure Suction Valves

Subsea & Gas Valves

SSW Power Unit System

Specialty Valves

Industries Served: • • • • • • • • • • • • • • • • • • • • •

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4/8/21 4:31 PM

Filters for clean compressed air in food zones

The MS series of filtration products are filters that lower the risk of particle contamination when compressed air comes into direct contact with food or packaging in the food zone. The MS series meets or exceeds the highest industry standards for clean air. Always in stock with guaranteed fast shipping, MS filters arrive assembled with safety and total productive maintenance features typically found as custom addons. The units install easily and are priced competitively.

The MS series is designed for food and packaging-in-food-zone applications in the dairy, baking, produce, processed foods, pet foods, craft beer, cold food processing, and beverage industries.

Furthermore, this versatile series is suitable for a range of industries outside of food and beverage where clean compressed air enhances the longevity and efficient operation of pneumatic cylinders and processes.

Happy Anniversary Help us celebrate 75 years with our Special Commemorative Book. Free for the asking while supplies last!

RFB compact Air-X return line filter

This exquisite, limited edition book can be yours by simply emailing or calling us today at: info@hunger-hydraulics.com 1.800.248.9232

HYDAC has announced the introduction of the RFB compact series filter – the newest member of the HYDAC Air-X return line filter series.

Appropriate for small to medium flow rates, the filter will be sold in five sizes ranging from 45 – 260 lpm. The flow of the filter is inward to outward in a design that is optimized for performance. Additionally, this optimized flow enables reservoir tanks and the fluid inside them to be reduced in size/volume by as much as 35%. Standard equipment on the filter includes: • • • •

CREATING HYDRAULIC SOLUTIONS FOR 76 YEARS 1945 - 2021

Integrated lid, including bypass valve Patented bayonet connection between the element and the lid Outlet via diffuser Anti-drain valve is included in the element

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The filter is mounted in the tank, and flow passes through it via a pipe connection from below.

www.hunger-hydraulics.com +1.800.248.9232

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Promo Code: FPW 75

PRODUCT WORLD

Automatic recirculating cylinder technology Milwaukee Cylinder milwaukeecylinder.com

Get digital. Now! Engineering with the Handling Guide Online

The new patent-pending ARC (Automatic Recirculating Cylinder) Technology is designed to increase cylinder life by 25% or more and is available on selected rod and bore combinations of the Milwaukee Cylinder H-Series (3000 psi) hydraulic family of cylinders.

“The problem with traditional cylinders is that, depending on hose length, oil from the cylinder never makes it to the power unit,” said Joe Logue, Senior Product Engineer at Milwaukee Cylinder. Since the piston is a dead-end flow path, over a cylinder cycle, oil simply goes from inside the cylinder, to the hose, and back into the cylinder — never making it back to the power unit to be filtered and cooled. “Oil in the cylinder can become stagnant because it does not get flushed out,” said Logue. “Over time, stagnant oil breaks down, potentially decreasing the life of the cylinder. This is like never changing the oil in your car.”

ARC solves this problem by using a patent-pending technology that allows the piston to be bypassed when the piston reaches the end-of-stroke on the side where ARC is installed. When not at the end-of-stroke, ARC closes, allowing the cylinder to achieve full force and speed.

Finding the right handling system couldn’t be quicker or easier: Configure and order your standard handling system in just three steps with the Handling Guide Online. All systems are delivered fully tested and assembled.

Try out the new software tool today!

www.festo.us/hgo

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Telematics demonstration kit HED Inc. HEDcontrols.com HED Inc. has announced the launch of its CANect Telematics Demonstration Kit with dual-purpose: a stand-alone benchtop demo or as a prototype that can be connected and tested directly on OEM vehicles. The kit is offered complete with all hardware connections and antenna, software, six months of services (back-end office and cell), and a step-by-step guide to train users on how CANect Telematics can differentiate the OEM offering.

CANect Telematics is an end-to-end solution enabling HED users to have complete flexibility in designing their own telematics solution. This flexibility allows the OEM to define the on-vehicle and cloud experience offered to their end-users.

Deployed by the OEM, the CANect solution provides software applications for end-users to monitor their fleets and has proven to be a useful tool for a variety of applications from condition-based maintenance to system integration to reduce total cost of ownership (TOC), improve productivity, increase safety and connectivity, expand functionality, and simplify ease of use.

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COMPONENT FOCUS Edited by Mary C. Gannon • Editor

What’s more efficient, reciprocating compressors or screw air compressors?

When it comes to choosing an air compressor for a service

switch. When running, the pistons create a lot of noise. The cooling systems of these units are typically just fins across which a pulleyshop, you must choose between types — standard reciprocating mounted fan blows a stream of cooling air. The air they produce is compressor or lubricated screw. Operating costs may be quite different usually very hot and oily — difficult to clean and dry unless auxiliary for the two choices. cooling and filtering is used. At full load they consume more power per unit output than a screw compressor (usually rated in kilowatts per 100 cfm, called specific power). But these units are not designed Reciprocating compressors use pistons to compress the air to the to run continuously at full load, average loads of over about 60% line pressure you desire. They are often mounted on a small receiver of the compressor capacity will overheat and damage internal tank, and usually run in start/stop mode on a mechanical pressure components, mainly due to poor cooling.

Screw compressors, on the other hand, are more complex and expensive and can often be mounted on the same sized storage tank. They often run in a load/unload mode which means they run continuously; alternately producing air at full load or running unloaded with zero compressed air output.

Screw compressors are quieter than reciprocating units and have good cooling systems, similar to automotive radiators across which passes cooling air generated by a fan. They run at full load and will produce much cooler and cleaner air, which can be sent directly to an air dryer to remove water vapor. They usually consume less power per unit output at full load than reciprocating units, making them more efficient in that condition. But compressors running in a service shop rarely run constantly at full load. They often run at average flows of 10% or less.

Screw compressors running in load/ unload with small storage receivers rarely Oil-injected screw compressor turn off completely to limit the number from Atlas Copco 54

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of motor starts, which could prematurely burn out the motor; therefore, they will run continuously, consuming power even when they are unloaded and producing no air. This unloaded power consumption typically consumes about 35% of the compressor full load value.

To compare the two types of compressors, the math works like this: For a 10 cfm load, a 100 cfm 25 hp (21.3 kW at full load) screw compressor consumes 21.3 kW for 10% of the time (2.1 kW) and 7.4 kW for 90% of the time (6.7 kW). This means the total average power consumption is 8.8 kW to produce 10 cfm, a specific power of 88 kW per 100 cfm.

A similar sized 25 hp reciprocating compressor that, say, can produce only 90 cfm at 21 kW, runs 11% of the time to feed the same load (2.3 kW) but consumes no power when it is not producing air.

This works to a total average power of 2.3 kW or a specific power of 23 kW per 100 cfm — almost 4 times more energy efficient!

To get a screw compressor running like a reciprocating compressor, add more storage (ten times normal) and widen the load/unload pressure band. Purchase a compressor with auto/dual mode, which will turn off the compressor between cycles.

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Precision

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