High performance with regenerative dryers p. 22
Clean design with manifolds p. 36
Modern hydraulics for metal working p. 40
www.fluidpowerworld.com
October 2020
Efficient hydraulics for electric machinery PAGE 44
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FLUIDLINES Mary C. Gannon • Editor
We need to do better for our future This year has given us plenty of opportunities to look inward and study who we are and how we treat people. We have been dismayed by the inequality we’ve seen over the years, culminating this summer with multiple protests. From what I’ve heard, most businesses and organizations are evaluating their own policies. We here at my parent company WTWH Media are doing just that, working towards diversity and inclusiveness corporately but also personally. As we look at our own fluid power industry, though, we must do better for our young people. In my network of the many wonderful people working in this industry, it’s rare to find minorities and women. That’s why I was delighted to learn that the NFPA is looking to diversify the applicant pool for its $2,000 Fluid Power Scholarships to help students enrolled in high schools, technical colleges and university engineering schools pursue their interests in fluid power. NFPA needs to identify organizations that would be interested in promoting the scholarship to these communities, through related engineering organizations, local community organizations, and others. Reach out to Amy Zignego at azignego@nfpa.com if you’re interested in helping in this regard. In the meantime, let’s start introducing engineering and fluid power at a young age — how can we develop and mentor teams
for the Fluid Power Action Challenge in schools that are mostly minorities? Can we work with minority teams for the Annual FIRST Robotics Challenge, which NFPA also provides a significant scholarship for? Are there mostly Black engineering colleges that could participate in the NFPA Vehicle Challenge? I am sure it’s rare to find a young person that says they want to be a fluid power engineer or work in fluid power distribution while they’re a child (unless, perhaps, they may work in a family business). But we can change that by actively getting into communities and schools and introducing children, of all races and capabilities, to an industry that offers a promising future and careers at some of the best companies in the world. It’s time for a change. Our future deserves it. FPW
Mary C. Gannon Editor mgannon@wtwhmedia.com On Twitter @DW_marygannon
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FROM THE FIELD Paul J. Heney • VP, Editorial Director
A look at geopolitical issues affecting fluid power and industry in general At the recent National Fluid Power Association’s International Economic Outlook Conference — this one held virtually, due to the Covid-19 pandemic, Sam Potolicchio of Preparing Global Leaders Forum, spoke about some of the key geopolitical trends likely to impact business in the coming months and years. Potolicchio explained that the upcoming U.S. presidential election will clearly constitute the top geopolitical event this year and will affect trade issues and business in general. And no matter what either political party wants you to believe, he said that the question often comes down to the “beer question” — who would you rather have a drink with? The issue of personality and charisma is important to voters. Potolicchio also said that so much of our elections will be determined by a head nod or an off-key comment, because we’re so on the knife edge of being split 50/50 in this country. As an example, he said that he thinks the small-at-the-time moment of Hillary Clinton slipping when getting into an SUV was a moment magnified in some voters’ heads and likely contributed to her loss more than many people would think. He also said that “anyone who tells you they know who is going to win President is full of bunk.” Advantages that Biden has include: He is not Hillary Clinton, Elizabeth Warren, or Bernie Sanders. Biden is dominating among voters who disliked both Trump and Clinton. He also has the Obama advantage, and will try to make this an extension of the Obama years. What’s more, Trump has not found a way to encapsulate Biden; the Sleepy Joe nickname is not hitting with voters in the way that Crooked Hillary did. What’s more, the pandemic has completely transformed things. Reagan asked: Are you better off now than you were 4 years ago? That will be a tough thing for Trump to battle. Trump’s advantage are: Never Trumpers are now firmly into his camp. It’s going to be difficult to see people switching sides. Biden is an establishment candidate, and they rarely win for the Democrats. Additionally, “Washington” candidates usually lose. Trump is actually not that historically unpopular as a president. He stays in a 42-43% popularity range, which means it will likely 4
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be a tossup. Voters who are more likely to vote for him are not as likely to vote for a third-party candidate. The big question remains — Will a second wave of the pandemic hit in October? We don’t know what voter turnout will be, and Potolicchio noted that higher turnouts generally mean a Democratic victory. But if it’s reduced to all mail-in voting, that could push down Democratic voting. Republican votes are generally more successful by about 5%, which could be a huge X factor. Potolicchio said that the #1 risk for business is that we may see an electoral banana republic come November. At the state level, a lot of the swing states are controlled by Republicans although some have Democratic governors. The Speaker of the House will become President if battles over ballots go to the courts. This could affect faith in the U.S. globally. He thinks that Biden will likely win by about 100 electoral votes. A razor thin win by Biden may cause Trump to fight it.
Four other issues to consider 1. Potolicchio said that China is definitely a serious competitor to American hard power, even if they don’t match us with soft power. The main areas of dispute between the U.S. and China are: trade war, Huawei spying claims, claims of blame for the Coronavirus, new Hong Kong laws, Uighurs human rights issues, contested territories in the South China Sea, closure of consulates such as Houston, and Tiktok ownership arguments. Toughness against China will likely be a commonality between Democrats and Republicans. Relations will continue to deteriorate between the two countries, no matter who wins in November. However, from a general population standpoint, the pandemic has accentuated our poor feelings toward China. Potolicchio is optimistic though; he thinks it’s going to be difficult for the two countries to decouple from each other. “We are too closely entangled with each other. … ultimately, it is going to be more brinksmanship than a head-on collision with fatalities both militarily and economically,” he said.
2. The pandemic has put a magnifying glass on some serious structural issues that we have not just in the U.S., but globally. Before everything hit, even with an uninterrupted bull market
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with steady incremental global growth and steady U.S. growth, 53% of Americans lacked emergency savings. 28% of Americans did not have adequate health insurance. 21.3 million Americans lacked broadband WiFi access. 33.6 million Americans did not have paid sick leave. There is an economic cataclysm that is occurring on Main Street, Potolicchio told the audience — but it hasn’t affected Wall Street and our stock portfolios in the same way. This Achilles heel is the inequity … he noted that breakups of countries generally happen when the richest state is 5-6 times wealthier than the poorest state. It’s been that way with the Soviet Union, Yugoslavia, or the EU before Brexit.
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3. There’s a mental health experiment going on and no one’s talking about it, Potolicchio said. Toxic stress is increasing by about 100%, according to some studies. This impacts people’s ability to function at high levels in the professional workspace. He thinks the pandemic is with us for 2-3 years and we are not going to have a vaccine that is going to wipe it out; rather it will be a guessing game, similar to the different influenza strains each year. If there’s a vaccine in November or December 2020, there will be a low level of confidence in it, and we will see less than 50% of people willing to get it.
4. Who’s actually in charge? Potolicchio said that the U.S. isn’t engaging in the world order, and we’re seeing other nations flexing muscle, as well as a decline in the general trust of U.S. leadership. At the university level, we may not get the level of talent that we historically have. This may lead to fewer inventions and new products. And concerning the climate crisis: it will be a miracle if we don’t have at least five enormous environmental events in the next three years that will have continued economic destruction and will cause new refugee flows into already pandemic-weakened systems. This is a permanent crisis that we are going to have to address.
But bullish on the future?
Still, Potolicchio is bullish about the future. He described a “youthquake” … we are going to see a new generation get into politics. With the new generation will come a new approach to solving problems, and we’ll increasingly see people who are willing to engage with others outside their political party. Potolicchio said that we need to talk to our political counterparts like they are co-pilots and not enemies. The younger generation is more willing to simply look at problems and not worry about party labels. FPW
Paul J. Heney
VP, Editorial Director pheney@wtwhmedia.com
On Twitter @wtwh_paulheney
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36 40 44
D E PA R T M E N T S
FLUID POWER WORLD
FluidLines
04
From The Field
12
Korane’s Outlook
14
Association Watch
18
Design Notes
26
Fundamentals
30
R&D
34
Energy Efficiency
50
Products
54
Component Focus
56
Ad Index
A Z B E E S A S B P E Aw a r d s o f E x c e l l e n c e
2019
ON THE COVER
Future mobile machinery, powered by electric and hybrid drives, will require more-efficient hydraulics. | courtesy of Bucher Hydraulics
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EDITORIAL
MARKETING
VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @wtwh_paulheney
VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia
Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon
Digital Marketing Coordinator Josh Breuler jbreuler@wtwhmedia.com @wtwh_joshb
Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora Contributing Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane Contributing Editor Josh Cosford @FluidPowerTips Contributing Editor Carl Dyke @carlindustry
PRODUCTION SERVICES
Digital Production/ Marketing Designer Samantha King sking@wtwhmedia.com
VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com VIDEO SERVICES Video Manager Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Derek Little dlittle@wtwhmedia.com @wtwh_derek
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ONLINE DEVELOPMENT & PRODUCTION Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave
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FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Noncommissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2020 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. SUBSCRIBER SERVICES: To order a subscription please visit our web site at www.fluidpowerworld.com FLUID POWER WORLD (ISSN 2375-3641) is published seven times a year: in February, April, June, July, August, October, and December by WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Fluid Power World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114
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KORANE’S OUTLOOK Ken Korane • Contributing Editor
The election’s impact on fluid power Of all the issues surrounding this year’s presidential election, fluid power is decidedly not at the top of list. Nonetheless, the outcome could have a long-term effect on the industry’s success. From onshoring to research to workforce skills, here’s where the candidates stand on several key issues. Manufacturing. President Trump’s secondterm platform embraces the goals: “Create 10 million new jobs in 10 months, and create 1 million new small businesses.” His actual record is mixed. Annual manufacturing job gains from 2016 to 2019 matched those from 2010 to 2015. That growth stagnated last year in part due to punitive tariffs and was decimated by Covid-19, although there has since been a modest recovery. His “America First” initiatives include mandating essential medical products be produced domestically. Business growth and investment policies are primarily tied to unspecified tax benefits, such as credits for reshoring certain jobs. He’d eliminate the Manufacturing Extension Partnership program. Joe Biden’s “Made in All of America” plan promises $400 billion in federal spending for products, materials and services made in the U.S. He seeks to “retool and revitalize” American manufacturers to modernize aging factories, invest in new equipment and reduce carbon footprint. Specifics include new smallbusiness credits, quadrupled funding for the Manufacturing Extension Partnership and creating a national network of free incubators and innovation hubs. Infrastructure. Biden’s $1.7 trillion energy and infrastructure plan commits to purchasing American steel, building materials and construction equipment. It will create “millions of jobs” rebuilding roads, bridges, water systems, electricity grids and broadband networks. Further, it will upgrade six million buildings and homes; and invest in carbon-free energy generation, a “green” auto industry, zero-emissions public transportation and climate-smart agriculture. 12
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Trump promised a $1 trillion infrastructure package in 2016 that has yet to materialize. He recently proposed $2 trillion in infrastructure spending to help the economy recover from the coronavirus-induced recession. The campaign plan calls for building the “world’s greatest infrastructure system,” with stated goals to rebuild crumbling roads and bridges, “win the race to 5G” and improve rural internet access. Science and technology. Trump aims to launch a Space Force, establish a base on the Moon and send a manned mission to Mars, which would likely require more R&D spending for NASA and DoD. The administration has proposed cuts to most other federal research, stating that commercial application of research should be industry’s responsibility. Some economists argue that greater public investment in basic R&D could help boost productivity and economic growth. Biden would target $300 billion toward R&D and “breakthrough” energy technology, including an Advanced Research Projects Agency for Health (ARPA-H) and for Climate (ARPA-C) and major increases in federal R&D spending for the National Institutes of Health, www.fluidpowerworld.com
tock
dobe S
esy of A
| Court
National Science Foundation, DoD and DARPA. And he supports allocating funds in areas like 5G, advanced materials, AI, battery technology, biotechnology and electric vehicles. STEM. Biden plans to support career and technical education (CTE) for high school students and establish free community college/ business partnerships that offer industryrecognized credentials and apprenticeships — to expand STEM careers in tech and manufacturing. Biden would also change current immigration policies, such as exempting recent Ph.D. STEM graduates from visa caps. Trump’s 2021 budget seeks to defund STEM education offices at NASA and the NOAA and cut similar programs at other science agencies — while launching a $150 million STEM initiative for minority institutions. A $2 billion CTE grant program would encourage organizations to “develop, implement, and expand high-quality CTE programs, particularly in STEM fields, including computer science, that drive innovation and economic growth.” He would also increase fees and restrict qualifications for H-1B visas, to “prepare American workers for jobs that are currently being filled by foreign workers, especially in STEM fields.” FPW
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ASSOCIATION WATCH Edited by Mike Santora • Associate Editor
IFPS Annual Meeting recap The IFPS recently held its 2020 Annual Meeting like most other organizations – virtually! Meeting virtually was not the same as meeting in person. Still, the board of directors, education, marketing, membership, and certification committee members worked on projects to help IFPS members and to educate and certify professionals in the industry. Projects for 2021 will include: • Upgraded Mobile Hydraulic Mechanic certification is in its final stages of development. Keep your eyes out for an upgrade to the MHM certification program developed for today’s mobile hydraulic mechanics. Areas of the Study Manual that were added and improved include: •
•
• • • • • • • • • •
14
Principles of operation explained for commonly found components within a mobile hydraulic system — pumps, valves, actuators, and accessories Color-coded cutaway illustrations of hydraulic components to aid in understanding operation Symbology updated to conform to ISO 1219 standard Expanded content on troubleshooting to include decision-tree aids Detailed content on pressure, flow, and directional control valves Improved graphics throughout and many real-life photos to assist in visualization Basic hydraulic calculations useful in troubleshooting Safety tips Basic principles of electrohydraulic control — open loop and closed loop Electrohydraulic valves Sensors used in electrohydraulic systems
•
Non-technical / Associate Certification — a subcommittee was formed to begin writing a study manual for a non-specialist certification for those who communicate fluid power information, such as product part numbers, standard options, promotions, and available services. Fluid Power Associate certification will require a written test. This Certification will be geared toward inside sales, customer service, parts personnel, clerical and support staff, and entry-level positions. Candidates could have no or minimal fluid power knowledge/ experience; however, prior basic hydraulic/ pneumatic education/training is recommended. This subcommittee is seeking active certified professionals to volunteer for technical writing.
•
Fluid Power Symbols Library — a subcommittee was formed to investigate the possibility of offering the fluid power symbols library to members.
Contact akayser@ifps.org to get involved on a committee or a shorter-term subcommittee (both meet via conference call a few times per year.) FPW
Mentorship Program — a subcommittee was formed to explore mentorship opportunities and investigate the prospect of a Mentorship Program. Any IFPS member may join in this exploration.
FLUID POWER WORLD
10 • 2020
www.fluidpowerworld.com
SECURE Metal-To-Metal NAHAD’s Fabrication Guides Are Live on NAHAD Academy
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The Association for Hose and Accessories Distribution has announced its Hose Assembly Fabrication Guides have been converted to a series of interactive courses now available on its e-Learning platform, NAHAD Academy. Newly updated and conveniently accessible via an online learning experience, these courses are designed to support employees’ knowledge and use of proper methods and techniques for hose fabrication. Upon successfully completing the course material and learning assessment, employees will be certified for up to three years in hose fabrication best practices. “NAHAD members deserve not only the best industry training, but also state of the art and conveniently accessible applications, handbooks, and e-learning programs to further their education and CE requirements,” said Molly Alton Mullins, NAHAD Executive Vice President. “NAHAD offers its members many educational opportunities, including Regional Training. This, combined with the power of NAHAD Academy and the recently re-released Fabrication Guides and courses, affords members anytime, anywhere access to quality and relevant digital training.” NAHAD’s Hose Assembly Fabrication Guides and courses cover industry regulations and requirements for the assembly and application of composite, hydraulic, corrugated, industrial, and fluoropolymer hose types. Three of five courses are available today, with Industrial expected in early October and fluoropolymer to follow soon. NAHAD will also provide Spanish translations for Hydraulic and Industrial Fabrication courses later in October. “We are excited about the long-awaited update and release of the Fabrication Guides and courses on NAHAD Academy,” said Joanna Truitt, NAHAD Director of Training, and the Hose Safety Institute. “They truly are a great addition to our existing course material and professional development learning tracks.”
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ASSOCIATION WATCH
NFPA and Purdue University host first Power Partner Event On September 11, NFPA and Purdue University hosted a virtual Meet the Students/Industry Connection Event. Students enrolled in Purdue University’s Mechanical Engineering and Electrical and Computer Engineering degree programs were invited to participate and learn about the fluid power supply chain and career opportunities presented by NFPA member companies. Ten NFPA member companies participated as industry panelists to discuss what their companies do, specific fluid power technologies, and opportunities for internships and jobs. The event also included presentations regarding the industry as a whole, Purdue University’s involvement in fluid power, and tours of their facilities:
NFPA’s President/CEO Eric Lanke gave a presentation on the state of the U.S. Fluid Power Industry to give students a better understanding of the diverse use and impact of fluid power technologies. Dr. Jose Garcia-Bravo, Assistant Professor of the School of Engineering Technology, provided an overview of Purdue University’s research in fluid power and involvement with NFPA. Dr. Andrea Vacca, Professor of the Department of Agricultural and Biological Engineering and the School of Mechanical Engineering, was featured in a video touring Purdue University’s state-of-the-art Maha Fluid Power Research Center, the largest academic laboratory in the United States entirely dedicated to research in fluid power. Dr. Lizhi Shang, Assistant Professor of the Department of Agricultural and Biological Engineering and the School of Mechanical Engineering, gave a live tour of Purdue’s testing rigs. FPW
FLUID CONDUCTING QUICK DISCONNECT COUPLINGS
NFPA | nfpa.com
Working Pressures to 6,000 p.s.i. | 3/4” thru 3” Size Hydraulics, Inc. thread to connect couplings are designed to provide high flow and low energy loss in fluid power systems. All products are built for rugged use and are designed with a minimum 4:1 Safety Factor. Notable features include superior flow characteristics and resistance to extreme pressures and systems induced shock loads. The carbon steel couplings are offered with both poppet style (5TV and 6TV Series) or flat face valves (TVF Series). A variety of port options and pressure ratings up to 6,000 psi, and proven performance in the field make these products popular in the mining, oil and gas, construction, and other natural resource sectors.
P.O. Box 6479 · Fort Worth, TX 76115 · V. 817-923-1965 · hydraulicsinc.com
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DESIGN NOTES Mary C. Gannon • Editor
Hydrotechnik’s MINIMESS Minivalv
is a throttle check valve that restricts the flow rate through a notch or hole in one direction and, in the other direction, releases it without restriction.
Throttle check valve provides precise control in mobile machinery In hydraulic systems, the actuator, typically one cylinder, must exhibit smoothstart acceleration to be able to guarantee safety, comfort and extreme durability. No one wants to sit in an excavator and move the joystick only to watch the boom shoot forward at full speed, scaring those working nearby, jolting the excavator driver and, what’s more, placing unnecessary strain on the mechanics. In fact, it is imperative that even an unexperienced driver can work in a controlled, precise and, at the same time, comfortable manner. MINIMESS Minivalv by Hydrotechnik is an effective, economical and easy-to-integrate solution for this. Complex controls and servovalves make it possible to control the movements of an actuator in any possible way and 18
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to optimize them for every situation. However, if yours is a cost-sensitive market segment and you want to use conventional directional valves with a hydraulic joystick, MINIMESS Minivalv offers an ideal alternative. MINIMESS Minivalv is a throttle check valve that restricts the flow rate through a notch or hole in one direction and, in the other direction, releases it without restriction. It can be mechanically preloaded if desired. It is typically integrated in the hydraulic pre-control line with throttle where the directional valve terminates and ensures that the valve piston is somewhat restricted in its movement from or into neutral position. In contrast to a simple throttle, the return valve’s design ensures that negative pressure does not build up during the supply process. www.fluidpowerworld.com
Symbol for MINIMESS Minivalv.
www.
Minivalv can be integrated in the pre-control line for rotation of the cab of the Volvo Construction Equipment ECR50D mini digger.
Depending on the desired degree of throttling, either a hole in or a notch on the valve piston is used to show the throttle cross-section. Preferably, the notched valve piston is used when throttle cross-sections are very small. This has the advantage that it is easy to flush out any dirt particles that collect in the notch when the flow direction is reversed. The more economical bored valve pistons are used when cross-sections are larger. MINIMESS Minivalv is known for its compact design. It is the size of a customary male connector and can therefore be integrated without additional effort. It is suitable for system pressures up to 400 bar. Mechanical connections, the size of the orifice or notch and the pre-load or cross-section are adapted to the requirements of the application. Typical applications include switch speed limitation of excavator booms, excavator bucket movement or the rotation of the cab as well as the optimization of the pre-control of counter-balance valves. The image shows how Minivalv can be integrated in the pre-control line for rotation of the cab of the Volvo Construction Equipment ECR50D mini digger. FPW
Hydrotechnik GmbH | hydrotechnik.com
MINIMESS Minivalv is known for its compact design. It is the size of a customary male connector and can be integrated without additional effort.
www.fluidpowerworld.com
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DESIGN NOTES Mary C. Gannon â&#x20AC;˘ Editor
Smart hydraulic actuators simplify hydroform tube processing upgrade
In this before and after shot, one sees the mess of the hydroforming line compared to the new system using Kyntronics smart hydraulic actuators with in-line configuration.
A chassis system manufacturer needed to retool a Tier-1 automotive hydroforming line to accommodate a new model design change. The new line required the flexibility to produce both the current OEM product and the new product at higher volumes. As a requirement for the new machine design, the manufacturer wanted to eliminate the messy and inefficient hydraulic system used in the old machine and implement new technology that provided better process control, was cleaner, quieter, saved energy and had the flexibility to handle the part variability. In addition, the new system would need to seamlessly integrate with Rockwell Automation controls and drives.
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Kyntronics smart hydraulic actuators with right-angle configuration compared to the inefficient system.
The manufacturer considered using electro-mechanical actuators but found that the large size and high cost of EMA technology would not meet their project requirements. Instead, the manufacturer chose 16 Kyntronics Smart Hydraulic Actuators (SHA). The SHAs were rated from 6,000 to 23,000 lb-ft (27 to 103 kN) of force and were provided in both in-line and right-angle configurations to optimally fit the available space envelope. The SHAs incorporated Rockwell Automation (Allen Bradley) servomotors and drives that met the customer’s control specifications. The Kyntronics SHAs implemented on the new hydroform tube processing machine exceeded the requirements of the machine builder and end customer including the following highlights: •
•
•
•
The SHAs eliminated the space-consuming HPU, manifolds, valves and hoses which helped contribute to the machine footprint being 50% smaller than the previous production line. The ability of the SHAs to operate independently with cycle overlap allowed the new machine to produce 25% more parts per shift versus the previous machine. The programmability of the SHAs provides flexibility to handle multiple part variations with improved process control – using position and force control to ensure optimal cycle times. Elimination of the hydraulics on the new machine results in an environment that is cleaner, less noisy and more energy efficient.
The Kyntronics SHA combines the power of hydraulics with the precision of servo control resulting in an ideal solution for the hydroform tube processing machine. FPW
Kyntronics | kyntronics.com
www.fluidpowerworld.com
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DESIGN NOTES Mary C. Gannon • Editor
Suburban Manufacturing’s Tsunami Tank-Mounted Regenerative Air Dryer
Regenerative dryer reduces costs, increases performance of dust collector system Dust collector systems play a critical role in maintaining compressed air cleanliness for manufacturers. Plant operators are always looking for any incremental advantage to improve pulse jet cleaning in bag (sock) or reverse flow cartridge systems. This is because even the slightest improvement in dust cake contaminate removal can create a costimproving ripple effect throughout the system by increasing bag life and reducing compressed air consumption (CFM) through less frequent pulsing.
a total solution available to optimize and protect the entire process? Suburban Manufacturing’s Tsunami Tank-Mounted Regenerative Air Dryer is revolutionizing how manufacturers maintain their dust collector systems for absolute performance at minimal costs. The challenge faced in every dust collector application is to maximize pulse effectiveness and extend bag life, while minimizing energy consumption in the form of compressed air. The system is optimal when the pulse interval effectively removes dust cake to the point where the filter life meets or exceeds the manufacturers’ specification. Unfortunately, this scenario very rarely occurs, if ever. While advancements in pulse valves, filter bags (socks), and pressure differential controllers show supporting data that doctor efficiencies in collector performance, this technology focuses on an incumbent enemy, that if corrected, will dramatically extend the life of all system componentry. Because dust collectors consume less than 30 cfm, on average, operators typically pay little attention to the quality of compressed air being supplied. Even though these collectors have low flow specifications, measured in cfm, the actual volume of air per pulse dramatically exceeds that specification. What happens to this high volume of air as it rapidly exhausts out the orifice of a pulse valve is the underlying issue termed supercooling — this is what Tsunami addresses with its bag house drying technology. Supercooling explains the rapid expansion of air that loses heat due to the immediate separation of molecules. Simply put, for every 20°F that air cools, it loses approximately 50% of its ability to hold moisture in the form of vapor, or humidity. In collector applications, this
What if engineers, plant managers, and operators have been missing the key component to radically improve system effectiveness all along? What if there was 22
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www.fluidpowerworld.com
A tank-mounted regenerative dryer at a tire plant helped dry air down to at least a –40°F dew point. This helped the pulse valves clean the bags more effectively, and cycled 50% less often than before the dryer was installed.
cooling effect converts water vapor to liquid as air quickly expands out of each pulse valve. Damp air hits the bags or elements creating a wet cake substance that prematurely clogs the filter and inhibits air from passing through. Not only does this wet air reduce the life of each filter, it also wreaks havoc on collector systems in climates where freezing may occur. Having excess storage of ultra-dry air in dust collector applications is necessary for eliminating moisture within the system and increases the life and efficiency on the system. Tsunami Compressed Air Solutions has designed an all-in-one regenerative air dryer to eliminate air-related issues that prevent a dust collector system from operating proficiently. Let’s examine how the system works. Air travels into the zero-maintenance water separator where water is removed and particles are filtered down to 10 micron. Before exiting the
Chart shows the data logger that was used to capture air consumption during the study.
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DESIGN NOTES
EVERY Part Matters!
PENINSULAR CYLINDER CO. ®
Hydraulic • Air • Custom Cylinders
pre-filters, the oil coalescing element removes aerosols down to 0.001 ppm and particulates down to 0.01 micron. A gate valve and flow meter, integrated before the inlet of the dryer, help prevent the collector from overrunning the system. Pretreated air enters the regenerative dryer where dew points and relative humidity are lowered down to –40° F and 0.01% RH. The technology features self-regenerating towers to eliminate the need for manually changing desiccant. This level of air quality prevents the chance of moisture creation during the supercooling process. A small amount of dry air is reverse-flowed to purge out the humid desiccant while the bulk of the air is stored in an 80-gal receiver tank. This excess storage of ultra clean, dry air is essential to supply the high surges of flow experienced during pulsing. To accommodate for these spikes in demand, a high-flow regulator is utilized on the tank outlet port. If monitoring compressed air quality is desired, a test port is located on the inlet side of the receiver tank. In one example, a tank-mounted regenerative dryer was installed at a tire plant and then monitored by use of a data logger. The goal of the installation was to reduce the air consumption and improve bag life. Dust collectors were filtering carbon black and the pulse valves cycled off a photohelic pressure switch that unintentionally robbed the plant’s air capacity. After just days of being installed, it was discovered that by using dry air with at least a –40° F dew point, the pulse valves cleaned the bags more effectively, and cycled 50% less often than before the dryer was installed. The included chart shows the data logger that was used to capture air consumption during the study. The dust collector dryer reduced the amount of air/pulses considerably. The facilities engineer stated that the effectiveness of each pulse extended the filter life by two times and estimated the return on investment to be about three months. FPW
Let’s Talk Cylinders
800-526-7968
Suburban Manufacturing gosuburban.com
www.peninsularcylinders.com
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www.DMIC.com
1-800-248-DMIC
HBS - Hose Barb To Split Flg SBE - Split Barb Elbow 90 Deg ESB - Split Barb Elbow 45 Deg
CSN - Downline Coupling CSN (P) - Downline Coupling Piloted HCSN - High Pressure Coupling HCSN (P) - High Pressure Coupling Piloted
HBL - Hose Barb To Male Thread BSE - Hose Barb To Male Thread 90 Deg EBS - Hose Barb To Male Thread 45 Deg
BV3D Actuator
SNS - Male Thread To Female Thread SNE - Male Thread To Female Thread 90 Deg ESN - Male Thread To Female Thread 45 Deg FL4SU - Flange
BVALP - Low Profile Suction Ball Valve
BVAL - Suction Ball Valve
SWFH61 - Split Flg Head To Weld
SWBARB - Hose Barb To Weld
CVH - Check Valve
SFM - C.61 Split Flg To Male Thread HSFH - C.62 Split Flg To Male Thread SSE - C.61 Split Flg To Male Thread 90 Deg ESS - C.61 Split Flg To Male Thread 45 Deg
3776 Commerce Court Wheatfield, NY 14120 1-800-248-DMIC (3642) Phone: 716-743-4360 Fax: 716-743-4370
BVH - High Pressure Ball Valve
FCHH - Flow Control
SSW - Swivel Socket Weld FSW - Fixed Socket Weld
BVLS - Stainless Steel Ball Valve
COMPANION FLANGES FMC - C.61To Male Thread SFC - C.61 To Male Thread 90 Deg ESC - C.61 To Male Thread 45 Deg
SWEL90 - Weld Elbow 90 Deg SWEL45 - Weld Elbow 45 Deg SWEL90SR - Short Radius Weld Elbow
330 Vansickle Road â&#x20AC;&#x201C; Unit 4 St. Catharines, ON, L2S 0B4 1-800-320-DMIC (3642) Phone: 905-688-3642 Fax: 905-688-9993
FUNDAMENTALS Josh Cosford • Contributing Editor
Hydraulic symbology 302 – high response valves A “high response valve,” is a relatively new term used to describe valves whose performance is variable, dynamic and powerful. Previously only servovalves running technologies such as a torque motor could be classified as high response, but with the proliferation of contemporary electronics, feedback and programming, proportional valves have closed the gap. Now some proportional valves match the performance of servovalves, but for the purpose of this discussion, I’ll call them all proportional valves. I discussed proportional valve operators in Symbology 301 – Electrical and Electronic Symbols, which appeared in the August 2019 Fluid Power World magazine. However, only the electrical operators were discussed, leaving out any holistic explanation of a high response valve. In Symbology 302, I delve deeper to elucidate how electronic and hydraulic symbology intertwines to produce hybrid symbols reflecting the purpose of each valve. I should stipulate, electronic symbols in fluid power are not representative of electrical symbols, although anyone fluent in electronic symbology catches on quickly. As mentioned in earlier articles in this series, there exists not only the ISO 1219 standard for drawing fluid power (and electrical) symbols but also a less relevant ANSI standard for drawing symbols. However, this does not stop individual manufacturers from drawing and detailing symbols as they see fit, either for clarity or narcissism, depending on who you ask. I’ve chosen actual catalog symbols from major manufacturers, so their depictions stray from explanations outlined by me previously. Bonus points if you can figure out who is who. I’m starting with the symbols for proportional accessories valves – in this case, a proportional relief valve and a proportional flow control. I’ve sidestepped simple symbols because I know you’ve learned the basics by now, so you’ll see no bare-bones components made proportional by way of just a diagonal arrow. These are compound symbols using various individual symbols concomitantly performing a single hydraulic function.
Figure 1. Proportional accessories valves 26
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In Figure 1 the proportional relief valve sits nested in the dash-dot boundary line, itself illustrating the encompassing nature of this symbol. In this case, the valve is an ISO 4401 D03 subplate mounted unit, which although nothing about the symbol tells us this, the functioning P (Pressure) and T (Tank) ports are being used while the A and B work ports are simply blocked due to obsolescence. The bottom of this valve may or may not exist with O-ring grooves for the work ports, and the optioning of them depends on the functioning of the proportional valve, which could also be constructed as a work port relief valve. Both the P and T lines are shown with fixed orifices, a feature that protects the valve from saturation of flow. The valve is intended to operate in a pilot circuit, either by controlling system pilot pressure or as the singular control over a larger valve (like a slip-in cartridge element), so it flows very little. Pressure energy flows directly into the left of the relief valve, where the pilot line can act upon the currently offset arrow to move it into the open flow path should upstream pressure overcome the solenoid’s active pressure setting. You’ll notice this manufacturer uses no spring in the symbol of the valve, although I assure you the spring exists in the physical part. They have simplified the operator as a simple solenoid rectangle bisected with the diagonal variable arrow. The diagonal arrow will be common to most, if not all, proportional valves, showing us that the current can be varied to adjust the position of a valve spool or poppet to achieve various ends. The manufacturer embellishes the symbol with a 7-pin connector, which is a common connector used for proportional valves with onboard electronics. Those electronics will include an amplifier circuit to take the input power and control signal and turn it into a PWM output the valve can use. As discussed in the earlier article, the triangular amplifier symbol differs slightly in fluid power from electronic symbols by way of the dashed line, so as to not confuse it with a pneumatic pilot source. A final note on this symbol is that the manufacturer used the circular connection node at the pressure port of the relief valve, something not standard for an ISO symbol. The next symbol in Figure 1 is also that from a major manufacturer, and at first glance appears to have a lot going on. It looks primarily like a 2/2 directional valve, and essentially it is. I’ve colorized this one to make explanations easy, but please note my color choices do not reflect any standard. It starts with a 2-way, 2-position valve symbol which is normally closed in neutral, with both A and B work ports blocked. The highly experienced among you will have noticed the dark red pilot line starting at the A port and working around to the right side positional
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envelope, and if you guessed this is a slip in cartridge valve, you’d be correct. This particular valve is a spool, however, rather than the traditional DIN poppet design. The dark red pilot line tells us this valve can pilot itself open directly with pressure at port A because fluid acts upon the bottom of the spool directly and fights against only the spring force. As always, the parallel lines above and below the two operator boxes show infinitely variable positions between the two extremes. The symbols to the left are stacked out quite wide, with three major components affecting performance. The first in magenta is the hydraulically operated pilot valve. The dark triangle (normally colored black) facing towards the operators differs from a pneumatic pilot source which would be a hollow triangle. The hydraulic pilot is required to overcome the flow forces at port A, which would prevent a direct operated valve from shifting.
The X line feeding into the bottom of the pilot triangle is the external pilot supply line, which for this valve must be equal to or higher than the work pressure at port A. The Y line is the pilot drain, which is needed to keep the spring chamber drained to allow both the pilot and main stage valves to perform predictably. Any pressure in the spring chamber of the valve can be additive to spring force, reducing valve performance or killing it altogether. Attached to the left of the pilot actuator is the solenoid valve that operates the pilot valve, which is one and the same component — a screw-in cartridge valve in this case. This cartridge valve is actually a pressure reducing valve. The spring symbol above the pilot actuator shares a chamber with the external pilot supply coming from X. The pilot valve will reduce pressure as required to allow the valve to open, increasing flow; full pilot pressure means the valve is closed, while exhausted pilot
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pressure at Y will allow the valve to open fully. The two dark orange orifice arrows pointing inward at the directional flow arrow are because this is an orifice spool, where fluid passes through the center from A to B to exert force upon the spool as a method to measure pressure drop. The force on the spool is measured by the linear transducer, the cyan symbol defined in the earlier article. The dark blue attachment at the left is the amplifier card containing all the onboard electronics, and with the feedback from the linear transducer (which if you remember was measuring spool position and its movementrelated to pressure drop), will modify the signal at the pressure reducing valve as needed to match flow rate with the desired analog input from the PLC to the amplifier card. This valve operates on a closed-loop to provide accurate flow despite viscosity, pressure or temperature fluctuations.
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FUNDAMENTALS
In Figure 2, we’ve kicked up the symbol a bit to show various primary symbols arranged in a compound symbol representing a pilot-operated proportional valve with onboard electronics and spool position feedback. Once again, I’m using the symbol as exists in the catalog of a major manufacturer, so my top students will note the differences between this and the standards I’ve covered thus far.
Figure 2. Pilot-operated proportional valve with onboard electronics and spool position feedback.
The pilot valve is a 4-way, 3-position proportional solenoid valve, spring-centerd with a “float” spool (P blocked with A and B to tank in neutral), which is sometimes called a motor spool. The parallel lines above and below the positional envelopes surrounded by proportional coils using diagonal arrows make it clear we’re dealing with a proportional valve. The center condition is the basic form of a float center spool but has added to it an orifice symbol to each work port. Orifices are shown in the center condition of many proportional valves to describe the nature of the spool and body combination installed in the valve. Axially machined grooves called metering notches are added to the valve spool so that partial flow occurs even while the spool grooves are not fully extended past the internal ports of the body. The orifices describe the metering notches, but also how it performs just off-center. The metering notches will allow a more gradual increase in flow rate as the valve shifts away from neutral, making this type of valve more desirable for applications accelerating smoothly from a stop. If the flow is regulated mostly while the machine is “at speed,” then more valve overlap can be used, but there tends to be a bit of a dead zone in the lower range of the command signal. On the far right of the pilot valve is a familiar shape, although a previously undiscussed version of a symbol: the amplifier. The same triangular amplifier symbol is used, but rather than the dashed line to differentiate from a pneumatic pilot source, this valve employs three simple lines nearly trisecting the main triangle. This manufacturer 28
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came up with their own solution to prevent confusion, but I wonder if it caused more questions than answers. The pressure and tank ports of the pilot valve are fed and drained respectively via pilot lines, which are both the same dashed line. Older versions of this example may have used the dotted drain line connecting the tank port to the tank line, but these days the dashed line represents both while allowing their obvious function to define the difference. The work ports exit the lower valve with pilot lines crossing and then feeding into the pilot operators on either side of the main stage spool. You’ll notice the pilot operators are “floating” outside the valve, an interesting choice outside the ISO standard of a rectangular box attached to the a and b envelopes as is used on the proportional flow control symbol in Figure 1. You’ll have noticed the pilot lines cross using the obsolete semicircular jump I described as old school way back in Symbology 101, which is an odd choice in this symbol since other crossed lines simply cross as usual. My intuition tells me they didn’t feel the pilot lines crossing with the work lines would be confused as a junction, even though the appropriate nodes are used to join lines in other parts of the symbol. The pilot lines need to cross each other to correctly direct flow from the pilot valve to the main stage valve. When the a envelope of the pilot starts to shift, it opens the P to B flow path, sending fluid to the a operator of the main stage spool. The opposite path exists when the b operator sends fluid from P to A across the pilot valve to shift the b operator of the main stage valve. Speaking of the b operator – it shows a symbol I’ve never seen used previously to this example. The closed center neutral 0 position is typical, as is the a position showing P to B and A to T. The b envelope shows P flowing through an orifice to A and then A also flowing through an additional orifice to B. For any directional valve, connecting the pressure port simultaneously to both work ports creates a regeneration circuit. Regeneration is a counterintuitive function that allows a cylinder to extend rapidly but inversely proportional to a reduction in force. Usually, the symbol looks like the float spool of the pilot valve, but with P joined to A and B instead. However, I suppose this unique design was required to accurately represent the sequential metering of the two orifices. As with most proportional valves, the main stage spool also shows the parallel lines above and below the main symbol to represent infinite variability between positions. As well, the transducer symbol perched at the top left measures the absolute position of the main stage spool to confirm the pilot signals are accurately positioning its larger spool. I would think that with proportional valve symbols using onboard electronics combined with spool position feedback, it would be helpful to draw an electrical line from the transducer to the amplifier to detail the concept of closed-loop control.
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RESEARCH & DEVELOPMENT By Bipin Kashid • Simulation Engineer and Mitch Eichler • Applications Engineer, Parker Hannifin Hydraulic Valve Division
Part 1: Fast-tracking innovation through CAE simulation This is the first in a two-part series on simulation in an economic downtown. Stay tuned for part 2 in our next issue, or find the complete article online at fluidpowerworld.com.
Economic slowdowns can hurt new business through tightening budgets, order reductions or losses and breeding uncertainty in the business. Because of this, many companies choose to put research and development departments in a slowdown in an effort to maintain a semblance of normal operations. However, while focusing on survivability in these times is understandable, neglecting long-term growth will ultimately harm a business, causing design engineers to make hasty decisions with limited information which can affect the quality of the products and the total product cost.
Innovation and R&D must always be an area of focus, especially during an economic slowdown, no matter how counterintuitive it may seem. To do this, engineering teams must harness the power of new technologies to drive innovation. Through computer-aided engineering (CAE), engineers can expedite R&D testing, bringing products to market faster, and developing higher quality products at lower development costs.
components and other hardware. Because parts made with permanent tooling, castings for example, can easily cost tens of thousands of dollars, the costs of design iterations can add up quickly. A cost-efficient prototyping process hinged upon getting the design right on the very first try, which, as any engineer would say, is about as likely to happen as winning the lottery. In engineering, it’s fairly easy to get it “right,” however it is not easy to barely get it right when it comes to perfectly optimizing for balanced performance and cost. Now, through CAE-enabled virtual prototyping, engineers can create an analytical model of their design. These models allow a product to be tested in a virtual environment without the time and cost associated with making a physical test specimen. When simulation is an integral design tool, more time can be spent on product optimization instead of working to create products that merely achieve the minimum functional design requirements. No matter where a design team is in the design process, simulation can help. Common virtual tests include:
The power of simulation
Physical, real-world testing and prototyping have long been the backbone of R&D. However, with modern CAE, simulations are now an effective and reliable way to fast-track product innovation, offering shorter design cycle timeframes and reduced costs. The power of CAE software centers around virtual prototyping. The advantages of virtual prototyping include: • • • •
Lower costs Shorter time to market Higher-quality designs More competitive products
Before a wider adoption of simulation, the prototyping phase of a new product development project primarily involved creating a new physical prototype with each design change, leading to countless hours spent and piles of discarded castings, machined 30
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CFD simulations. Images courtesy of Parker Hannifin.
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• • • •
Linear/non-linear static stress simulations to evaluate the strength of components based on how they will be loaded and constrained during operation, Thermal analysis and CFD simulations to gauge heat distribution through a model, and determine fluid flow in and around objects, Modal/vibration simulations to examine what happens to a part and how it performs when it undergoes vibration, and Fatigue simulation to identify the maximum stress, strain and deformations components will experience in use.
Simulations keep testing flexible and cost-effective, saving months or even years stuck in the design phase. That flexibility is key. Virtual prototyping allows an engineer to perform sensitivity and optimization studies where manufacturing tolerances are varied to determine acceptable and achievable tolerances from the very beginning of the project. This leads to fewer product iterations and less scrap during prototyping and production. Simulation also makes it possible to benchmark designs against competitors by comparing a competitor’s product against the engineer’s own designs with virtual analysis tools. This way engineers can achieve better performance indicators and surpass the competition before finalizing the design. This can help to build confidence in simulation modelling to accurately predict product performance. Economic downturns present an opportune time to focus engineering efforts on building simulationbased predictive models with confidence. With virtual prototyping, design issues are often more apparent, allowing engineers to catch mistakes before they make it to final production. Late design changes and on-site modifications are risky and extremely costly; they delay project timelines and negatively impact customer confidence and growth, making it critical to identify errors as early on in a project as possible. Simulation coupled with tools like Design Failure Modes and Effect Analysis (DFMEA) can identify failures early in a development cycle so that engineers can create successful designs and not be forced to compete with mediocre products or limited resources. Engineering simulation can also help to break into new markets. With up-front benchmarking against competitors and using virtual prototyping to mitigate design risks, Parker was able to develop the VO20, a new aluminum open center sectional valve. Parker was able to make the valve lighter and more reliable while increasing efficiency and product life, making it a good fit for mobile equipment applications in the trailer market. With the valve’s simulation-validated test data
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RESEARCH & DEVELOPMENT
regarding fatigue life and hydraulic efficiency, Parker was able to break into the trailer equipment market and is now expanding the use of the product into other markets where weight reduction is critical. In the last decade, simulation has been key in the expansion Parker has achieved in these markets and in others, like oil and gas. By using simulation tools to combine proven valve technology already used in mobile and industrial applications with advanced subsea technology, Parker has been able to repeatedly create products greater than the sum of their parts.
Power beyond prototyping
Simulation enables the creation of better prototypes quickly and efficiently, but the power of simulation doesnâ&#x20AC;&#x2122;t end after a final design is chosen. Extensive virtual testing across multiphysics domains make it possible to account for scenarios that cannot be replicated in physical testing. It also enables design space exploration to drive innovation in ways that are simply not feasible in physical tests. Simulation also allows troubleshooting any issues in the field without having to perfectly recreate the physical environment. By analyzing the problem with CAE software, design engineers can easily identify potential problematic characteristics that are not otherwise observable.
How simulation can combat effects of a downturn
Part of what makes simulation so powerful is its ability to resist, and even reverse, the impact of economic downturns. Layoffs, facility shutdowns and other economic hardships that would normally prevent product development are less of an issue with virtual testing. Design teams can use simulation to help identify and eliminate areas of high cost or inefficiency, leading to more cost-effective virtual solutions. Playing into Value Analysis and Value Engineering (VAVE), simulation allows the team to explore creative problem-solving strategies that can promote product development and improve processes. By creating internal communities of practice (CoPs), as Parker does between seemingly disparate technology groups including aerospace, filtration, and fluid power, it is possible to leverage a large engineering team to examine simulation and design best practices without increasing engineering headcounts or incurring large overhead costs. Legacy product lines that were designed before the advent of simulation can be revisited for the team to identify the hidden potentials for cost savings. These could include:
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Industry Examples of Simulation Engineering simulation testing has been a key performance differentiator for many markets. Examples include: • • • •
Reduced time to market for automotive tires Optimized consumer container designs Reduced testing and development times for equipment power trains Reduced design cycles for golf equipment
http://www.acqnotes.com/Attachments/ Federal%20Agency%20(NSF)%20View%20of%20 Simulation-Based%20Engineering%20and%20 Science,%209%20Nov%202010.pdf
• • • •
Material reductions Simplifying electrical and mechanical systems Using more modular components Avoiding large welds
make sure to highlight any key features in the next marketing pitch. The product quality team can step in to analyze analytical models as if they were physical products, then advise the design team on any problematic features. Make sure to then loop in supply chain as the teams work toward the final product so that they can provide further component-related feedback and quickly find suppliers and implement their design for manufacturing suggestions to drive down cost. By using CAE tools at every stage in the design process, from initial conception to the delivery of the final product, engineers will be able to add even greater value and help protect the business, even when business opportunities are threatened by a sluggish economy.
However, don’t make the mistake of ignoring how important simulation can be outside of the niche role of engineering product development teams. Simulation can play a part in many cross-functional teams, bridging the gaps between departments. Simulation can provide value through the new product development stage by forming a relationship with customers through exchanging simulation models to better understand their systems and desired outcomes. Beyond designing, virtual tools can also assist marketing and sales in identifying what the most marketable features of products are. CAE testing provides a good salesperson more data than ever before, so
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ENERGY EFFICIENCY Ron Marshall • Contributing Editor
Figure 1. The expected specific power of this system was 22 kW per 100 cfm, but the actual was sky high at almost 80 kW per 100 cfm.
Compressed air fail: Verification spots trouble
AN
An aerospace plant purchased a new high efficiency variable speed drive compressor to replace an older VFD unit that had come to the end of its lifespan. The new compressor was more efficient than the old unit and was expected to save significant energy; calculated specific power was projected at 22 kW per 100 cfm including dryer purge. Confident in good efficiency, the plant maintenance manager invited a compressed air auditor in to do efficiency measurements so the project could qualify for a utility incentive. Measuring devices were placed on the system to measure pressure, flow and power. Within hours, the auditor delivered the bad news — the actual specific power of the system was 79 kW/100 cfm, a sky-high number! Investigation revealed a few issues. The first was one of two existing desiccant air dryers was left in fixed cycle mode. During the measurement period, the average compressed air flow to the plant was only 19 cfm, yet the air dryer purge was consuming 40 cfm of purge flow. This purge was the largest air flow in the plant — and was unnecessary!
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The second problem was a leaky condensate drain; this flow was consuming an estimated 10 cfm of wasted flow. A third problem is significant. The compressor installed is a 55 kW unit rated at 390 cfm and with a minimum speed of 55 cfm, but the average plant air flow is much less than 55 cfm (with very high peaks). This means this VSD unit will be running in start/stop mode for the majority of its life. Operation in this range is not desirable, and in this case results in inefficiency, because the compressor chosen uses recirculation to generate heat to boil off any water in the condensate. This recirculation uses extra power, reducing system efficiency. This experience illustrates the value of verifying compressed air installations after a project takes place, not to mention the problems with oversizing VSD compressors. The customer is investigating ways to improve the situation to get expected power consumption.
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H Y D R A U L I C
M A N I F O L D S
CLEAN DESIGN HYDRAULIC MANIFOLDS WITH
JOSH COSFORD, CONTRIBUTING EDITOR
MANIFOLDS SIMPLIFY HYDRAULIC CIRCUIT DESIGN IN HYDRAULIC MACHINERY, SAVING SPACE AND WEIGHT FOR STREAMLINED MACHINES.
Clean hydraulic manifold design helps reduce energy costs and improves efficiency. Optimised circuitry provides benefits in terms of reduced pressure drop and reduced heat generation, while reductions in weight and size aid installation and save space. Image courtesy of Related Fluid Power 36
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The word manifold is a bit of a blanket term in hydraulics to describe one of many objects used to consolidate plumbing or components for the purpose of fluid transmission. In the strictest sense of the word, a manifold is a single piece of material with many ports used as a junction or header to feed other parts of a circuit or to combine returning flow. For example, a plumbing header may have a single large port machined in one end, then include two or more smaller, perpendicular ports running down its length. You may have a 20 SAE port feeding into the manifold lined with 12 SAE outlet ports. The idea is to feed a high volume into a large port and then provide equal proportions of reduced flow out the auxiliary ports. A return line manifold provides an equal and opposite function to the header; multiple tank lines provide you with a neat and tidy return location that skips the messy jumble of fittings teed into a single reservoir tank line. By feeding smaller return lines into a single header, you also provide a single point of flow into the reservoir. The consolidated flow may be filtered through a single unit, if necessary, although care should be taken for drain lines. A pump’s case drain line should avoid any significant backpressure related to filtration.
On the other hand, a plumbing header is not likely the image that first pops into your head when you think of a manifold. A more likely image would be the bar stock manifolds used to mount stack valves or the custom-made ported manifolds using cartridge valves for integrated circuits. This article will focus primarily on bar stock manifolds, since custom manifolds constitute an entire new missive. Standard bar stock manifolds
Manufactured from either 6061 aluminum or ductile iron, bar manifolds come in a series of standard configurations to suit the application’s needs. Aluminum suits the needs of most hydraulic systems operating at 3,000 psi or less and is also relatively inexpensive and easy to machine. Ductile iron is a highly machinable metal with improved characteristics over plain cast iron and is suitable to 5,000 psi. Bar manifolds come in a range of sizes to accommodate not only the different sizes of ISO (CETOP) industrial
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stack valves from D02 to D10, but also different flow rates. A D03 (NG6) valve flows up to 20 gpm (75 lpm) in some cases, so the bar stock manifold manufacturers offer a solution to suit. While a standard 14 gpm (36 lpm) manifold comes equipped with SAE 10 and 08 P/T and work ports, respectively, the high flow version employs pressure and tank ports at SAE 16 with work ports expanded to SAE 12 to handle the extra flow. The additional flow capacity enables up to 25 gpm (95 lpm), increasing the flow potential across a multi-station manifold, which has to share that volume. Although it depends on the individual manufacturer, you can purchase bar manifolds up to twenty stations long. That’s an incredibly long chunk of metal requiring specialized CNC gun-drilling equipment. The manifold’s length doesn’t change its flow rating, so understand that a long manifold must share the same input of flow. Also, larger valves such as D07s, for example, cannot support quite so many stations as the smaller manifolds. And
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8-station D07 manifold approaches three feet long and tips the scales at over 250 lb when specified in ductile iron. Conversely, the sixteen-station D03 manifold weighs about half as much, although it is much longer. Obviously, aluminum, which is half the weight, is an excellent option for any manifold running 3,000 psi or less. Regardless of the valve size or number of stations, some features are common to most bar manifolds. Most hydraulic valve stacks require porting for pressure, tank and work ports alike. At first glance, bar manifolds look the same, with pressure and tank ports mirrored at the far ends of the manifold and then work ports stacked atop each other and equal to two times the number of stations. Parallel and series designs
Of course, we all know that looks can be deceiving, and as you might expect, there is more than one plumbing configuration to bar manifolds. You can purchase them in either series or parallel flow paths, and both require understanding for your hydraulic circuit to function correctly. The parallel bar manifold is simpler to manufacture; two gun-drilled passages run the manifold’s length, joining the left side pressure port to the right-side pressure port. Similarly, the tank port runs the manifold’s length, allowing flexibility in plumbing from either side of the valve assembly. Both the pressure and tank port may be plumbed from the right side, left side, or both. Each valve station of a parallel manifold picks up its valve’s ports from downward cross-drillings. These drills are located in four or more places, joining ports P, T, A and B to their respective locations in the valve mounted above. Valves larger than D03 may contain dual tank ports, and others employ separate pilot and drain ports, as required. The parallel ported manifold provides equal flow to each valve station along its length but must deal with one of the all-tooinfrequently misunderstood concepts of fluid power — the path of least resistance. You cannot overlook the tendency for fluid to move from a place of high energy to that of lower energy (lowest energy, in fact). Parallel circuits provide that path of least resistance, so take precaution and use flow controls or pressure compensation to prevent an entire circuit’s worth of flow from rivering through only a single valve.
Manifold adapters, like these stack modules from Daman, mount between the existing manifold and a valve. They convert the existing manifold valve pattern to an alternative size valve without disrupting the existing configuration.
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Standard manifold options from Daman Products range from ISO 02 valve patterns through ISO 10.
The series circuit will provide fluid power novices with just as much confusion if they’re not paying attention. The series circuit sends fluid through the center of each top mounted valve. Commonly known as tandem center valves, they flow P to T in neutral. But rather than drain to tank, when using these valves on a series manifold, their tank line feeds the next valve’s pressure port. A series setup is complicated in a couple of ways, but it allows the use of open center hydraulics and readily available fixed displacement pumps. A parallel circuit is susceptible to flow taking the path of least resistance. The series manifold experiences pilfered flow from each valve in the circuit ahead of the trailing valves. If there are four valves in series and no functions operating, fluid passes from one valve to the next until after the last valve; it then returns to tank. Should function one activate, fluid flows out to the actuator where work is done and then returns to flow through the second function. What you must consider is the pressure available to downstream functions while the first function is operating. If the first function uses 1,500 psi of available pressure and the main relief valve set to 3,000 psi, only 1,500 psi is available for all three following functions. Design choices
You can see how one must intelligently design circuits using either parallel or series type manifolds. A parallel manifold requires a pressure compensated pump or an innovative unloading circuit. A series manifold is exclusively used in fixed flow circuits because it’s a bad idea to unload pressure compensated pumps. Regardless of the circuit type, there’s more than just the number
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of stations to consider when selecting a bar manifold. The raw material used in the manifold’s creation comes in slightly more exotic metals, such as stainless steel or chromoly alloy. On top of metal choices, there are standard and special options to ensure your circuit is optimized. Porting options for bar manifolds come in as many flavors as the general fluid power industry offers. SAE, NPT, BSPP or Metric are not uncommon, but flanged ports are also available. Work ports may come out the front (which could be the back if so mounted) but employ bottom work ports. A bar manifold with bottom work ports makes a vertical mounting method a great option. A common option on especially smaller manifolds is the ported cavity to install a relief valve. Cartridge valves are inexpensive, and the extra cost to machine a 2-way cavity into the manifold is quite reasonable. The
same goes for a gauge port, which provides an economical and clean method to observe system pressure without the mess of adaptors typically required to add a gauge as an afterthought. Manifolds are foundational in the operation of hydraulic machinery. They have provided an effective solution to creating an entire hydraulic circuit by merely joining a series of valves on top of a ported chunk of metal. FPW
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Header and junction blocks, also known as “distribution manifolds,” connect several threaded connections into one common block to eliminate leaks and reduce plumbing labor. Image courtesy of Daman Products.
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Phased upgrade minimizes downtime A strategic approach to modernizing hydraulics signif icantly improved extrusion-press performance without breaking the bank.
Bosch Rexroth and GEI engineers configured new manifolds to make more-effective use of available space. The manifolds include Rexroth LC-LFA cartridge directional-control valves, which can be independently controlled to maximize system efficiency and minimize shock.
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The extrusion press is arguably one of the most valuable and hardworking systems used in any industrial setting. Productive and long-lasting, many presses operate for decades with proper maintenance and lifecycle management. For hydraulically driven extrusion presses, the pumps, spool valves and other elements operate under challenging conditions. One U.S. aluminum extrusion company, after assessing the performance of the drive and control of their aluminum extrusion press, undertook a carefully planned, phased process of upgrading key hydraulic and electronic control components. The goal: Ensure that the machine continues to reliably supply high-quality aluminum extrusions to a wide range of customers. Hydraulics upgrade
General Extrusions Inc. of Youngstown, Ohio, is a third-generation, family-owned manufacturer of aluminum extrusions, supplying products to machine builders and users across the automotive, transportation, consumer durables and many other industry segments. The seven-inch, 1,675-ton unit at GEI’s Youngstown plant is the company’s primary aluminum extrusion press. It has been in operation since 1967 and runs three shifts to ensure uninterrupted and on-time parts delivery. “This press is at the heart of our manufacturing process,” said Jason Andre, general manager at GEI. “We generally produce between 12 and 15 million pounds of product a year, so keeping the press healthy and operating at peak efficiency and productivity is crucial to our business and keeping customers satisfied.” In recent years, the leadership at GEI began an organized assessment of the performance of the press hydraulics and controls. This strategic planning and management review evaluated the risks associated with maintenance downtime on the press, as well as reduced extruding efficiency and output due to the aging of the legacy hydraulics. “The wear and tear on older hydraulic components led to an increase in fluid leaks,” said Andre. The system’s existing spool valves were based on dated technology, making it difficult to find replacement parts for repairs. In addition, the system’s original design meant that there was a higher level of inherent shock in operating the press, forcing GEI to deal with fluid leaks on a weekly, and sometimes daily, basis. “Once these factors started adding up, we made the decision that it was in the best interest to move forward with newer, modern hydraulic systems,” said Andre. The company recognized the need to carefully plan the upgrade process. The goal was to modernize the extrusion press over time to better manage capital expenditures and make it easier for the company to “pay as you go,” instead of being saddled with one large and expensive project. Equally important, GEI wanted to identify how to sequence the upgrades during regularly scheduled outages, instead of taking the press out of production for a multi-week shutdown.
Phased approach
After considering the product offerings and capabilities of several industrial hydraulic technology suppliers, GEI chose the drive and control experts at Bosch Rexroth as their partners. According to Andre, Bosch Rexroth supported a step-by-step upgrade program, and its engineers helped GEI define the key elements of each phase. “One of the things that Bosch Rexroth brought to the table, besides their hydraulic technology, was the concept of doing this project in stages,” he said. “Their ability to come in, work through with our team so that we could lay out the project in a manner that was more doable in a shorter time frame was a real positive.” Michael Kramer, press application engineer at Bosch Rexroth, was the lead point of contact for the upgrade project. According to Kramer, after assessing the legacy hydraulics at GEI and understanding their goals, Bosch Rexroth assisted with or worked on the following project phases: • • • • •
Upgrade the hydraulic fluid conditioning system. Replace the line-mounted spool valves with a hydraulic manifold system. Replace key piping elements. Install new state-of-the-art hydraulic pumps. Modernize the control system.
To-date, several of these phases are complete or are ongoing, while others are being planned. Bosch Rexroth recommended the hydraulic fluid conditioning system upgrade as a first step to ensure that the new hydraulic pumps and other equipment would operate with peak efficiency and quality. GEI has replaced their cleanliness system’s pumps, filters and heat exchangers to meet ISO cleanliness targets and ensure trouble-free startup as new components are introduced. Custom manifolds
One of the major elements of the upgrade project was to replace the line-mounted spool valves controlling hydraulic fluid flow throughout the press with a state-of-the-art manifold system. The existing, decades-old spool valves were obsolete, difficult to replace or repair, and inefficient — wasting energy through excessive leakage. According to Kramer, a manifold system reduces the number of potential leak points in a hydraulic system. The modern logic valves that are part of the manifold system can be independently tuned to reduce hydraulic shock while speeding up machine cycle times. This can help improve productivity due to faster actuation times, and their leak-free design also offers greater pressurization rates of the main ram. Bosch Rexroth supplies hydraulic manifolds for a wide range of industrial applications. Using proprietary software and an advanced production facility, the manifolds are designed, manufactured, assembled, and tested to ensure reliable, efficient performance that satisfies specific press requirements. According to GEI’s Andre, Kramer and his Rexroth team provided
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a detailed explanation why a customengineered manifold solution would provide a dramatic improvement for the press. “Initially, we were mainly interested in how using manifolds to replace the spool valves would reduce our leakage issues and some of the issues related to shock,” he said. “A real bonus was how the manifolds helped improve our dead cycle time. We have documented roughly a three-second reduction, and that translates into approximately 200 additional production hours on an annual basis, giving us increased capacity to fill customer orders.” The manifolds incorporate Rexroth LC-LFA cartridge control valves. These valves can be independently controlled to open in sequences that maximize efficiency and help minimize system shock — capabilities that the spool valves could not support. And because they are readily available off the shelf from Rexroth, the risk associated with obsolete spool valves is eliminated. The manifold system helped significantly reduce hydraulic shock, which is a huge benefit to the entire press, according to Andre, resulting in fewer failures and problems with mechanical elements such as
tie rods and other press components. The installation of the manifolds also gave GEI the opportunity to upgrade piping in the system, going from a welded network of pipes to a weldless system. This can better absorb shock and reduce potential leak points, compared to the older piping. New-generation pumps
Once the manifold installation and piping upgrade were complete, upgrading the two hydraulic pumps powering the press was next. The legacy pumps were difficult and expensive to repair and were significantly less efficient than modern pumps. They also required approximately 30 to 40% more energy to operate compared with current designs. The antiquated pumps also generated a lot of heat which had to be removed. “Not only would new pumps be easier and less costly to operate and maintain,” Kramer said, “pump replacement offered us the opportunity to increase the hydraulic flow rate and power input to the press to increase productivity.” The team selected the Rexroth AA4VSO 355 axial-piston variable pump, which is designed
The decades-old, line-mounted spool valves on the GEI extrusion press were obsolete and difficult to repair. They were also inefficient, wasting energy due to excessive leakage. The replacement manifold system with modern logic valves minimized potential leaks, reduced hydraulic shock and led to faster machine cycle times.
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for high-pressure industrial applications. The AA4VSO 355 is a 355-cc pump that can operate at 1,800 rpm. According to Andre, the existing pumps delivered approximately 108 gpm, whereas the new AA4VSO pumps will increase pump output by 30%. “In hydraulics, volume is directly related to the speed you can run your press at,” he said. “By going to a higher volume, the new pumps will help reduce dead cycle time on top of the improvements we’ve seen with the new manifold, once the new pumps are installed.” By performing the manifold upgrade first, the legacy pumps, originally designed and installed with two pressure ports requiring a complex valve arrangement, were converted to “one-way” operation. The manifold design completely changed the hydraulic circuit, setting the system up for easier installation of the new pumps. When the time came for the pump upgrade, it was virtually a “drop-in” operation performed over a weekend shutdown. In addition, planning the project in this way allowed GEI to replace one pump at a time, spreading their capital investments out and improving their cash-flow position. The new pumps also provide significant space savings, as the old pumps and their motors were mounted horizontally on top of the press, with suction lines feeding the pump. The new Rexroth pumps are vertically mounted and submerged in the tank, providing major space savings, as well as making it easier to install and service the system. “That space savings lets us open up 20%, 25% of that space, and from a maintenance standpoint everything is housed in a very compact, localized space,” he said. “Plus, installation time is very short —it takes about four hours to remove the legacy pump and install the new Rexroth pumps, keeping our downtime to a minimum.” He added that the new pumps also provide Industry 4.0 performance information that they did not have with the older pumps, giving GEI more predictability and insight into their hydraulic system.
Successful approach
Upon completion of the pump upgrades, GEI’s next major step will be to upgrade the press controls platform. Bosch Rexroth is proposing an upgrade that leverages the company’s extensive experience with extrusion-press hydraulic controls. Rexroth’s platform is capable of highly dynamic control of press force and velocity and can perform power-limiting, to ensure the press uses all available power to maximize production. The velocity control function provides extremely accurate speed control during extrusion, including during the critical breakthrough period, helping improve product quality and reduce scrap rates. The pressure control function is always active, limiting maximum tonnage even during breakthrough, which offers the added benefits of reducing stress on the press and extending die life. In addition, a new control system offers the opportunity to improve press availability and maintainability through fast and flexible Ethernet I/P communications, I4.0 data collection and analysis (including predictive maintenance), and custom diagnostics to assist in troubleshooting. GEI is currently assessing the potential costs and timeframe for this project. Throughout the project, the teamwork between GEI and Bosch Rexroth has helped ensure that the right technology and engineering design decisions provide the best solutions. From the beginning, GEI was confident that Bosch Rexroth had the right combination of drive and control technology and extrusion press expertise for this project. “Mike and his team were able to come in and show us how this project could be split into phases that would minimize any downtime we might have to face,” said Andre. “That, combined with the history of the company within the aluminum extrusion business, their reputation within the industry, their size and ability to meet our needs — so we could continue to meet our customers’ needs — really gave us the confidence that this would be a success.” FPW
Bosch Rexroth boschrexroth.com/en/us/ General Extrusions genext.com
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The old, horizontally installed pump and power unit (right side of the photo) take up significantly more space than the new vertically installed power unit on the left. The pump itself is installed in the reservoir.
M O B I L E
H Y D R A U L I C S
HIGH-EFFICIENCY HYDRAULICS FOR ELECTRICALLY POWERED MACHINES Flow-on-Demand systems enable energy-saving mobile drive technology.
Dierk Peitsmeyer, Product Portfolio Manager Bucher Hydraulics, Klettgau, Germany 44
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The Paris Agreement is the landmark environmental accord that aims to address the negative impacts of climate change and substantially reduce global greenhouse gas emissions. Although the U.S. will formally withdraw from the Agreement on Nov. 4, nearly 200 countries have signed on, and many American city and state government officials, scientists and businesses leaders, researchers and academics continue working toward the goals of the accord. Likewise, countries around the world are driving clean-energy advances to mitigate climate change. For example, the E.U., with the “Green Label” initiative and the German government with the “Energy Efficiency Strategy 2050,” have politically stipulated that CO2 emissions must be significantly reduced. These provisions will have a major impact on technical developments in the next few years, and the changes will most-assuredly affect manufacturers and users of construction, agricultural, mining and forestry equipment. Already, highly efficient drive systems, alternative powerplants and hybrid drives are increasingly used. Future mobile machines will likely be equipped with battery-powered electric drives, fuel cells, or diesel generators. To adapt to this changing landscape, hydraulic systems will require more efficient components and systems for precision movements. Drive-technology challenges
Mobile machines of the future, powered by electric and hybrid drives, will demand more-efficient hydraulic components and systems. Fortunately, a number of designs that minimize losses are in the works.
Many major mobile-equipment manufacturers, and their drive-system suppliers, are investigating alternatives to conventional IC-powered machines. A number of OEMs have developed battery-powered prototypes, and some have introduced commercial products. But there are challenges when adopting new drive technologies. For operators to work economically, electrically driven mobile machines must fulfill some important criteria. The designs will need to achieve sufficiently long operating times without tedious recharging and to work reliably and quickly at high power levels, similar to current machines. Operating companies also demand low noise emissions and low costs in terms of energy consumption and maintenance. Higher efficiency will be a primary factor in the success of the new designs. Lengthy operating time can be achieved with large batteries or other energy sources. However, this results in high expenses for the components. Systems with low power dissipation using efficient components or systems can prove to be useful, as they reduce the need for cost-intensive energy. Electric drives already have a high efficiency over a wide operating range. On the other hand, the hydraulics used today in mobile machines powered by diesel engines are not efficient enough. Improved systems need to be installed. www.fluidpowerworld.com
Limits of existing hydraulics
Hydraulic systems that adapt to the current volume and pressure requirements with the aid of variabledisplacement pumps, so-called load-sensing systems (LS systems), are not optimal for electrified machines. The noise emissions of conventional variabledisplacement axial piston pumps are too high. They will be particularly prominent in electrified machines due to the absence of diesel engine noise. Another problem is that the level of efficiency of LS systems is not optimal throughout the entire operating range. Load-sensing systems adapt their pressure to just above that of the highest load. A pressure difference, typically around 20 to 30 bar (290 to 435 psi) between pump and load, is necessary to overcome losses in hose, connectors and valves. These losses are system dependent and will change with external conditions such as temperature (for instance, poor cold-start performance), oil properties, and hose and tubing lengths. Thus, the pressure margin must be set to worst-case conditions to handle all operating demands. The control deviation causes unnecessary losses at most operating points. Another weakness of load-sensing systems is possible stability issues. The pump in an LS system is controlled in a closed-loop mode. At certain points of operation, this might result in an oscillatory behavior. Significant damping is occasionally necessary to operate the LS system without oscillation. This extends the response time considerably. Consequently, it is not advantageous to replace the diesel engine with an electric motor and leave the existing hydraulic system unchanged. Inadequate electromechanics
Some researchers have looked at minimizing the use of hydraulics, for example, replacing hydraulic cylinders with electromechanical linear drives. But in nearly all cases it has proven to be impractical. Mechanical gearboxes are not suitable for the high loads of a construction machine. Furthermore, every electromechanical linear drive requires an electric motor with correspondingly high power. The installed power will be quite high in total, even though it is rarely or never needed all at the same time. 10 • 2020
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Electric-hydraulic system Diesel engine: Optimal engine operation, no losses by towed idling pumps Generator DC intermediate circuit Diesel engine (e-fuels?)
Energy transfer in electric hybrid system. Recuperation, recovery, storage cylinder 1 Hydraulic 2Q-Linear drive in open circuit applications with recuperation potential
Fuel cell cylinder 2
Battery, Super Caps Storage, boosting Hydraulic control
cylinder 3
Hydraulic 4Q-Linear drive in closed circuit for powerful linear drives with recuperation potential
Hydraulic 4Q-Linear drive in open circuit applications without recuperation potential
drive
Flow on Demand System in the electric hybrid system for drives with less power and operation time
Rotational drives: Traction, swing drive, brake energy recuperation
As a favorable compromise between high efficiency and low cost, an optimized hydraulic system can be used. Closed-circuit displacement controls are an excellent choice for high-performance functions with a high potential for energy recovery. These are the ones with the lowest energy losses. One proposed solution for high-efficiency mobile hydraulics is shown in the accompanying “Electric-Hydraulic System” graphic. Here, each linear function requires a combination of electric motor and pump, comparable to
electromechanical linear drives. Active control of the motor’s rotational speed precisely meters flow to the actuator. And in these circuits, the pump is typically smaller and sized to the specific actuator, versus a pump that must supply maximum flow to numerous cylinders. Electric motor/pump applications means closed-loop motor control for each cylinder. It provides for the highest energy efficiency and regeneration, such as from crane or excavator booms. Such systems are not yet common in commercial mobile machines, although somewhat similar concepts are used
The LVS12 proportional valve with split spools allows for independent activation of control edges that govern metering in and out.
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One proposed solution for highefficiency mobile hydraulics is shown in the Electric-Hydraulic System graphic. Here, the energy source — which could be a diesel engine (operating at optimal rpm) driving a generator, a fuel cell, batteries or supercapacitors — supplies power to a dc intermediate circuit. The circuit powers individual electric motor-pump combinations to supply working actuators. Energy transfer in the electric hybrid system enables recuperation, recovery and storage. Likewise, it powers rotational drives for traction, swing drives and brake energy recuperation. Flow-on-Demand systems are for drives that demand less power and shorter operating cycles.
in aerospace applications. But is an expensive solution, which does not make sense for every work function. Flow-on-Demand hydraulics
For precision movements, valve controls with “Flow on Demand” (FoD) are an economical alternative. FoD applies one e-motor and one pump for several cylinders, consequently for lower costs. This makes sense for work functions that require less power, shorter operation times and without regeneration potential. The idea behind Flow on Demand is to use operator joystick signals to control the pump flow and valve openings simultaneously. The pump displacement setting is controlled according to the
requested load flows. Compared to traditional load sensing, the function does not need a pressure-control margin (Δp). Pump pressure is always at the lowest possible level needed to satisfy the load and overcome line flow resistance inherent to any system. When an actuator is stationary, the pump destrokes and delivers no flow and the directional valves close. Activating a joystick will simultaneously open a valve and increase the displacement of the pump. Because pump pressure will adapt itself to a level needed by the system, Flow-on-Demand systems can be significantly more energy efficient compared to load-sensing systems. The pressure difference between pump and load is given by the system resistance, rather than by a prescribed pump pressure margin. Advanced controls
Several elements are key to a successful FoD system. Hydraulic control blocks with separate
control edges, such as the LVS12 valve from Bucher Hydraulics, reduce power loss and enable movements to be more dynamic; therefore, the effectiveness of the machine is further increased. The LVS12 is a proportional valve with integrated pressure sensors and flow-sharing compensators. The valve uses split spools that allow for independent activation of the control edges that govern metering in/out. FoD and the meter-in edge only control cylinder speed; the meter-out edge controls generative loads, such as for lowering and braking. It is possible to combine variants of electric drives and hydraulic systems optimally in machines with a dc intermediate circuit. For example, the hydraulic pump can be operated as a fixeddisplacement, variable speed pump. The speed of the electric motor must be set accordingly. As mentioned previously, in FoD systems the operator’s joystick signals control the pump flow and valve opening simultaneously. For this
Advanced axial-piston pumps like the Bucher AX series offer efficiencies of 92 to 94% over a wide operating range. They are key components in Flow-onDemand systems and closed-circuit displacement controls.
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Load-sensing systems can be inefficient and prone to instability issues. FoD systems are stable and provide quick response without damping, and they offer energy savings compared to LS systems. to work properly, the system software needs knowledge about every flow consumer. That, in turn, requires sophisticated control algorithms. Bucher Hydraulics’ FoD software makes this possible without additional effort for the hydraulics user. The system calculates the required optimum speed based on the valve actuation characteristics. The result of the FoD system is always the lowest possible pressure at the pump. It depends on the current load and pressure losses, the latter which can be minimized by optimizing system design. It is particularly advantageous that the control pressure difference required in LS systems is eliminated. As a result, the responding behavior is extremely fast and direct, comparable to the performance of electric travel drives. The control system works in a stable fashion without oscillations. This allows the operator to drive the machine more effectively. The FoD system also offers additional advantages for controlled functions, such as the assistance control systems. And Bucher Hydraulics’ FoD 48
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software features additional options that are not available with a traditional LS system. Pump efficiency is crucial
In variable-speed operation, the pump is of particular importance to meet the special requirements of an FoD system and closedcircuit controls. The pump is the heart of the system. Comparable to the efficiency of high-quality electric motors, it must run at 92 to 94% efficiency over a wide operating range. This minimizes the need for costly battery capacity and extends the achievable service life. Reducing power dissipations at the hydraulic pump, for example, from 5 to only 2.5 kW, contributes significantly to the energyefficient operation of the machines. The efficiency chain further enhances this effect. The AX series hydraulic pumps from Bucher Hydraulics are especially suitable for such drive combinations. Even during demanding high-performance operation, the noise level is low and pleasant, as expected by end users. The pumps can be started at high www.fluidpowerworld.com
pressure and operated at very low speed — only a few rpm —without premature and excessive wear. Due to low leakage and the high number of pistons (24 versus 7 or 9 in a typical axial piston pump), smooth cylinder movement can be achieved even at low speeds. This is particularly beneficial for positioning work and large booms. The design principle with consistent hydrostatic relief of the components makes these pumps particularly reliable. (For additional information on AX pumps, see www.mobilehydraulictips.com/new-designovercomes-piston-pump-limitations.) With AX pumps and FoD software, as well as closed-circuit linear drives, the hydraulic systems of Bucher Hydraulics perfectly meet the requirements of electrified machines. Currently, such systems are in the early stages of beta projects for truck-mounted applications, construction machines and material handlers. FPW
Bucher Hydraulics bucherhydraulics.com
Some of the best companies in the USA use GRH Products in their machines. Why shouldn’t you?
The best American manufacturers buy only from the best.
ALA INDUSTRIES LIMITED 3410 Delta Drive • Portage, IN 46368 Tel. 877-419-8536 Fax. 219-762-2066
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PRODUCT WORLD
Seal for hydraulic aerospace systems
High-pressure proportional pressure controls
New L-Cap seal for hydraulic systems in aerospace applications is made with proprietary Avalon PTFE, Arlon PEEK, and elastomer materials. It exceeds industry standards for performance and durability, ensuring long service life, minimal ďŹ&#x201A;uid leakage, and excellent performance across a broad temperature range. Used in critical ďŹ&#x201A;ight actuation systems, the L-Cap seal provides superior ďŹ&#x201A;uid sealing in hydraulic cylinders under high pressures. The proprietary Avalon PTFE, Arlon PEEK, and elastomer materials ensure high durability and minimal wear over the lifetime of an aircraft. These proprietary materials exceed the low-temperature performance requirements set forth by aviation industry standards without sacriďŹ cing high-temperature performance. The L-Cap seal also delivers unmatched leak prevention, exceeding customer requirements for minimizing hydraulic ďŹ&#x201A;uid leakage. L-Cap seals are also easier to install than other aviation rod seals, reducing actuation system failures upon initial startup.
The Cordis HP500 pressure controls use the EV line of electronic valves allowing for steady, repeatable downstream pressure under static conditions. The result is a precise linear pressure control within a closed-loop system. The Cordis uses a microcontroller, integrated pressure sensor, and two Clippard EV electronic valves. The inlet valve is connected to the moderately regulated supply pressure, and the exhaust valve is connected to a port that vents excess pressure to the atmosphere. Once a command is increased, the inlet valve opens up to allow supply pressure to pass over the sensor element providing an active feedback for the micro-controller to satisfy the set point in the process. If at any point, the sensor detects a value higher than the set point, the exhaust valve will modulate open to vent oďŹ&#x20AC; the excess pressure to maintain a stable and accurate control pressure in the process. The Cordis HP500 pressure regulator is adaptable to a variety of sensors that can close the loop around pressure. It oďŹ&#x20AC;ers: â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘
Smooth linear control Pressure range of 0 to 500 psig Integrated internal or external sensor feedback Customizable pressure ranges and mounting options
Screw-in, cartridge-style hand pump The DCHP102 screw-in, cartridge-style hand pump with integrated dual check valves is suitable for hydraulic backup, hydrostatic testing, heavy-equipment parking brakes, and safety applications â&#x20AC;&#x201D; this hand pump displaces hydraulic ďŹ&#x201A;uids. The seat is made from hardened steel for long operating life. Doeringâ&#x20AC;&#x2122;s standard plating, used on the DCHP102, has superior corrosion resistance. The piston is treated and hardened for improved wear and corrosion, heat, and friction resistance. Doeringâ&#x20AC;&#x2122;s DCHP102 hand pumps are available for operating pressures of 2,100 psi (145 bar) or 3,000 psi (207 bar). Their operating temperature ranges are â&#x20AC;&#x201C;40 to 212°F (â&#x20AC;&#x201C;40° to 100°C). The lever socket rotates 360°, and handle lengths are 9, 16, 20, and 24-in. 50
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Fluid condition monitoring kits Schroeder Industries introduces the all-new plug-and-play Condition Monitoring Starter Kits for real-time ďŹ&#x201A;uid condition. Contaminated hydraulic ďŹ&#x201A;uid is the leading cause of system downtime. Full line of top-tier sensors catch less-than-ideal hydraulic ďŹ&#x201A;uid before it enters the system. The Condition Monitoring Starter Kits (#1-4) are plug-and-play packages that provide the technology, necessary cables, hoses, and wires all in a single purchase order â&#x20AC;&#x201D; everything operations managers need to start monitoring (and saving) their hydraulic equipment like a pro. The Condition Monitoring Starter Kits come in four unique sets: Local Data Display (#1), IoT (#2), HY-TRAX IoT (#3), and CSM-Economy (#4).
Helping You Sell More Machines
The Mobile Hydraulic Experts. The Mobile Hydraulic Kraft Fluid Systems helps Experts. you sell more machines The Mobile Hydraulic Experts. by allowing you to focus on your customers Kraft Fluid Systems is the leading distributor and systems integratorand
Kraft Fluid Systems is the leading distributor andyou systems integrator letting our experts help with hydraulic of hydraulic equipment and electric drive technology foryour mobile Kraft Fluid Systems is the leading distributor and systems integrator of hydraulic equipment and electric drive technology for mobile off-highway applications. With more than 45 yearsWe of experience, and electric drive systems. are the leading ofoff-highway hydraulic equipment andWith electric drive technology forexperience, mobile applications. more than 45 years of Kraft is the preferred distributor when seeking hydraulic distributor and systems integrator of hydraulic off-highway applications. With more than 45 years of experience, Kraft is the preferred distributor when seeking hydraulic components, power transmission equipment and electronic equipment andseeking electric hydraulic drive technology Kraft is the preferred distributor when components, powerOEM transmission equipment controls for mobile integrated solutions.and electronic for mobile off-highway applications. components, power OEM transmission equipment and electronicWith controls for mobile integrated solutions. controls for mobile OEM integrated solutions. nearly 50 years of experience, Kraft is Sales | Service | Inventory preferred distributor when seeking Sales | Service | the Inventory Serving Connecticut, Indiana, Kentucky, Sales | Service Delaware, | Inventory hydraulic components, power transmission Serving Connecticut, Delaware, Indiana, Kentucky, Maryland, Michigan, New Jersey, New York, Ohio, equipment, and electronic controls for Serving Connecticut, Delaware, Indiana, Kentucky, Maryland, Michigan, New Jersey, New York, Ohio, Pennsylvania, West Virginia and Wisconsin. Maryland, Michigan, Newmobile Jersey, Newintegrated York, Ohio, solutions. Pennsylvania, West Virginia andOEM Wisconsin. Pennsylvania, West Virginia and Wisconsin.
1-800-257-1155 www.kraftfluid.com 1-800-257-1155 www.kraftfluid.com www.kraftfluid.com
Serving Connecticut, Delaware, Indiana, Kentucky, Maryland, Michigan, New Jersey, Ohio, Pennsylvania, West Virginia and Wisconsin. 1-800-257-1155
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FLUID SYSTEMS FLUID SYSTEMS FLUID POWER WORLD 51 FLUID SYSTEMS FLUID SYSTEMS
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Pneumatic valve with embedded wireless connectivity
Emerson has introduced a wireless automatic recovery module (ARM) for its Aventics G3 electronic ďŹ eldbus platform that makes it easy for technicians to perform pneumatic valve system commissioning and diagnostics from a mobile phone, tablet or laptop computer. The ARM module and Aventics G3 ďŹ eldbus platform are suitable for pneumatic valve system applications in the automotive, food and beverage, tire, packaging, and metalworking industries. The module provides easy access to the Aventics G3 ďŹ eldbus platformâ&#x20AC;&#x2122;s diagnostic and commissioning capabilities via an internal Wi-Fi access point and mobile website . It oďŹ&#x20AC;ers visual beneďŹ ts of a hard-wired HMI. The wireless ARM module generates error notiďŹ cation for alarms, voltage levels, short circuits, module errors, open load errors, and distribution errors to reduce system downtime. The device has a small footprint that connects easily to the Aventics G3 ďŹ eldbus platform in the space of a jumper clip. It has three power settings for low, medium, or high-distance signals to ensure safe and secure access to data â&#x20AC;&#x201D; regardless of where the valve system is mounted.
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Electronic proportional flow control valve STEP 12 self-contained, media-separated electronic proportional ďŹ&#x201A;ow control valve brings a new perspective to controlling liquids and gasses. With more than 1,500 diďŹ&#x20AC;erent positions (or steps), it precisely regulates ďŹ&#x201A;ow output and requires minimal power to maintain a desired position, maximizing energy savings. The STEP 12 is self-contained with control circuitry (including an innovative M12 connector) for both the motor and valve embedded into the unit. This eliminates needing to purchase a separate control device, which can compromise performance. In addition, control can be tailored to increase resolution, enhancing reliable and repeatable ďŹ&#x201A;ows. Additionally, the valve is designed for full ďŹ&#x201A;ow under maximum pressure conditions with a ½-in. NPT version capable of accommodating 30 gpm of water with a maximum pressure of 150 psi.
HOW ARE YOU ASSEMBLING PUSH-LOK HOSE AND FITTINGS? A REVOLUTIONARY NEW TOOL that easily assembles Push-Lok style hose and fittings. WORKS WITH A VARIETY OF FITTINGS using a changeable mandrel system. Application specific mandrel design services are available. PORTABLE take it to where the hose repair is. A convenient carrying case included, no additional tools required. SAVES YOU TIME by utilizing a cleat style hose grip on a light weight hand operated system that produces up to 300 psi of fitting insertion force. REDUCES INJURIES by reducing the forces required of your hands to almost a 1/3 as well as preventing over bent wrists, a common cause of (RSI)/(OOS) claims.
WE TAKE THE PUSH OUT OF PUSH-LOK BARBTECHTOOLS.COM | 541-204-1899
COMPONENT FOCUS Edited by Mary C. Gannon • Editor
What measurements are required for hose assembly sizes?
Figure 1. Measuring male fittings
With hydraulic hose assemblies, one should consider several measurements to ensure their correct size — ID (inner diameter), OD (outer diameter), and length.
Inner diameter is the bore of the hose and the size of the orifice that the fluid has to travel through over a particular length. The OD of the hose could be critical for various things like where the hose is going to fit and how strong the hose is. A very strong high-pressure hose tends to have a larger thickness as a ratio to its ID. And of course, the length will help you determine what kind of flow rates you can handle, factored in with your ID. Obviously a smaller hose will have a higher pressure drop or an overall long length than will a larger diameter hose. A hose must be sized appropriately to handle the flow with as little pressure drop as possible because that pressure drop is wasted just trying to move fluid through a conduit. The total amount of pressure drop should be as minimal as possible, not only for efficiency, but because you want all the energy you’re putting 54
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into your prime mover to eventually do useful work at one of your actuators, whether they are a motor or cylinders. Specifying the wrong length is a common mistake. You absolutely cannot use a hose that it is too short, because it won’t either fit or will break if stretched too far. If it’s too long, it could have too much slack. A hose with slack can rub, fray or cause a catastrophic failure from moving too much around the machine. These longer hoses can also sag, which creates forces on the crimp and hose interface. This can cause wear and leakages over time. In addition, hanging and sagging hoses can get caught on something or be a tripping hazard. If a hose is only mildly too long — an inch, say — you can bolt that down to ensure safety. Overall length is not the tip-to-tip of all the components. What really matters is measuring the interface point between the fittings on the assembly. For example, if you have a swivel JIC, you do not measure to the end of the nut, but instead, will measure to where the seat attaches to the face of the JIC interface. In the example in Figure 1, you’re measuring the male fittings. If you have your hose or tube that has a male JIC, you want to measure to the interface point on that male. This ensures accurate hose length. This procedure is a little more difficult when you have something like a 45° or a bend fitting. With those, you must measure in the center of the fitting because the angled interface crosses various points of the entire hose length, so the middle point is obviously the average length that the hose would expand over that period. When making the hose assembly, you must consider the cutoff length, as seen in Figure 2. If looking at this hose assembly, you see the hose cut length. On the coupling
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Figure 2. Consider hose cutoff length on the left-hand side, there’s a CA dimension which is your hose cutoff length. What that means is after you have your entire hose length determined, you want to subtract the amount of space that’s taken up by the fitting itself, and that goes from the actual measured length, so you can see that it goes to the female part of the JIC. Coupling number two is a male NPT, so that cutoff length goes right to the tip, because you’re measuring to the tip of the
male fittings, while the female fitting is going to be the point of interface. But those two dimensions of your overall length must be subtracted. Note, you can’t assume that they’re the same for each coupling, and you can’t average it out. You actually have to know what that is based on the catalog information of your hose and fitting supplier. This allows you to subtract that from the total length. For example, let’s say it’s 1 in. on one side, 1 ¼ in. on the other, so you must
subtract to 2 ¼ in. from that cutoff length to get your actual total hose length. Remember, sizing a hose assembly doesn’t just mean you measure your application and cut the the hose to length. Considering pressure drop and fitting size is critical, too. FPW
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441
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12,436
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Madison Co. ............................... 39 Main Manufacturing .................. 10 MP Filtri USA ................................ 7 Peninsular Cylinder .................... 24 Prince Manufacturing ............... 47 RAM Industries Inc. .................... 55 Rota Engineering ........................ 52 SFC Koenig .................................. 15 SIKO Products ............................... 2 Spartan Scientific ....................... 43 Stauff .......................................... 11 Super Swivels ............................... 6 Tompkins Industries Inc. ...... IFC,10 Veljan Hydrair............................. 17 Yates Industrial ............................. 5 Zero-Max, Inc. .............................. 3
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Adaptall ...................................... 27 AutomationDirect ........................ 1 Barb-Tech Tools .......................... 53 Clippard ...................................... BC DMIC .......................................... 25 Doering Co. ................................ 13 Fabco-Air, Inc.............................. 33 Flow Ezy Filters........................... 23 Fluid Line Products..................... 19 FluiDyne Fluid Power ................. 31 GRH Power ................................. 49 HYDAC International ................. IBC Hydraulex Global .......................... 9 Hydraulics Inc ............................. 16 Kraft Fluid Power ........................ 51 LunchBox Sessions ..................... 35
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EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson
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