Fluid Power World September 2017

Reservoir designs for mobile machinery p. 34

Pneumatic design 101: Go with the flow p. 40

A fitting end to hose connections p. 56

www.fluidpowerworld.com September 2017

Couplings ensure smooth conveying PAGE 48

COVER_FPW 8-17_Vs2 MG.indd 1

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Building a better event Although you may be thinking Fall, we’re already thinking Spring, because we’re knee-deep in the midst of planning for our third annual Fluid Power Technology Conference & Expo in Milwaukee. The conference, held at MSOE’s Kern Center, is already set for May 15-16, 2018.

One of our takeaways after successfully running two of these events was that we wanted to get more of you involved. So, we created a Program Committee, comprised of manufacturers, users and academics. We’ve already held several successful in-person meetings and phone calls, and we’re making some wonderful progress on next year’s program.

As part of that, I’m excited to announce that we’ve now secured our Opening Keynote speaker for the conference: Austin Ramirez, President and CEO of HUSCO International. Ramirez, who’s been very active in the NFPA, at one point leading its Future Leaders group, was selected as a White House Fellow by President Obama in 2016—and served on the National Economic Council for both the Obama and Trump Administrations. His unique blend of experiences will inform what’s sure to be a fascinating talk, “What Washington gets right—and wrong—about manufacturing today.”

As always, the Conference will be heavy on fluid power education, and we’re working closely with our friends at the Milwaukee School of Engineering to make sure all aspects of the industry are represented.

I encourage you to add those dates in May to your calendar now, and check out the Conference website at fluidpowertechconference.com. If you have specific ideas for what you’d like to see in 2018, please email me at the address below—I’d love to hear your thoughts.

FPW

Paul J. Heney

Editorial Director pheney@wtwhmedia.com

On Twitter @DW_Editor Available In BSPP

Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423 Email: sales@superswivels.com

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FLUID POWER WORLD

9 • 2017

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SEPTEMBER 2017 • vol 4 no 6 • www.fluidpowerworld.com

IF YOU USE HYDRAULIC FLUIDS

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Setting the Standard as a Global Manufacturer of Steel & Stainless Hydraulic Fittings.

www.worldwideďŹ ttings.com World Wide Fittings 2-17_IFPE_FPW.indd 5

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September 2017 C ontents |

vol 4 no 6

|

fluidpowerworld.com

•

09

|

2017

F E AT U R E S MOBILE HYDRAULICS

Reservoir designs for mobile machinery In the brutal conditions faced by heavy equipment, the hydraulic reservoir has to endure more, and operate flawlessly in a whole lot less space.

PNEUMATICS Pneumatic Design 101: Go with the flow

34 40

34

The benefits of pneumatic power can be realized by following some basic design rules for specifying air preparation units, actuators and valves.

INDUSTRIAL HYDRAULICS

Fluid couplings ensure smooth conveying

D E PA R T M E N T S

02 Editorial

48

08 Korane’s Outlook 10 Association Watch

Hydrodynamic torque transmission protects belts, motors and drives.

HOSE FITTINGS

A fitting end to hose connections

Here’s a look at fundamentals of hydraulic hose fittings, and some recent innovations.

12 Design Notes 18 Fundamentals

56

22 Training 24 Research and development 28 Energy Efficiency 30 Safety 64 Products

70 Component Focus 72 Ad Index

FLUID POWER WORLD

A | S | B | P|E

American Society of Business Publication Editors

American Society of Business Publication Editors

Fostering B2B editorial excellence

48

ON THE COVER

Hydrodynamic fluid couplings protect large conveyors from torque overlods and torsional shocks. | courtesy of Voith Turbo

6

A | S | B | P|E

9 • 2017

2017 Regional

Fostering B2B editorial excellence

2017 Regional

PR INT

DESIGN

Revenue of $3 million or under

Revenue of $3 million or under

Award Winner

Award Winner

| istockphoto.com

Contents_FPW 9-17_Vs2 MG.indd 6

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Kuriyama 9-17_FPW.indd 7

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Ko ra n e ’s O u t L o o k Ken Korane • Contributing Editor

Fluid-power universities among world’s best With kids returning to school, parents and academics alike are gravitating to the annual college ratings hitting the newsstands. One of note is the World University Rankings 2018, published by Times Higher Education, a spin-off of London’s The Times newspaper.

It reviewed about 20,000 research-intensive universities around the world and ranks the best from 1 to 1,000— the top five are Oxford, Cambridge, Cal Tech, Stanford and MIT. Ratings are based on criteria like staff-tostudent ratio, PhD percentage, published research, international scope and industry funding for R&D.

Granted, most of the institutions that made the grade do not focus on fluid power. But those that do fare surprisingly well, as numerous schools affiliated with the Center for Compact and Efficient Fluid Power (CCEFP), the European CETOP association and major Asian fluid-power centers are on the list. These ten rated among the top 1% of all schools surveyed.

33. Georgia Tech. Houses labs for acoustics, biorobotics, computational hydrodynamics, fluids and intelligent machine dynamics. Work includes research on compact fluid-power systems for surgery and rehabilitation.

37. University of Illinois at Urbana-Champaign. Research focuses on the dynamics of mobile-hydraulic systems, and on humanscale devices like soft pneumatic actuators for orthosis devices.

56. University of Minnesota. The Fluid Power Controls Lab applies advanced control and mechatronic concepts to fluid-power systems in innovative ways, in human-friendly, transportation and renewable-energy applications.

60. Purdue University. The Maha Fluid Power Research Center conducts fundamental research on piston pumps and motors, and on control systems, acoustics, high-efficiency drives, and machine prognostics.

79. RTWH Aachen University, Germany. The Institute for Fluid Power Drives and Controls (IFAS) is widely recognized as a premier academic and research facility. It’s involved in all aspects of fluid power and areas like IT, servocontrols, tribology and environmentally friendly systems.

105. Vanderbilt University. Is developing power supplies for human-scale robots that outperform the best batteries and motors.

CCEFP projects include Stirling thermocompressors, strain-energy accumulators and miniature medical devices.

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| Image courtesy of iStock

133. Karlsruhe Institute of Technology, Germany. A member of the prestigious TU9 German Institutes of Technology, specialties include futuristic mobile machinery as mechatronic systems, anthropomatics and robotics.

155. Technical University Dresden, Germany. The Institute of Fluid Power focuses on novel drive and control concepts for mobile and autonomous machines. And fluid-mechatronic work melds mechanical and electronic technologies with innovative hydraulic and pneumatic drives and controls.

177. Zhejiang University, China. Home to the State Key Laboratory of Fluid Power Transmission and Control; National Engineering Research Center of Electrohydraulic Control; and the Institute for Mechatronic Control Engineering.

190. Aalto University, Finland. Mechatronics-focused education integrates hydraulics, pneumatics and control systems with mechanical, electrical, telecommunications and computer engineering for industrial and mobile machines.

Note that the rankings exclude many entities because they specialize in just one core area or don’t offer doctorate degrees. So by default places like the Milwaukee School of Engineering, one of the top U.S. fluid-power institutions, aren’t on the list.

The authors say that in general, American and European ratings have dropped in recent years at the expense of Asian universities.

Nonetheless, the 2018 numbers offer a nice endorsement for fluidpower education in the U.S. \FPW

www.fluidpowerworldonline.com

9/21/17 9:01 AM

FINN-POWER Innovation, Precision, Durability...

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Lillbacka 4-16 FPW.indd 9

Global Presence...Local Service 9/21/17 3:45 PM

Paul J. Heney • Editorial Director

ASSOCIATION WATCH

Takeaways from this year’s IEOC At this year’s Industry and Economic Outlook Conference, held by the National Fluid Power Association, most of the analysts and economists roughly agreed that things will remain positive into the early part of 2018, with a modest downturn in 2018-2019.

Highlights included: Jim Meil, ACT Research (pictured at right): There are some danger signals to watch for a possible recession. These include the Federal Reserve Board continuing to raise rates, Fed funds nearing the 10 Year Treasury level, an upward surge in oil prices, and a 15-20% stock market correction.

The North American economy will continue its gradual expansion with rates of about 2.5% through this year and next. Outlooks will remain positive for Europe and Japan, neutral for developing countries and BRICs.

For fluid power specifically, total fluid power shipments are forecast at a 14% year-over-year change for 2017 and a 7% year-over-year change for 2018. Mobile remains the most positive segment at 16% and 9%, respectively.

Eli Lustgarten, ESL Consultants: Between 2013 and 2018, global growth has been remarkably stable, with increases from 2.5 to 3.0% Growth did slow in 2016—to 2.3%, the lowest rate since 2009—but world GDP growth is currently improving, with approximately a 2.8% rate this year and 3.0% next year. He also sees a deceleration of growth in emerging markets and China.

For domestic manufacturing specifically, industrial production was influenced by a strong dollar, weak global growth and oil and gas declines.

Industrial production stood at -0.1% last year, with some moderate growth seen this year.

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Alan Beaulieu, ITR Economics: Ongoing concerns include China, NAFTA and international trade, Brexit, the German elections, the health care debate in the U.S., South America and oil prices. But he sees positive signs, too—banks are lending, consumers are in great shape, retail sales are at record levels, employment is rising and interest rates are still favorable.

Beaulieu said that business will accelerate the remainder of this year, but will slow down in some key markets in 2018. Expect a slightly positive year in 2018 and slightly negative year in 2018 for business. But the economy is on solid footing for economic reasons—and not because of noise from Washington or the presidential election.

FPW

www.fluidpowerworld.com

9/22/17 10:29 AM

They all look alike . . . . . . they cost the same . . .

SO HOW DO I CHOOSE?

Don't scratch your head.

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Know our people and you will understand the positive difference that FABCO-AIR products can make in your life. Know that we are the ones who will work tirelessly with you to get the results you want! Of course we have all the great, off-the-shelf products you use - the highest quality products with proven performance and reliability.

But, when a standard won't cut it, we'll put everything we have into prototyping a special product for you within 72 hours!

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Fabco-Air | FPW 9-17.indd 11

9/21/17 3:48 PM

DESIGN NOTES

Excavator with intelligent machine control provides 63% more efficiency Edited by: Mary C. Gannon • Managing Editor

The latest machine release from Komatsu America Corp. is the new PC210LCi-11, Intelligent Machine Control hydraulic excavator.

This second generation PC210LCi leverages the proven track record and success of its predecessor, the PC210LCi-10, with added machine-controljoystick functionality.

This offers up to a 63% improvement in excavating efficiency over a standard PC210LC-11 and traditional stake-plus-grade-checker methods.

This extra efficiency can save time and money by: 12

FLUID POWER WORLD

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9 • 2017

1. Minimizing the need and expense of grading dozers and grade checkers 2. Minimizing the costs associated with over-excavating, including extra materials, fuel and time, and 3. Using the time usually wasted waiting on grade checkers and over-excavation to finish jobs and potentially collect on-time or finish-early project bonuses.

“This excavator is productive and precise enough to be a fixture on jobsites from basement and foundation pads to utility work,” said Sebastian Witkowski, product marketing manager, Komatsu America. www.fluidpowerworld.com

9/21/17 9:25 AM

NEW Instant Online

DESIGN NOTES

Configurator.

Now you can configure Fabco-Air products anywhere.

On the shop floor. At the airport. At a remote job site. And you can do it with almost any device.

Even your smart phone!

The Fabco-Air configurator is the most comprehensive, user-friendly, and dynamic program in the industry.

It generates everything you need from one location.

Komatsu’s new PC210LCi-11, Intellige nt Machine Control hydraulic excavato r takes advantage of integrated solu tions and existing technology such as stro ke-

sensing hydraulic cylinders, machine

control function enabled joysticks,

and more to provide 63% greater excavati ng

efficiency, freeing up the need for othe r machines and tasks.

Pioneering intelligent machine control almost five years ago has given Komatsu’s network of Technology Solutions Experts (TSE) unmatched experience helping customers maximize their intelligent machine control investment. That experience has also helped customers identify integrated solutions and services opportunities, such as: • SmartConstruction solution services, including 3D modeling, jobsite setup, operator training www.fluidpowerworld.com

FPW_DESIGN NOTES 9-17_Vs3 Final.indd 13

•

•

•

Additionally, the program includes an unprecedented DECONSTRUCTION feature.

Simply input a valid Fabco-Air part number to display all relevant information.

DECONSTRUCTION can also be used to re-configure a basic part number for different mounting, stroke, added options, etc.

Remote support, troubleshooting of 3D GNSS technology via included cellular modem Bundled block time TSE support packages, including on-site and remote/phone support Komatsu distributor single point-of-contact for all base machine or machine control issues 9 • 2017

FLUID POWER WORLD

A few clicks instantly give you: • Product Part Numbers • List Prices • Lead Times • CAD Files • Seal Part No's & Prices • Repair Kit Part No's & Prices • Mounting Hardware • Accessories & Attachments • Switches/Sensors

Try it out now at

www.FABCO-AIR.com 13

Phone (352) 373-3578 • Fax (352) 375-8024 E-Mail service@fabco-air.com

9/21/17 9:25 AM

DESIGN NOTES

Key features of this technology include: • Factory integrated: Intelligent Machine Control technology is factory installed, integrated into the base machine, and validated to Komatsu’s quality standards.

• Machine control function enabled joysticks: Frequently used machine control functions are now located on the operator’s control lever for increased convenience and comfort.

• Full 3D GNSS capabilities: Not limited like 2D-only systems, the PC210LCi-11 features full 3D capabilities, allowing it to dig to grade everywhere on the jobsite a 3D GNSS dozer can.

• Work equipment automation: GNSS technology is tied into the machine hydraulics to allow actual automation of work equipment functions—not just the indication/manual-only operation typical of aftermarket offerings.

• Stroke-sensing hydraulic cylinders: There is no delay position readout with Komatsu’s proven, robust technology, validated in thousands of machines worldwide.

• Intelligent guidance: Advanced features such as facing angle compass and minimum distance bucket control are delivered in a simple and intuitive manner, with a 12.1 in. touchscreen display.

FPW

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9 • 2017

Komatsu America Corp. komatsuamerica.com

www.fluidpowerworld.com

9/21/17 9:26 AM

Check this out!

DESIGN NOTES

Edited by: Mary C. Gannon • Managing Editor

Hose fabrication machines help company to serve diverse hose needs

A Geib technician uses the FinnPower FP20UC crimper, a serial

You have a new source for NFPA Hydraulic Cylinders

production crimper for high-volume production applications that require

optimal crimping force, speed and

Working with the right suppliers is efficiency. key to the growth of Geib Industries, which focuses solely on fabricating hose assemblies and hose-related products.

With 70 years in business, the company was able to expand into a 74,000 ft2 facility in Bensenville, Ill., last year. The company said this longevity is due to its dedication to helping its customers fill their hose and fittings requirements.

What sets the company apart from its competitors is its focus on only hose assemblies and hose related products. “Our product line consists of hydraulic, metal, industrial, Teflon (PTFE), thermoplastic, and composite hoses,” said Chris Geib, president.

“There aren’t many companies that have the ability to fabricate all hose varieties in-house. Hose is all we do…and we really focus on it.”

The business also has a very diverse customer base that has helped the company maintain a steady growth trajectory. “Each year, the company grows from anywhere between 3 to 12%,” said Geib. “We don’t have large peaks and valleys because we have

www.fluidpowerworld.com

FPW_DESIGN NOTES 9-17_Vs3 Final.indd 15

9 • 2017

FLUID POWER WORLD

Operation to 3,000 PSI Bores: 1-1/2" to 24" Strokes to 10 feet All NFPA Mounting Styles Oversized Piston Rods Proximity Switches and more

Tel (352) 373-3578 • Fax (352) 375-8024 www.fabco-air.com E-Mail service@fabco-air.com 15

9/21/17 9:27 AM

DESIGN NOTES

The Geib product line consists of hydraulic, metal, industrial, Teflon

(PTFE), thermoplastic, and composite hoses. There aren’t many companies that have the ability to

fabricate all hose varieties in-house

such a diverse customer base that crosses over many different industries. And we are equally divided between OEM and MRO accounts, which also helps with our diversification. We don’t hone in on one particular market segment then live and die in it.”

The company plays in a variety of markets, including industrial engine builders, pump manufacturers, food processing, hydraulic equipment, packaging, steel mills, petro-chemical plants, and nuclear power plants. “We really excel when a customer needs a hose-centric supplier,” Geib said. “If hose is an important piece of their business, that’s when we shine. We have the ability to provide all hose products, the service, the engineering, and the know-how customers need from one source.”

Suppliers are key to success Geib said the company chooses its suppliers carefully and that it aligns itself with highly respected suppliers. This is why the company only uses Lillbacka Finn-Power crimpers and hose cutting machines. The company switched to Finn-Power from another brand, said Mike Mirch, general manager. “They were real

16

FLUID POWER WORLD

FPW_DESIGN NOTES 9-17_Vs3 Final.indd 16

9 • 2017

.

dinosaurs in terms of stroke speed.

They were very slow and had very low tonnage,” Mirch said. “In addition, the older crimpers had huge footprints.”

Geib replaced the old crimpers with five Finn-Power crimpers and one hose-cutting machine because the company touts itself as a job shop, not a production house. “We crimp small lots of 5, 10, 15, 20 units,” Mirch said. “Each Finn-Power crimper is performing a different service for the different styles of hoses that we sell.”

The latest additions have been the Finn-Power FP20UC crimper and the CM75PH hose-cutting machine.

The FP20UC serial production crimper was designed for high-volume production applications that require optimal crimping force, speed and efficiency. It offers a 10 to 61 mm crimping range and operates with a 1500 kN crimping force. The FP20UC is highly efficient and can produce 2,300 crimps per hour quickly, accurately, with high repeatability and quality.

In addition, it features a UC Controller, which offers automated quality control reporting options and an easy-to-use menu guided operation. The UC Controller has many options such as pressure crimping, multi-step crimping, and process control monitoring. It also has energy-efficient modes to place the crimper into a standby mode when not in operation.

When Geib purchased the FP20UC crimper, it also purchased the Finn-Power CM75PH hose-cutting machine. This hose-cutting machine is designed to cut all types of hose up to 2 and 3 in. diameter, and 6-spiral hoses. The 520/650 mm diameter blades operate at 3,000 rpm. The hose is pushed against the blade by a

www.fluidpowerworld.com

9/22/17 10:32 AM

NOW Get

DESIGN NOTES

more drop-in interchanges

pneumatic cylinder. Piston movement speed can be quickly and easily adjusted to choose optimal cutting speed for each type of hose. Lower speeds are used with thick hoses to avoid overheating of the blade.

The blade can be re-sharpened when necessary. The cutter has a builtin bin for the collection of cutting waste.

Another Finn-Power crimper feature that Geib staff likes is the Quick Change Tool System (QC), which allows the entire die set to be changed in one easy operation. The pins on the QC Tool engage the QC holes in the dies. As the master dies open/close, the die segments are released from the master dies and retained by the QC tool. The die segments are held to the tool by a magnet. The die set then can be stored in the QC storage rack. In this way, the segments are kept in complete sets and are always used in the same order. “The speed of the Finn-Power crimper is definitely a benefit, both in the stroke of the crimping and in the ability to quickly change dies,” explains Geib.

“Because we are a job shop, we change on every order. The order has 6 or 7 line items, and 80% of the time each one of these different line items will need to have a different die change.”

Finally, integrity of the crimp is very important for Geib. “We have a tremendous maintenance schedule, and the Finn-Power crimpers are extremely sturdy and reliable. They keep their ovality, and the crimp spec is always right on. We also use the Finn-Power crimpers for coolant lines and large oxygen and water hoses used in the primary metals market, and steam hose assemblies used in oil and gas refineries, nuclear power plants, etc.

“New customers often visit our facility,” said Geib.

“They are impressed by the ease of use of the Finn-Power WHAT Connect with crimpers and their attractive appearance. The crimpers thousands of DO engineering really help us sell our facility. There is a lot of engineering in YOU design the crimpers. They are very reliable, the hardest working, THINK? professionals online. and the most durable.”

from the air cylinder source

FABCO-AIR

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Phone (352) 373-3578 • Fax (352) 375-8024

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FUNDAMENTALS

Edited by: Paul J. Heney • Editorial Director

Why compact air cylinders are still important The “less is more” trend seems to be prevalent in the pneumatic actuator market, as real estate on OEM equipment is at a premium. Compact air cylinders go back to the late 1950s, and satisfy the need for short stroke, low profile, compact actuators that have to fit in very tight spaces. In fact, this cylinder type provides the longest stroke possible in the smallest overall envelope size.

Today, compact cylinders using compressed air are most often the primary solution when space is limited and mechanical actuation is desired. A typical compact air cylinder is between the bore size range of ½ to 4 in. (12 to 100 mm) with standard strokes ranging from 1⁄16 to 4 in. (1.5 to 100 mm). With the typical maximum standard stroke of 4-in. (100 mm), these cylinders are also frequently referenced as short stroke cylinders.

The original pancake cylinder is a bored body design as shown in the cutaway view in Figure 1. In addition to the bored body design, compact cylinders are now offered in a conventional tie-rod/spacer configuration in both a round and square design, Figure 2, as well as extruded body designs, Figure 3.

Compact air cylinders have a piston rod configuration (as opposed to a rodless cylinder). Piston rod cylinders function in two ways: double-acting and single-acting. Double-acting cylinders (of which Figure 1 is an example) use compressed air to power both the extend and the retract stroke (moving the rod back and forth). This arrangement makes double-acting cylinders ideal for pushing and pulling loads. Here are some common double-acting, compact air cylinder application functions: • • • • • • •

Assembling Bending Clamping Feeding Forming Lifting Lowering

• • • • • •

Positioning Pressing Processing Punching Shaking Sorting Figure 1. Bored body designs. | All images courtesy of Fabco-Air

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FUNDAMENTALS

Single-acting cylinders have compressed air supplied to only one side of the piston; the other side vents to atmosphere. Depending on whether air is routed to the cap or rod end determines whether the rod extends or retracts. The most common type is pressure-extended with an internal spring returning the piston to its original position when air exhausts. This is typically called spring return.

Spring extend is when air pressure retracts the rod and the spring force causes the rod to extend when pressure is removed. This makes single-acting cylinders suitable for when a force is needed in one direction only and where the return stroke is unimpeded and unloaded. These are also popular in areas where, for safety reasons, a defined position must be taken in the event of a power failure.

Typical single-acting, compact air cylinder application functions include: • • •

Figure 2. Round and square head designs.

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FUNDAMENTALS

Figure 3. Two extruded body designs

A single-rod configuration is far and away the most common throughout the entire air cylinder industry.

However, a double-rod cylinder design is quite useful in many applications.

Double rod cylinders are used: • when equal displacement is needed on both sides of the piston • when the cylinder is required to perform work on both sides • when it is mechanically advantageous to couple a load to each end, or • when the extra end can be used to mount cams for operating limit switches.

Multiple piston options Multiple pistons are used to increase thrust force of the cylinder. Multi-Power air cylinders from Fabco-Air provide the same output force as much larger bore, single piston cylinders. Higher forces can be achieved in tight spaces versus larger bore cylinders, which require a larger footprint and center-to-center space when more than one cylinder is required.

This technology has been incorporated into the compact cylinder segment as well. Figure 4 shows a 4-stage force-multiplying compact cylinder. Figure 5 shows its extend function in a cross-sectioned view.

If the application requires a compact style air cylinder as well as intermediate load position, three or more rod positions can be achieved via a single cylinder. The most popular is the 3-position configuration.

Figure 5. Cutaway diagram of a four-piston cylinder.

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Figur

e 4. F our-p

iston

cylin

der.

Figure 6. Cutaway diagram of a three-piston cylinder.

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FUNDAMENTALS

Figure 6 shows a cross-sectioned view of an extruded body, 3-position cylinder in which the piston rods are shown partially extended for illustration purposes. The two cylinder bodies are coupled using two socket head cap screws. Piston rod ‘B’ extends through the cap end of the front cylinder and can push Piston ‘A’ as it extends. To set Position #1, imagine that both pistons are retracted; in Position #2 Rod ‘B’ extends moving Rod ‘A’ partially forward; Position #3 is reached when Rod ‘A’ is fully extended. You can see that Rod ‘A’ must be longer than ‘B’ in order to get three discrete positions with your cylinder.

Applications Compact air cylinders are selected by their ability to perform a specific function. These functions are boundless. Here is a sample of some common applications and industries that typically employ compact air cylinders: • • • • • • • • • • • • • • •

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TRAINING

Josh Cosford • Contributing Editor

Understanding solenoid valves

A solenoid valve is an electrically activated valve, typically used to control the flow or direction of air or liquid in fluid power systems. Solenoid valves are used in both pneumatic and hydraulic fluid power systems, and most often in either poppet or spool configurations.

The spool or poppet of the valve is connected to a ferrous metal plunger, which is typically spring centered or spring offset. The plunger slides within a core tube of non-ferrous metal, which itself is surrounded by a coil of electrical windings. The coil can exist as any range of voltage from 12-48 Vdc to 110220 Vac. When power is sent through the coil, a magnetic field is created that pushes or pulls the plunger, shifting the valve.

The most basic solenoid valves are two-way, two-position poppet valves, which simply open and close to allow flow when their coil is energized. They are available as “normally-open” and “normally-closed” versions, which means normally-flowing and normally-blocked, respectively. Normally-open in fluid power is the opposite of normally-open in electronics, which means the switch or contact is open and not flowing electrons.

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TRAINING

Three-way, two position poppet valves are also common, allowing fluid to be diverted from one channel to another. Two 3/2 valves in parallel can be used to control a cylinder bi-directionally. Although construction varies depending on the use, this type of valve can be used for either pneumatics or hydraulics.

Spool solenoid valves consist of a machined spool that can slide within a machined valve body. Each end of the spool can have a plunger attached, allowing the solenoid valve to be pushed in either direction, allowing three positional envelopes. The 4/3 hydraulic solenoid valve is one of the most popular, allowing for bidirectional control of a cylinder in a single valve body. The “ways” of a solenoid valve refer to how many ports it contains, and the “positions” of a solenoid valve refer to how many states it can operate within. A three-position valve requires a springcentered neutral state along with two actuated positions.

Pneumatic valves are available as five ported valves, allowing for a 5/3 solenoid valve for control of cylinder applications. The ways of a pneumatic valve also include its exhaust port, of which there are usually two.

Solenoid valves for either hydraulic or pneumatic applications are available as manifold-mounted modular units, such as the pneumatic or hydraulic ISO valves. These valves contain standard mounting and porting patterns, allowing valves from any manufacturer to be installed upon the same manifold. Most often, these valves are also quite economical, and readily available “off-the-shelf.”

The coils of a solenoid valve can be had with DIN connectors, lead wires, Deutsch connectors or any other popular form of electrical connection used in fluid power and automation. Solenoid valves often have removable coils, allowing quick and easy replacement after they fail.

Coils also have a wide range of application and purpose.

Some are intended for the WHAT Connect with industrial environment, thousands of DO engineering where atmosphere conditions YOU design THINK? professionals are consistent. Mobile environments are much more demanding, and require coils that can handle both extreme temperature ranges and exposure to road film and salt.

FPW_Training 09-17_Vs3 Final.indd 23

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RESEARCH & DEVELOPMENT

Ken Korane • Contributing Editor

The Logset 12H GTE harvester is one example of a hybrid mobile machine. | courtesy of Logset Oy

Decentralized hydraulics for micro excavators

Environmental restrictions and economic pressures have spurred greater interest in hybrid and electric off-road mobile machinery. According to researchers Tatiana Minav, Matti Pietola and Shuzhong Zhang of Aalto University in Espoo, Finland, in addition to well-established methods for energy saving in hydraulic systems, a promising concept is zonal or decentralized hydraulics—an approach first pioneered in the aircraft industry.

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In a presentation at The 15th Scandinavian International Conference on Fluid Power, held this June in Linköping, Sweden, they described a fully decentralized system that can increase productivity, minimize energy consumption and ensure robust performance in mobile machines operating in various environments.

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RESEARCH & DEVELOPMENT

In a conventional excavator, said the researchers, hydraulic power corresponding to the maximum workload is always supplied from a pump and excessive power dissipates as heat. It is often difficult to reduce input power, even during low-workload operation, because combined controls of actuators require distributed flows. In addition, potential and kinetic energies during lowering and slewing braking also dissipate as heat.

Multi-actuator construction machinery is often equipped with load-sensing (LS) systems. In LS systems, the pump supply pressure is adjusted to match the highest load pressure plus a constantpressure offset. When multiple actuators operate simultaneously, power losses in lower-load actuators are particularly significant.

Sizeable energy losses during the working cycle could be avoided by removing the control valves in a typical digging cycle, and a portion of the energy could be recovered.

The researchers noted that hybrid systems have been developed for construction machinery, such as series and parallel hybrid hydraulic excavators. Hybrid systems minimize the power peaks normally required from the engine, which significantly reduces fuel consumption, prolongs engine life, and lowers maintenance costs. Examples include a Komatsu 20-ton parallel hybrid excavator, the Hitachi ZH200 and the Logset 12H GTE hybrid

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forestry harvester. Other trends in the industry include valveless or displacement control and the common-pressure-rail method.

In contrast, the work of the Aalto engineers centers on decentralized hydraulics using direct-driven hydraulics (DDH). In a fully decentralized system, the hydraulic pumps are disconnected from the engine and replaced within hydraulic power packs distributed throughout the system.

DDH combines the best properties of traditional hydraulics and electric intelligence and offers benefits such as: easy electrification of construction machinery; higher efficiency compared to conventional machines; fewer potential leak points; smooth and precise movements; controlled power-on-demand; and energy regeneration.

In this research, a 1-ton class JCB micro excavator was electrified by replacing the 14-kW diesel engine with a 10-kW electric motor and lithium-titanate batteries. A start-stop logic system of electric motor operation improved energy efficiency with conventional valve control.

The aim was to investigate the energy efficiency of an excavator hydraulic system with DDH for typical digging cycles. First, they developed a coupled multi-body dynamics model in Matlab Simulink. To acquire the dynamic response and energy consumption

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RESEARCH & DEVELOPMENT

distribution of the actuators, this study constructed a particular model in Matlab/ Simulink which integrated the mechanics, hydraulics, electrics and control systems of the micro excavator. Simulation results were subsequently validated by a simplified prototype of the micro excavator.

In the micro excavator, internal gear motors (referred to as pump/motors) were selected for DDH units, with operating mode switching between pumping and motoring.

The original valve control system for boom, arm and bucket was replaced with three DDH units respectively. In the DDH unit, a fixed displacement pump/motor with a speed-controlled electric servomotor directly controls the amount of hydraulic oil pumped into and out of the system. The hydraulic pump/motor creates a flow depending on the rotating speed of the servomotor.

Additionally, a hydraulic accumulator replaces a conventional tank.

In the simulation, a typical digging cycle represents an excavator digging a load of earth, rotating, releasing the load onto a pile, and then returning to its initial position.

Bucket capacity is 20 kg.

A key objective was to calculate the energy efficiency of DDH units and overall efficiency in a typical operating cycle, and to determine the energy recovery potential.

Results showed energy efficiencies of the boom DDH, arm DDH, and bucket DDH were 67.5%, 75.4% and 77.5% respectively for the work cycle. The overall efficiency of the front attachment with three DDH units was approximately 73.3%, much higher than the reported 31% efficiency of a typical 5-ton excavator with an LS system. Further, the potential energy recovery for boom DDH was estimated as 1.54 kJ.

For simplicity, simulation results were validated using a standalone DDH power pack representing a bucket or arm cylinder and the same required pump/motor displacement 26

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RESEARCH & DEVELOPMENT

Researchers examined decentralized hydraulics in a machine similar to this JCB micro excavator. | courtesy of JCB

ratio. Measurement results of position, velocity and pressures showed acceptable accuracy, compared with the simulation.

The researchers cautioned that the model entailed a number of simplifications.

The model for cylinder friction did not account for temperature and pressure changes. The pump leakage model considers only pressure difference, not speed and temperature variations. The on/ off valves are not included in this model, and piping is regarded as static fluid volumes. Likewise, cavitation problems

were not investigated. For this initial stage of research, these simplifications are considered acceptable, although they should be accounted for in the future, they said.

System control for DDH and decentralized hydraulics was not the focus of this research and was not investigated in detail. A selfadjusting fuzzy PID control handled speed control for the electric motor, using a fixed PID control as current control and cylinder position control in response to load–torque disturbances from the hydraulics. Because decentralized hydraulics did not use a proportional control

valve, system damping is low compared to conventional systems, which leads to some oscillations. Therefore, the control strategy of the DDH can be improved in the future.

Energy regeneration with DDH could offer additional benefits. For instance, potential energy recovery for the boom DDH can be transformed into electrical power. In this study, the inverter for the DDH was directly powered from the electrical grid, and energy storage, inverter and power electronics were not considered in this stage of research.

Energy could be stored using a battery or supercapacitor, although that requires additional components and affects costs, efficiency and maintenance.

Nonetheless, this research has shown that efficiency gains, typical cycle control and potential energy recovery by DDH are feasible in micro excavators. Therefore, the decentralized approach could be recommended for future constructionequipment designs.

FPW

Aalto University | www.aalto.fi/en/

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ENERGY EFFICIENCY

Ron Marshall • For the Compressed Air Challenge

Compressed air fail: Cooling choke

A tire manufacturer used air-cooled, lubricated screw compressors to feed the production machinery in its medium-sized plant. The plant is located in an extremely hot climate. Over the years, some of the air compressors at the plant reached the end of their useful life and were replaced.

Because the production demand was growing, the plant management decided to increase the total capacity of the system.

Previously the plant used three compressors sized 75, 55, and 30 kW to feed the compressed air to the production machinery. To gain enough spare capacity to protect against compressor failure, a smaller compressor was replaced with a larger 90 kW unit. The plant quickly noticed that whenever this new large compressor was running near full load, it would overheat. Therefore, they adjusted the pressure settings so a smaller compressor operated at full load, while the large unit ran in load/unload with very low duty, reducing the heat it produced.

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A compressed air auditor monitored the system to assess its efficiency; when the data was analyzed, the 90-kW compressor was found to be running at extremely poor efficiency. About half of its energy consumption was consumed in the unloaded state.

The auditor recommended base loading the large compressor so it would carry the full plant load, allowing the small compressor to remain off. Unfortunately, the overheating problem returned when this strategy was applied.

After some investigation the auditor noticed that, while the 90-kW compressor had a very large opening for ventilation at the top of its enclosure, the ducting had to be reduced substantially to fit the ventilation ducts leading away from the compressors. After some questioning, the auditor found that the ducting used for the new compressor was the same size as was used for the previous 30kW compressor. This caused a significant restriction in air flow when used with a much larger compressor—and made the compressor run very hot. The plant is currently changing the ducting so efficient compressor operation can return.

Learn more about air compressors in our next Compressed Air Challenge seminar in your area.

Visit www.compressedairchallenge.org for more information.

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SAFETY

Ken Korane • Contributing Editor

Bucher safety valves deliver energy savings

Safety valves from Bucher Hydraulics help protect personnel and machines in mobile and industrial settings.

Safety valves are critical for protecting equipment and personnel. And, according to officials at Bucher Hydraulics, Neuheim, Switzerland, they can also play a major role in the global competitiveness of mobile machines like cranes and excavators when the focus is on high performance and availability. The company offers an extensive portfolio of safety valves that ranges from application-proven standard products to advanced versions with additional built-in features. And in response to more stringent exhaust-emission regulations, it has now integrated energy-regeneration capabilities into safety valves.

The CINDY-REG series valves (REG stands for regeneration) raise the efficiency in a safety circuit and deliver energy savings of up to 25%. Capabilities reportedly extend far beyond that of a conventional excavator pipe-rupture valve, as the valve controls a load over the entire speed range.

The innovative unit differs from previous designs in that no additional energy is required to retract a cylinder. Instead of controlling lowering operations on mobile vehicles with a conventional counterbalance valve or excavator pipe-rupture valve, a counterbalance valve with “intelligent” regeneration directs a portion of the oil flow into the opposite side of the cylinder. When this volume fills, surplus flow routes to tank with no significant backpressure. The system thus significantly reduces the demand for pump flow, which—depending on the circuit—can then be available to power other operations.

The CINDY-REG safety valve has a zero-leakage control assembly, fast-acting directly operated pressure relief, and an integral balance valve for tandem applications. It can also incorporate a preload that stabilizes the system in the event of oscillations.

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This combination of safety functions and energy savings is finding ever-wider use in the material-handling field, in applications such as ship unloading and long-reach excavators. Thus, the CINDYREG ensures a competitive total cost of ownership (TCO) wherever customers demand shorter cycle times, greater energy efficiency, low maintenance and comprehensive safety, explained experts at Bucher Hydraulics.

Comprehensive valve offerings The CINDY-REG is but one offering in the company’s overall product family. Five different types of safety valves for handling wide-ranging machine-safety requirements include: • • • • •

Basic pipe-rupture valves Excavator pipe-rupture valves Leak-free load-control valves (CINDY series) Spring-loaded counterbalance valves Travel brake valves

All are suitable for safety systems that conform to the DIN EN ISO 13849-2 standard. They can be used in industrial and mobile

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SAFETY

Schematic for the CINDY-REG safety valve

applications, with a particular emphasis on first-rate stability and responsiveness combined with leak-free and energyefficient operation.

Basic pipe-rupture valves close automatically when flow exceeds set ratings. Such valves are used wherever a load must not be allowed to drop rapidly if a pipe or hose bursts—causing, for example, uncontrolled movement of a cylinder. Normally the valve is open and allows flow in both directions. When actuating flow rate exceeds maximum limits, say due to a hose burst, the pipe-rupture valve closes suddenly and blocks flow without leakage.

Excavator pipe-rupture valves (EPRVs) are used when manufacturers must comply with ISO 8643 and EN 474 requirements for excavators equipped with a lifting device.

For example, as soon as a load hook is attached to a bucket, the boom, arm and adjusting cylinders must be safeguarded against a possible pipe burst; and, in the event of an actual failure, prevent uncontrolled lowering or excessive acceleration of the load. In addition, the valve holds the actuator in position when the main valve is centered.

Users can fit these valves to excavators without changing the basic hydraulic system, which may or may not include a material-handling function, because machine behavior remains the same in both cases. Likewise, operators will not notice any difference. This is due to a virtually load-independent, two-stage follower design that features permanently low opening pressures and, even under different loads, retains fine controllability right up to the maximum pressure. At the same time, in closed-loop systems the pilot system has a beneficial effect on energy consumption.

The sophisticated EPRVs have hardened metal seats for durability and reliability, as well as other technical advantages. First, the absence of dynamic seals in the main

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SAFETY

control axis ensures low hysteresis and stable, unchanging settings. Second, load pressure acts in the closing direction, so the valve closes completely even if the spring should break.

Leak-free load-control valves are yet another type of safety valve. These combine load-holding and pipe-rupture functions.

They prevent hydraulic actuators from running ahead of the available oil supply and can be used at pressures up to 420 bar with a safety factor of at least 3.

Thanks to the particular design of the main control axis, load-control valves offer extremely low leakage.

Again, load pressure acts in the closing direction and maintains safe operation over the entire pressure and flow range. Among their advantages, operation is independent of flow forces. In keeping with the trend toward higher flow rates, these safety valves are available in larger sizes with capacities up to 1,000 lpm.

Over the years, engineers at Bucher Hydraulics have developed many applicationoriented systems with these valves. As just one example, they integrated load-control valves into a crane winch that demands the highest levels of safety. Working with the hydraulic motors, the valves ensure reliable closing, and their high opening ratio permits extremely low motor inlet pressures under all load conditions. This is consistent with today’s trend toward increased energy efficiency.

Spring-loaded counterbalance valves typically handle lower flow rates. They are available with various opening ratios as a cost-effective option. Thanks to their special design with a damped actuating piston, these valves provide excellent stability and good controllability.

Travel-brake valves, as the name implies, are an integral part of hydraulic travel drives. The valves prevent drive motors from overrunning when travelling downhill and provide metered braking without cavitation or loss of control.

The design safeguards ride comfort through a

The CINDY-REG safety valve offers energy recovery directly at the cylinder, which reduces energy consumption by as much as 25%. well-thought-out balance between damping and fast valve response.

Depending on the application and available installation space, the valves can be supplied as plate-type, cartridge or SAE flange designs as well as in-line mounting configurations. To withstand often-harsh environmental conditions, valve surfaces are coated with a high quality zinc-nickel finish.

This extensive family of valves helps safeguard the operation of earthmoving and construction equipment, and that demands high reliability. Bucher Hydraulics officials stress that no safety valve leaves the factory without hydraulic testing.

This ensures that users can select safety valves that meet rigorous safety standards and suit their specific requirements, while the underlying sophisticated technology creates competitive advantages such as higher efficiency and machine availability.

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Bucher Hydraulics AG www.bucherhydraulics.com www.fluidpowerworld.com

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WHAT Connect with thousands of DO engineering YOU design THINK? professionals

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With limited space and harsh operating conditions, engineers must often be creative when designing a hydraulic reservoir into mobile machinery. Special materials, shapes and installations can help. | courtesy of Hitachi

Reservoir designs

mobile machinery

FOR

J OS H CO S F O R D • CO N T R I B U T I N G E D I TO R

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Mobile hydraulic machines are the unsung heroes of the world, literally digging the trenches and taking abuse as they fabricate for us the asphalt and concrete world we take for granted.

The extreme weather and extreme demands are waylaid by machines performing at extreme levels. That an excavator, skid steer or farm tractor can perform at such a high level for extended periods in the worst conditions is an absolute marvel of modern engineering.

The unique demands on mobile machinery require no stone left unturned when it comes to the design and engineering time put into them. There are tradeoffs which must be balanced accurately between performance, reliability, efficiency and cost, and it’s an unfortunate reality that one of those factors often displaces the others; you rarely get all four.

To ensure a mobile hydraulic machine performs optimally, regardless of cost, intelligent design of the hydraulic fluid conditioning system must be a priority. Keeping hydraulic fluid clean, cool and dry will ensure reliability regardless of its level of performance or efficiency. The first tool in well-conditioned hydraulic fluid is the reservoir.

A hydraulic reservoir performs many duties of which you may not be aware. It’s obvious the primary function of a reservoir is to hold the hydraulic fluid used to circulate into the actuators of the system, via the pump(s) and valve(s). However, if this were its sole purpose, it would only need to be large enough to hold a volume equal to the differential volume of all the cylinders. Although textbooks may call for reservoir volume to be three to five times the flow rate of a pump, this is a pipe dream for mobile hydraulics, so typically they are much smaller than ideal.

In the brutal conditions faced by heavy equipment, the hydraulic reservoir has to endure more, and operate flawlessly in a whole lot less space.

Cooling considerations The reservoir, often just called the tank, also provides significant surface area for cooling of the hydraulic fluid. You can imagine a 50-gallon steel box with 150° F liquid inside will radiate a fair amount of heat, even if airflow was minimal. Of course, cooling capacity depends upon the differential between hydraulic fluid temperature and ambient air temperature. And herein lies the challenge with mobile equipment; the machines themselves create extensive heat, and that heat can make it hard for a reservoir to radiate anything, sometimes even absorbing that heat.

Although engines are often surrounded by protective shrouds and panels, which provide some barrier to contain the heat, it’s often prudent just to mount the reservoir away from the engine and exhaust components. On truck-mounted hydraulic systems, this is relatively easy to do, as not often engine or exhaust components are mounted aft of the transmission. www.fluidpowerworld.com

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Mobile reservoirs are smaller, so regardless of mounting location, they have less surface area to radiate away heat. It makes me wonder why mobile reservoirs aren’t all made from aluminum cast with integral cooling fins, but then I remember how cost comes into play for mobile machinery. The cooling fins still wouldn’t provide enough cooling, so forced air coolers are used in most mobile hydraulic applications to provide the necessary oil cooling.

However, cooling problems aren’t the only consideration for mobile hydraulic reservoirs.

These 20-gpm, nylon Cyclone cylindrical reservoirs are ideal for mobile machinery, as they rapidly remove suspended air from hydraulic fluid in a compact design. This results in weight and size reductions as well as reduced costs for fluids. | courtesy of Price Engineering

Rivers and baffles A reservoir also gives fluid time for both air bubbles and particle contamination to settle out, but a smaller reservoir provides less of that time. If an industrial reservoir sized five times the pump flow will provide five minutes of settle time, a mobile reservoir sized twice the pump flow will provide only two minutes before that fluid is sucked back into the pump.

Because of the reduced dwell time, reservoirs must be designed effectively to prevent fluid from rivering from the return line to the pump suction line. Rivering is detrimental because fluid recirculates to the pump without first being conditioned; air, water or particles are not given time to settle out. Adding a baffle—or series of baffles—to a reservoir can provide a couple advantages.

The first advantage of the baffle is fluid is given more time to cool before entering the pump again. The baffle is a plate or internal shape added to the reservoir to force fluid to travel a longer distance to reach the suction port.

Because the baffle forces fluid to remain in the tank longer, more time is given to settle out water and particles, and also to allow air bubbles to rise out of the fluid. This is especially effective when the return line enters high in the tank, and the cutouts in the baffle are low in the tank.

Conditioning the fluid Another purpose of the reservoir is that it provides ideal pump inlet conditions. Aside from closed-loop hydraulic systems, which use charge pumps to force fluid into the pump, it’s not ideal to send fluid right from the system back into the pump inlet. With filtration, cooling and deaeration occurring prior to pump suction, all fluid entering the system is once again clean, cool and free from bubbles. Hot, dirty oil can regenerate itself exponentially for two reasons; hot oil is less viscous, causing more internal leakage, which itself creates more heat. The second reason is that dirty oil is like a lapping compound, exacerbating component wear.

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Ideally, your hydraulic machine will employ a kidney loop for filtration and cooling, which less disturbs fluid entering the reservoir, and provides the second benefit of more time for cooling and filtration. A DC electric circulation pump can cool and clean fluid even when the machine is off, just as a modern car’s electric water pump can keep a modern car cool even after it’s shut off.

Because a kidney loop system can be thermostatically controlled, it doesn’t waste energy by cooling in cold weather or low temperature start-ups.

Other considerations Aside from fluid conditioning difficulties related to mobile hydraulic machinery, size and weight limitations must be considered. Mobile machinery has a twofold disadvantage when it comes to choosing a reservoir, in that size and weight are priority considerations. Some machines simply have no large real estate to put a giant cube, and any excess weight reduces payload and increases fuel consumption.

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Although the size of a mobile reservoir can be offset by efficient cooling and filtration, sometimes a big cube is just plain hard to place on a tightly buttoned machine. Engineers of mobile hydraulics can employ various techniques to save space with a fluid reservoir.

One such technique is to use the machine itself as the reservoir. A structural steel channel can be fitted with the ports for suction and return lines, or even the top cut-out to accept a dropin filter assembly. This technique saves both space and weight, since no more extra raw material is needed for the job.

Not all machinery is built with channels of steel, so taking advantage of advanced material construction allows compound reservoir shapes to be effective at reducing space. A hard plastic reservoir can be blow-molded into a compound shape that can be fit amongst several other components. Not only does it remove the limitations of a rectangular steel reservoir, it allows mounting amongst other components that would typically be in the way.

Using a molded plastic reservoir also saves weight. A 50-gal plastic reservoir can still easily be lifted with one hand, compared to a steel unit weighing many more times that. Even more cutting edge is the carbon fiber reservoir.

Although they could be in any shape, just as a plastic unit, they’re often built as lightweight cylinders, mountable anywhere alongside other components. Not only are these tanks lighter still than plastic reservoirs, they’re stronger than steel. For some mobile machinery, and especially with Tier IV emissions restrictions, every ounce of excess weight counts. Although neither plastic nor carbon fiber transfer heat efficiently, they’re effective on machines already employing a cooler.

Mobile machinery is unique in its design and implementation of hydraulics, with many components and circuits used only in conjunction with internal combustion prime movers. The mobile reservoir is not exempt from these unique requirements, so considerations other than fluid conditioning must be factored.

FPW

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Pneumatic

design 101:

Go with the flow

The benefits of pneumatic power can be realized by following some basic design rules for specifying air preparation units, actuators and valves.

Chip McDaniel • Educational Specialist at AutomationDirect

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Compressed air use by industrial machines is a close second to the use of electricity in terms of cost, and well ahead of other utilities such as water and natural gas in most plants and facilities. Electricity is less expensive per dollar of unit energy, but compressed air and pneumatics have other advantages encouraging their use.

This article will show why pneumatics is such a popular

linear power option. Basic pneumatic valve selection will also be discussed—along with a primer on sizing pneumatic air prepara-

Figure 1: This AutomationDirect NITRA Total Air Prep Unit contains the common air preparation components, and allows easy mounting and reduced installation space and cost.

tion units, and selecting pneumatic valves and actuators.

Pneumatic advantages

Linear power transmission is typically done with fluid (pneumatic with air or hydraulic with oil) or electric power. Many vendors like to promote use of electrical actuators and their efficiency, yet simple and reliable pneumatic actuators and cylinders still often drive linear motion.

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Pneumatic components are simple to work with, provide high-speed motion, are positionally repeatable, and are very reliable. Most maintenance personnel are comfortable or quickly trained in the use and troubleshooting of pneumatic valves and cylinders. The use of solenoids, cylinders and sensors is less complex than the electronics, gearboxes and other devices needed to convert motor rotation to linear motion.

Pneumatic hardware is also very affordable. Cylinders, solenoids, hoses and fittings can be purchased at a low cost. This simple pneumatic hardware and low purchase price also drive down the cost of maintenance.

Air cylinders and pneumatic actuators can also actuate and move very quickly when properly sized, and are easily adjusted using inline or cylinder-mounted flow control components. External hard stops or internal cushions provide repeatable positioning at a cylinder’s end of travel.

Pneumatic cylinders and actuators pack significant force in a small package. A typical one-inch cylinder can easily provide more than 100 lb of clamping force. This force is controlled by a simple manual valve, or a by a solenoid.

Figure 2: These valve types, with related circuit symbols, are also often identified by the number of ports.

Pneumatic valve selection

Fluid power control of pneumatic cylinders starts with proper valve selection to deliver clean and dry air to cylinders, actuators and nozzles. The pneumatic valve selection criteria listed in Table 1 helps with specifying the right valves to control air flow and cylinder activation within automated machines.

Table 1: Pneumatic valve selection criteria Switching methods Types of valves Number of ports and position Valve configuration Form factor Valve integration Many valve switching options are available. Directional control valves can be manually switched, but on automated machines solenoid-operated or air-piloted valves are more common.

Solenoid-operated and air-piloted valves are typically switched using 12 Vdc, 24 Vac/dc or 120 Vac power. In larger valve sizes, air-piloted valves are more electrically efficient as they switch a small valve spool, which then 42

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Figure 3: There are many styles of pneumatic actuators: diaphragm cylinders, rodless cylinders, telescoping cylinders, through-rod cylinders, etc.

operates the much larger main valve spool.

The simplest valves are 2-way, and there are also 4-way valves (Figure 2).

These valve types are also often identified by their number of ports. All valves have an air in (P) port, and one air out (A) or two air out (A and B) ports. A valve may also have one or more exhaust ports. A 5-port valve can add a little confusion, but it’s technically a 4-way valve with two exhaust ports, labeled R and S, so the 5-ports are P, A, B, R and S. The two exhaust ports lead to the same place, open to the atmosphere, and are thus considered to be the same “way.”

A 2-position valve, as the name suggests, will be in one of two positions, open or closed. With 5-port, 2-position valves, the two output ports are always in opposite modes. When one is receiving inlet air, the other is exhausting air.

A 3-position valve has a center or neutral position that is either center closed and blocking all ports, or center exhaust with output ports connected to exhaust.

The center-closed valve may be a good option to hold position or perform an inching operation of a cylinder. The center exhaust valve works well to dump air pressure from a cylinder when the actuator is not actuated, often for safety purposes.

What type of valve do you need?

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Generally, a 2-port valve would be used in an air blast application. A 3-port valve could pressurize a vessel, and then drain the pressure when switched. A 3-port valve is also used to control spring-return cylinders, with the spring retracting the cylinder when the valve is de-energized. A 5-port valve is often the best choice for controlling double-acting cylinders as it can pressurize and exhaust both sides of the cylinder for extension and retraction.

Valves are available in poppet, diaphragm and spool configurations. A poppet valve is often directly operated by a solenoid, with an example being a 2-way, 2-position gate valve. Diaphragm valves are like poppet valves but the diaphragm isolates the solenoid operating the valve from the fluid being switched. A direct- or pilot-operated spool valve uses a piston and seals to switch air and is commonly used in 4-way valves and 3-position valves.

A wide variety of form factors and valve integration methods are available.

The ability to manifold-mount or stack valves is often important to simplify plumbing. Simplified wiring of the valves—using a single cable connected to a compact, modular valve bank—is another benefit and should be considered for all applications with multiple valves to avoid running many individual cables.

Air prep specification and sizing

All machines and processes benefit from a supply of clean, dry air. This requires a suitable plant air supply at a consistent pressure, along with air prep at both the plant and machine level.

Plant air should be connected to a manual, lockable air dump valve at the machine level. The machine air prep system should also include a filter regulator to remove water, dust and debris. A regulator is required to reduce the typical 100-130 psi plant air supply to a suitable machine control pressure of 60-90 psi. A pressure switch should also be used to ensure adequate pressure is available.

An electric soft-start valve is important as it both removes motion-causing air pressure from the equipment during an emergency stop, and slows the re-supply of air to the system when turning the equipment back on. This prevents unexpected fast cylinder motion that can cause banging and damage during machine startup.

These air prep systems can be assembled by combining the dump valve, filter regulator and soft-start valve. A more convenient method is to use an all-in-one unit that also contains all the common air prep components along with an automatic drain air filter with a clogged filter indicator (Figure 1). These all-in-one air prep units

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Robust Design for Rough Environments

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Pressure reducing valves are available on each function.

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Complete Motion Solutions Pneumatic, Electric & Hydraulic Actuators

reduce cost and installation space, while simplifying purchasing.

With any air prep system, air usage should be estimated before specifying the hardware. There are a variety of interactive tools online to estimate required air consumption.

The biggest consumers of air are the cylinders and air blast nozzles. Cylinder bore and stroke should be known, and air blast flow determined.

When and how often the air is consumed by these devices is important as well. Users need to collect the data and size appropriately, and remember that the air is not all consumed at the same time.

Pneumatic actuator basics

Pneumatic actuators come in many designs and sizes—and include a variety of mounting methods, internal features and options to provide a robust solution in industrial environments (Table 2).

Table 2: Pneumatic Actuator Options Basic styles Force Speed Mounting Cushions Magnetic pistons

PHD offers an extensive line of pneumatic actuators that are known for long life and high quality. We have 60 years of developing and delivering productivity solutions. Our product offerings include built-to-need components, price alternative components, electric actuators, specialty workholding clamps, and motion control robots. From single actuator solutions to multi-unit systems, PHD and Yamaha Robotics can provide complete solutions for practically any application requirement.

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phdinc.com/fp917 • 1-800-624-8511

Many physical configurations and styles exist to enable a pneumatic actuator to fit into just about any machine or application (Figure 3). Some basic styles include compact, round body, tie rod, guided rod, rotary, ISO and gripper. A piston moving inside a cylinder is the most popular style with aluminum, steel, stainless steel or polymer body materials.

Some can be disassembled and repaired, and others are non-repairable and must be replaced with a new unit if they fail. Single-acting cylinders with a spring return, and double-acting cylinders requiring a switched air supply and exhaust at each end of the cylinder, are available options.

Pneumatic actuator force and speed are a big part of the selection process, and the cylinder must be properly sized to meet design requirements. To start, use an online sizing software, such as AutomationDirect’s Interactive Cylinder Bore Calculator, when selecting an actuator. It’s good design practice to have about 25% more force available than calculated requirements.

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Speed is also an important design requirement, and there are many variables to consider. To see some rules of thumb, check out an online application such as AutomationDirect’s Interactive Theoretical Speed Table to help define required cylinder bore, system pressure and tubing.

If a specific cylinder speed is desired, it’s advisable to size the valve, tubing, fittings and cylinder for a faster stroke—and then use flow control valves to slow the cylinder down to the desired speed.

If extremely fast action is desired, some trial and error testing will probably be required, along with cushioned cylinders to prolong the life of the components in these high-speed systems.

There are many mounting options available including rod clevis, self-aligning rod coupler, rod eye, pivots, mounting

brackets and flanges. Internally, end-of-travel cushions smooth the last half inch or so of cylinder travel, help prevent pounding the end caps off a cylinder, and prevent damage/wear/ tear to connected mechanical apparatus.

Another internal feature is the use of magnetic pistons, which allow magnetic proximity sensors to be easily mounted to the cylinder wall to sense actuator position.

Carefully specify the pneumatic air preparation systems, the valves and the actuators—and add hose, fittings, flow controls and sensors. The result will be a simple, cost effective and robust solution to meet your linear motion needs.

FPW

AutomationDirect | AutomationDirect.com

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Fluid couplings smooth conveying ENSURE

Hydrodynamic torque transmission protects belts, motors and drives.

Kyle Kluttz • Director of Mining and Minerals Div. Voith Turbo York, Pennsylvania

Conveyors used in surface and underground mines, mineralprocessing facilities, harbors and ports routinely move hundreds if not thousands of tons per day. The growing worldwide demand for natural resources has manufacturers upping the limit on beltconveying capacity, resulting in larger and longer designs that require more powerful drives. That brings with it higher loads and possibly heavier wear. These higher-capacity conveyors are often designed with reduced safety margins on the belt which requires greater drive system control to ensure maximum availability and reduce any unexpected downtime.

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I N D U S T R I A L

H Y D R A U L I C S

Hydrodynamic fluid couplings protect large conveyors from torque overloads and torsional shocks.

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H Y D R A U L I C S

Hydrodynamic fluid couplings actively cushion motors, belts and gear reducers in such systems from torque overloads and torsional shock. They maximize power transmission and steplessly control torque, acceleration and operating speed. In addition, they “slip” when loaded beyond maximum capacity and effectively protect the driveline from harm.

Perhaps no single element contributes more to smooth belt-conveyor operation than a fluid coupling. Rugged, robust and compact couplings, such as those from Voith Turbo, work dependably and ensure safe and reliable performance, even under the toughest environmental conditions.

Key components of a fluid coupling are a centrifugal pump and a turbine wheel positioned face-to-face inside a metal housing. Rotating fluid flow generates torque.

Hydrodynamic basics Hydrodynamic couplings transmit mechanical power from a primary driver—usually an electric motor or combustion engine— to a driven machine like a gearbox or conveyor. Two bladed wheels, a centrifugal pump (connected to the motor) and a turbine (connected to the output), are positioned face-to-face inside a metal housing. Rotating fluid flow from the pump deflects through the respective vaned wheels, turns the turbine and generates torque.

Unlike in shafts and gears, hydrodynamic power transmission is indirect. The pump converts mechanical energy to kinetic energy as fluid flow; and the turbine reconverts fluid energy to mechanical energy and torque. Power transfers without physical contact between pump and turbine and, thus, with virtually no wear. Only the requisite antifriction bearings and seals are subject to normal wear.

The fluid itself is also an important design element in a hydrodynamic coupling. Density and viscosity are of prime importance as engineers strive to minimize fluid friction and maximize power transmission and efficiency. Other fluid-related considerations include heat-transfer capacity, lubrication properties for bearings, and material compatibility of the seals.

Fluid couplings typically use mineral-oil based hydraulic (HLP) fluids with ISO VG 32 viscosity. In special cases, such as at low temperatures, users can adjust viscosity as recommended by the coupling manufacturer.

Mineral oil may not be an option in underground mines, hazardous locations and environmentally sensitive sites. As alternatives, water or water-oil emulsions (HFA fluids) are often used, although limited temperature range and cavitation tendency can limit the power rating of a coupling. In contrast, water-free, flame-resistant synthetic fluids (HFD-U) and biodegradable fluids based on synthetic esters often do not require significant design changes.

Constant fill versus fill control The two general types of hydrodynamic couplings are constant-fill and fill-controlled.

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MAIN DRIVE

I N T E R M E D I AT E D R I V ES

TA I L D R I V ES

B E LT T E N S I O N I N G M EC H A N I S M

The belt is often the most expensive part of a conveyor system. Couplings protect that investment through smooth, dependable operation that eliminates mechanical shocks in the drive chain.

Constant-fill couplings are self-contained, surface-cooled units primarily used to limit start-up torque, maximum torque and torsional vibration in the drive chain. As the name implies, they hold a pre-set amount of fluid.

They are filled before commissioning; the ratio of fluid volume to the overall volume of the coupling (called the fill level) affects output.

Manually adding or removing fluid (when stopped) changes operating characteristics.

Various versions are mainly differentiated by their internal volumetric chambers, and the means by which they automatically meter filling and emptying to influence start-up behavior.

They generally don’t need external controls and provide seamless, trouble-free performance.

Application requirements determine the specific design, torque and power capacity. For example, Voith’s smaller TV models provide moderate start-up time, smooth torque build-up, and limit start-up torque to 160% of nominal load. The TV is well matched with short horizontal or steeply rising conveyors in a straight layout, and is mainly used with lowpowered belt drives. It’s suited for speeds from 900 to 1,800 rpm and 37 to 1,000 kW power levels. Other constant-fill models such as Voith’s TVV and TVVS further limit the maximum acceleration torque to as low as 140% of demand.

Fill-controlled couplings are advanced drive-system components that provide higher power-transmission capacity with precisely controlled torque—reducing wear and tear on belt conveyors and the entire driveline.

They include an external fluid circuit. A fill pump delivers fluid from a reservoir to the coupling, and inlet and outlet valves control supply.

In any coupling, power transmission is proportional to the fill level in the working circuit. Fill-controlled couplings are usually empty when the motor starts. Inlet flow raises fill level in the working chamber and, in turn, torque-transmission capability. The unit’s controller can vary the fill level between full and empty, and continuously adjust transmission behavior to maintain precise operation.

The external fluid circuit can also include a heat exchanger to aid cooling. This increases thermal capacity, allowing longer acceleration times and more frequent start-ups with high loads—enhancing overall productivity and equipment reliability.

Fill-controlled couplings such as the TurboBelt 780 TPXL are designed to work with the longest conveyors; conveyors with curves or complex layouts; heavy-duty, high-inertia systems; and those with frequent and demanding start-up conditions. The coupling provides smooth acceleration under heavy belt loads with easy-to-use controls, and a compact design lets it connect directly to 6- and 8-pole motors. It’s optimized for operation at 900 to 1,200 rpm and is rated from 700 to 1,900 kW. Benefits and advantages The belt is often the most expensive part of a conveyor system, and couplings must protect that investment through smooth, dependable operation. As mentioned above, hydrodynamic couplings by design transfer power with negligible wear and eliminate mechanical shocks in the drive chain. Here are some additional advantages over other powertransmission methods. www.fluidpowerworld.com

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I N D U S T R I A L

H Y D R A U L I C S

Load-free motor run up. Asynchronous (induction) electric motors are widely used, particularly in stationary drives like conveyors. However, a disadvantage of such motors is high starting current, which can easily be five times the rated current. High starting current causes a drop in voltage and motor torque and, particularly in weak power systems, could strain the electric grid or cause the power supply to fail.

A fluid coupling in the drive chain significantly relieves motor loads during run up, so the motor quickly moves through the high-current range and minimizes the effects of voltage drop on the drive system. It also permits the use of cost-effective standard motors that don’t need to be oversized.

Fill-control couplings completely decouple the motor and driven machine, so conveyor start-up is independent of motor run-up. The coupling remains empty until the motor powers up, then slowly fills and increases torque. In combination with electronic controls, the coupling gradually applies tension to the belt and effectively avoids shock and vibration. When filled, the coupling operates with efficiency of up to 98.5% and automatically compensates for small torque and load variations.

Load sharing. Many belt-conveyor systems rely on multi-motor drives. Fluid couplings enable sequential start-up of the motors—avoiding simultaneous current peaks and helping protect the power grid. Fillcontrolled couplings remain empty until all motors are activated, so torque builds-up gradually and tensile force on the belt is applied gently in a controlled manner.

Torque can be held within tight limits, depending on the load. Voith fluid couplings also provide active load sharing, which protects individual motors from overload and manages different load situations for various types of drives.

Torque limiting. A coupling limits maximum torque in the drive train in relation to speed.

This provides overload protection and longer life, and drive-system components do not need to be oversized to handle the higher torque for breakaway conditions to accelerate the belt.

Inherent damping. Another advantage of this method of power transmission is the effect on uneven torque conditions. The couplings significantly dampen low-frequency torque fluctuations, and higher-frequency variations barely transfer at all. They improve dynamic characteristics of the drive and protect all system components. Torsional frequency issues in the drive train are virtually eliminated when a fluid coupling is part of the drive system.

Low maintenance. As noted, fluid separates the input and output sides of a coupling, so pump and turbine see little wear and require minimal maintenance. In addition, the robust units are designed and built to be unaffected by environmental influences. They run reliably even in harsh operating conditions. The result is high system availability, greater productivity and less downtime.

Safe operation. Voith fluid couplings meet specifications for demanding underground belt conveyors. They use water as a safe, non-

Hydrodynamic couplings transmit mechanical power from an electric motor to a gearbox with virtually no wear.

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flammable operating medium and are specifically designed for use in explosive environments. The couplings have earned all the relevant certifications for underground mining, such as ATEX, MA, and MSHA approvals.

Non-contact thermal monitoring devices can switch off motors or trigger alarms if overloads raise coupling temperature.

Selection considerations Reputable manufacturers offer a wide range of fluid couplings suited to many different applications. Voith, for instance, offers a broad portfolio of couplings for belt conveyors in power levels from 37 to 4,000 kW. To determine the right coupling for an application, experts say it’s important to know the total system inertia—not merely the power level. The result will be a better-engineered belt drive that costs less and improves efficiency.

Voith engineers typically evaluate parameters such as conveyor layout, conveyor length, conveyor inertia, frequency of starts, adaptation of start-up torque to load conditions, torque limitations, start-up time, and effective power of a conveyor or motor to select the best fluid coupling for a drive. And today, computer-aided engineering tools are an indispensable part of the process.

Custom Features: • Integrated linear position sensors

• Special materials for high strength / weight savings

• Integrated valves for load-holding & counterbalance

Cylinder Manufacturing Capabilities.....

Cylinder Manufacturing Capabilities: • Bore sizes ranging from 1” to 20” (even larger bores are possible)

• Strokes up to 50’ • Operating pressures up to 6,000 PSI

• Internal Cushioning options for deceleration of motion

• Multi-stage telescopic

Visit us at: www.PrinceHYD.com

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Raising the bar on coupling performance AMONG the newest models designed for equipment like large mining conveyors, Voith Turbo recently introduced its TurboBelt 500 TPXL fluid coupling. The fill-controlled coupling reportedly combines the advantages of proven hydrodynamicdrive principles with advanced control technology.

It’s built to handle heavy and varying loads and steplessly adjust transmitted torque and operating speed.

The TPXL’s electronic control system can adapt the coupling’s output torque exactly to conveyor start-up conditions. It permits run-up times that can last several minutes, reduces tensile forces on belts and minimizes current peaks when motors switch on. These couplings allow the use of lowcost electrical soft-starters which can reduce the inrush current of the motor by 50% for installations with a weak grid.

In operation, users need only transmit the belt’s required torque and basic start-up parameters, and the control unit automatically calculates the optimum fill quantity and immediately fills or drains the working circuit accordingly. Equipped with a self-learning function, it simultaneously stores all relevant operational data to match control behavior with actual operations, based on the respective load and previous empirical values.

In addition, the controller, pump and oilsupply unit are designed to work as a single subsystem that offers the capability for predictive, requirement-oriented maintenance of the coupling.

The controller monitors temperature, pressure and speed sensors on the coupling and provides relevant diagnostic information, such as the condition of the oil filter. Remote access capabilities are available.

Another significant enhancement is that Voith engineers have considerably increased the power density of the new coupling, due to a redesign of the vanes on the TPXL pump and turbine wheels. Combining years of experience with CFD simulations resulted in a design that deepens

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vane profiles and channels more operating media into the working circuit of the coupling, which maximizes torque transmitted between the wheels for a given size.

The fluid coupling now transmits twice the power of previous designs without any increase in installation space.

That means the TurboBelt 500 TPXL only requires half the volume to transfer the same torque, doubling the power density compared to similar, conventional couplings. As a result, it’s more compact and the overall footprint is smaller, letting it transmit more power at a lower cost.

In parallel with the controller, the unit is also equipped with fieldbus capabilities. That lays the foundation for future networked-mining applications that encompass the entire extraction process, and is intended to increase conveyor performance, productivity and worker safety.

The 500 TPXL is rated for speeds of 1,200 to 1,800 rpm and a power range of 250 to 600 kW. As a self-contained system, the coupling permits quick and straightforward installation to avoid long production interruptions.

The TurboBelt 500 TPXL is a fill-controlled coupling rated for speeds of 1,200 to 1,800 rpm and a power range of 250 to 600 kW.

www.fluidpowerworld.com

9/21/17 11:22 AM

SECTIONAL DRAWING OF TURBOBELT 500 TPXL TURBINE WHEELS PUMP WHEEL

PUMP WHEEL

CO O L E R

TA N K FILL PUMP

Fill-controlled couplings are advanced drive-system components that provide high power-transmission capacity with precisely controlled torque. A fill pump delivers fluid from a reservoir to the coupling, and inlet and outlet valves control supply. The unit’s controller can vary the fill level between full and empty, and continuously adjust transmission behavior to maintain precise operation.

Outstanding customer service High quality products www.aignepusa.com

Voith TurboSim, for example, is a software simulation package used to analyze belt-conveyor drivelines with hydrodynamic couplings. In particular, TurboSim lets engineers simulate the start-up behavior of belt conveyors under various ambient conditions and loading scenarios. This enables more precise computer-aided coupling selection, provides greater planning safety, reduces operating risks and helps determine output reserves.

During simulation, a key element is verifying thermal performance of a coupling under different loads, as well as with nominal operation or frequent start-ups. TurboSim can analyze a range of ambient conditions (temperature as well as elevation) and interactions with motors and other components.

Based on these calculations, the software can generate start-up curves that can be used to optimize other conveyor parameters, such as belt quality and tension settings. Overall conveyor performance can also be analyzed based on different load and operating conditions. The result is a more accurate, data-driven method for determining which drive system will perform best.

TurboSim is a powerful tool that helps project managers reduce uncertainties and risks, ensuring timely commissioning, high availability and greater productivity, as well as helping identify possible areas for cost optimization.

FPW

Voith Turbo | voith.com

615 -771-6650

The ultimate solution for eliminating leaks

24 Hour Shipping Available

Flaretite Seals Proven performance in: • Construction • Mining • Nuclear Power

• Automotive • Turbines • Refrigeration

• HVAC • Off Shore • Space Exploration

• Steam Applications • Marine • And Much More

Flaretite, Inc. USA 502 S Leroy St. • Fenton, MI 48430 • Tel: 810-750-4140 • www.flaretite.com

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Hose fittings from Europeanmanufacturer Tieffe are built for a wide range of OEM and aftermarket uses. courtesy of Tieffe S.P.A.

A fitting end to

hose connections Hydraulic fittings connect hoses to pumps, valves, cylinders and other

Here’s a look at fundamentals of hydraulic hose fittings, and some recent innovations.

components used throughout a hydraulic system. These secure connections help contain and direct the flow of hydraulic fluid to where it is needed while preventing leaks and safely maintaining pressure.

Experts say that it pays to differentiate the hose from a completed hose assembly. While selection of the hose is obviously important, selecting the hose without considering the fittings can be a costly mistake. Any hose assembly includes fittings that are specific to the application. An industrial hose assembly must have the hose, fittings, and a way to attach the fittings to the hose. For most hydraulic hoses, the fittings have a barbed end that inserts into the hose ID, and an outer shell or ferrule that attaches to the cover or reinforcement.

Crimping is the most common method for assembling hoses and fittings.

Once the crimp specifications have been checked for a specific hose and fitting, a crimping machine is adjusted to the appropriate crimping diameter setting.

MARY GANNON MANAGING EDITOR

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When your system is under pressure

High pressure filters ● All mounting styles and connection options ● Both single and duplex options available ● Pressures up to 14500 psi ● High flow capacities

● Full range of micron ratings all Beta

1000 media ● Stainless steel range for various fluid applications/environments

...because contamination costs!

MP FILTRI USA Inc. Tel: 215 -529 -1300 Email: sales@mpfiltriusa.com

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The “right” components

for safe, long-lasting hydraulic assemblies are couplings, hoses, and crimping equipment and accessories that are designed to work together.

TOMPKINS QUICK DISCONNECTS Tompkins Quick Disconnect series allows for the connection of multiple hoses in multiple circuits easily.

Tompkins supplies flush face, poppet and ball style quick disconnects in most ISO standards in sizes up to 2” for mobile, off road, agricultural and industrial equipment. www.tompkinsind.com

The next step is to lubricate the fitting, push it into the end of the hose, and then insert the fitting into the crimper dies.

Actuating the crimper closes the dies and compresses the fitting permanently onto the hose.

Many companies offer no-skive options on their hoses.

Skiving refers to a process where part of the hose cover or even the inner tube is removed—exposing the reinforcement layers—before a hose end is attached. No-skive hoses do not require this step. Many users prefer no-skive options because it makes hose assembly quicker and reduces the risk of hose damage during crimping.

Hoses come in many different types made of various rubber compounds, elastomers, plastics, PTFE, composites or even metals. Fittings are made of different materials, too, including steel and stainless steel but also brass, “exotics” like Monel and more. This multitude of materials creates fittings with a wide array of performance capabilities.

Therefore, in addition to the hose, users must choose fittings for chemical compatibility, as well as the security of the connection. Most hydraulic fittings have designated pressure and temperature ratings as well as size and dimension standards set by organizations like SAE International.

There is also breakdown by application to consider, such as operating pressure, flow capacity, environmental and temperature extremes, and the operating fluid.

When installing a hose assembly, it’s important to pay attention when identifying the threads of the connections. Often, connections from one standard appear to thread into another standard port but do not have sufficient engagement to be safe.

Furthermore, most fittings are brandspecific for certain hoses and may not work with other brands. While fitting dimensions often correspond to the size of the conductor there can still be a variance in fitting options for one size of hose.

That brings up a common question, “Can I use hose and fittings from different manufacturers in the same system?” According to many experts, the short answer is “no.”

www.tompkinsind.com | 800-255-1008

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The Leading Supplier of Complex Components for the Fluid Power Industry Mixing and matching components from different manufacturers is the traditional way of life for many industrial hose distributors and end-users, but this approach to making hose assemblies leaves fabricators and users open to greater liability than ever before.

The “right” components for safe, long-lasting hydraulic assemblies are couplings, hoses, and crimping equipment and accessories that are designed to work together. Tolerances vary from one manufacturer to another and are not interchangeable. Different components from different manufacturers can adversely affect coupling retention. Casual mixing and matching can lead to hoses bursting, couplings leaking and blown-off ends maiming or even killing workers.

In addition to the dangers involved, mixing and matching brand names will void the manufacturer’s warranty and could also exclude manufacturers from liability should someone get injured from a failed hose assembly.

Companies that make their own hose and fittings say their products are combined into finely engineered hose-assembly systems that are specifically designed to work together. However, companies that only make fittings often have their products certified by third-party testing organizations to work with specific types and brands of hoses. For the user, when in doubt, always consult with an expert to guide you through the selection process.

Many manufacturers around the world produce hydraulic hose fittings.

Here’s a look at several interesting offerings for industrial and mobile applications.

Precision CNC Turning Precision CNC Milling Plastic Injection Molding

Custom Seals, Couplings, Fittings, Bearings, Valves, Insulators and Cylinders for Fluid Power Applications

STREAMLINED FIT TING LINE

ContiTech, with North American headquarters in Fairlawn, Ohio, manufactures an extensive range of low-, medium- and high-pressure fittings for braided, spiral and thermoplastic hose. They come in thread ends that meet all common specifications, including SAE, NPTF, JIC, British Standard, DIN, JIS, and API; and in end styles that include straights, swivels, elbow,s and flanges.

For example, the company’s B2 and SG fittings provide users with size variations simplified into two families to streamline selection of the proper fitting for an application. A full-length crimp offers maximum coupling retention for a safe and long-lasting assembly. And the interlocking Biteto-Wire design has serrations that penetrate the cover and firmly attach to the wire reinforcement, resulting in even hose compression and maximum integrity without requiring an internal or external skive.

The couplings are used with various hoses, including the new ContiTech constant-pressure spiral hydraulic hose that offers high-pressure capacity, abrasion resistance, and flexibility that the company says is markedly better than SAE bend-radius specs.

ContiTech, like its major competitors, says users should only match hose with the same manufacturers’ fittings. ContiTech supports this through crimp

Materials Used: Aluminum, Ultem, PVDF (Kynar), PEEK, PVC, UHMW, Delrin, Teflon, Torlon, Nylon, Phenolics (G10, XXX, LE, etc.), Steel, KEL-F, PPS, and Polypro

www.brogan-patrick.com Brogan & Patrick Manufacturing Wisconsin Office 515 E. Centralia St. • Elkhorn, WI 53121 Phone: 262-723-6909

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Contact: Shawn Healy • shawn@brogan-patrick.com • 630-639-5011

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specs that are developed and rigorously tested to ensure that fittings will stay on the hose at 4X the working pressure, as required

by SAE. Customers can quickly find relevant specs by downloading ContiTech’s Hydraulic MyCrimp Spec App for smart phones from Google Play or the App Store. It provides users with up-to-date specifications to properly crimp ContiTech hydraulic hose and fittings. Users can search by hose style, coupling style, hose size and crimper, and the app details the information required to properly set up and crimp the desired assembly.

CONTITECH | CONTITECH.US

SPIRAL-HOSE FIT TINGS

Eaton, Eden Prairie, Minn. offers the 4S/6S series of spiral hose fittings, which are said to feature major advancements that help provide a robust, practical and complete engineered hose-assembly system. The fittings are designed for high-pressure hydraulic systems commonly found in mobile and industrial equipment used in the machine building, mining, construction and agriculture markets.

The updated fitting series now features Dura-Kote plating for superior corrosion resistance, a non-brazed nipple design to decrease the risk of product failure, and Class 0 cool-down leakage following impulse testing as outlined under SAE J1176 when coupled with Eaton hoses. Built with captive nuts instead of crimp nuts, the fittings prevent cracking, even if over-torqued.

Because durable, reliable engineered hose assemblies are critical to machine performance, the 4S/6S series of fittings are designed to work with the majority of Eaton’s spiral hoses, and the assemblies meet or in most cases exceed industry requirements set

by EN, SAE and ISO standards.

The 4S/6S fittings have also been simplified to a common design, and can be used on the widest variety of Eaton rubber hydraulic hose products, reducing inventory requirements and making management easier. The fittings are available in sizes -12 through -32.

BRAIDED AND SPIRAL HOSE FIT TING

Interpump Hydraulic Connectors, Muncie, Ind., supplies a complete line of hydraulic hoses and both one-piece, no-skive fittings for spiral and braided hose; and two-piece fittings in external skive and no-skive variations. The fittings come in numerous sizes and configurations. As just one example, the one-piece G series fittings offer end connections such as NPTF thread, JIC 37°, O-ring face seal, SAE boss, inverted flare, metric/DIN, British and French standard, and JIS versions for Komatsu and others manufacturers. Depending on the configuration, sizes can range from 3⁄16 to 2 in. in straights, elbows, swivels, banjos, flanges, and junctions. Interpump Group company Muncie Power Products supports Interpump Hydraulic Connectors, providing ancillary services for the North American market.

INTERPUMP HYDRAULIC CONNECTORS INTERPUMPHOSE.COM

EATON | EATON.COM/4S6S-FIT TINGS

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LunchBoxSessions.com 1·866·628·3224 | info@lunchboxsessions.com

REVOLT AGAINST BORING

Hydraulics and Electrical Training You’re in charge! Move the directional valve levers and see the results of your pressure compensator adjustments firsthand.

Grab the working on-screen multimeter to find the circuit fault. This inventive, explorable training comes from two decades of research, and from breaking the old-school rules.

THIS IS THE TRAINING REVOLUTION YOU’VE BEEN WAITING FOR A fresh take on training from CD Industrial Group Inc. | 1·866·628·3224 | www.LunchBoxSessions.com

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EXTENSIVE FIT TING FAMILY

Hydraulic hose fittings from Tieffe, Cura Carpignano, Italy come in a number of series of one-piece (precrimped) and two-piece no-skive fittings. And they are available in a wide range of sizes for hose IDs from 3 ⁄16 to 2 in. (5 to 51 mm).

Tieffe fittings are designed to handle rubber hoses with steel-wire braided reinforcement (such as SAE 100R1, R2, R16, R17 and R19); steel-wire spiral reinforcement (R12, R13 and R15); and versions with textile-braided reinforcement (such as SAE 100R3 and R6). They also have fittings for connecting with thermoplastic hoses (R7, R8 and R18). In addition, they offer many complementary ISO versions.

End connections include American standard NPTF 60° cone and swivels, JIC 37° connections in straights, 45° and 90° elbows, O-ring face seal (SAE J516), SAE O-ring boss, and Code 61 and 62 flanges. OEM "Supercat" flanges in straights, 45° and 90° elbows are also available.

Other options are British, French, and Japanese standard connections, and a wide variety of DIN-standard connections.

TIEFFE | TIEFFE.COM

NEW TWIST ON JIC FIT TINGS

Engineers at Ryco, Houston Tex., have developed the JSEAL hose fitting, a JIC fitting that reportedly meets or exceeds the performance of O-ring face seal (ORFS) fittings. The design features a convex female seat that is engineered for use with any male JIC fitting. Due to a repositioned strike zone away from the male tip, and the strength and rigidity of the redesigned nut, the JSEAL reportedly handles double the torque and eliminates side-load issues.

And thanks to its convex seat, the design can withstand up to double the working pressure of conventional JIC fittings, depending on the size. Company officials say the JSEAL fitting increases efficiency, improves productivity and reliability, and is more cost effective in terms of warranty claims and parts replacement.

The fitting stands out with a distinctive black nut, which resists vibration as well as excessive torque, stretching and cracking.

For the user, no equipment modifications are required and the JSEAL is fully interchangeable with JIC. They're available in versions for hose sizes from 0.25 to 2 in. and maximum working pressures from 250 to 700 bar, depending on the size.

RYCO | RYCO.COM.AU

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STAINLESS HOSE FIT TINGS

Volz, with headquarters in Deilingen, Germany, manufactures a wide range of hydraulic hose fittings, as well as tube fittings and adapters, in both zinc-nickel coated carbon steel and corrosion-resistant stainless steel.

The company’s stainless-steel hose fittings and ferrules are made from V4A materials—1.4571 (316 Ti) stainless steel. The materials are 100% traceable to the smelting furnace with a 3.1 inspection certificate, if required.

The stainless-steel fittings are compatible with industry-recognized EN, ISO and SAE-type hoses for constructions that include braided, spiral, textile, PTFE, and thermoplastic versions. The range of fittings comes in a variety of configurations, such as

male and female JIC 37° and BSP 60°, DKO in L and S, 3,000 and 6,000-psi flanges, and connections for high-pressure cleaners. All fittings are available in 45° and 90° bend connections, plus numerous step sizes.

According to company officials, Volz stainless fittings are designed for excellent temperature and corrosion resistance combined with high performance under adverse environmental conditions and high loads.

For instance, they’re suited for use in conditions with high salt levels or acids, or near weld seams. They’re especially recommended for long service life in demanding operations, such as in wind-

energy systems, chemical- and paper-processing plants, ships and drilling platforms, and diving robots, just to name a few possible applications. The fittings are used in combination with hoses from manufacturers like Eaton, Gates and Manuli.

FPW

VOLZ | VOLZ.DE

The Quality Choice Look to Dura-Bar to perform better than castings and many lowmedium carbon steels for hundreds of applications. Industries using Dura-Bar for their parts include machine tool, fluid power, oil and gas, industrial, defense, mining, agriculture, automotive and more.

Dura-Bar’s dense grain structure, lack of porosity and shrinkage make for a highly consistent materials with superior machinability, thereby reducing production costs. With continuously cast Dura-Bar, no costly patterns are necessary and bars are available as quickly as the next day from an extensive network of distributors throughout North America and in China.

There are many ways to save with Dura-Bar Continuous Cast Iron.

Customers who have made the switch profit most from significant total part cost reduction due to: • Faster Machining Speeds & Feeds • Zero Defect Guarantee • 10% Lighter Weight • Superior Vibration Damping • Pressure Rated to 6,500 psi Contact us to discuss your application at sales@dura-bar.com 800-BAR-MILL (227-6455) or visit www.dura-bar.com

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PRODUCT WORLD

Drain valve technology with Wi-Fi Spartan Scientific spartanscientific.com Spartan Scientific is introducing its new condensate removal drain valve technology with Wi-Fi capabilities. The CRDV/S and CRDV/S Wi-Fi Series keeps pneumatic systems, air compressor tanks and air lines free of moisture using a closed-loop drain system and smart sensors.

Features include: •

Closed-loop compressor drain system with secure Wi-Fi connection and free app for iOS and Android

•

Reliable water sensing. Remove water when it's there, not when it isn’t

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Timely notification of drain hits through text and email alerts

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Bonus feature that monitors ambient temperature and sends freezing alerts

•

Special ball valve/strainer combination in Wi-Fi version

Hydraulicallyreleased, lightweight failsafe brakes Dellner dellner-brakes.com Dellner Brakes has introduced two new failsafe brakes to its SKP range that combine high power with modular, lightweight design. The new spring-applied SKP failsafe brakes are designed to quickly stop rotary or linear motion in applications such as cranes, winches, conveyors, deck machinery, draglines, wind turbines, oil rigs (draw works) and other machinery.

The new SKP 180, weighing 315 kg, delivers braking force from 141 up to 226 kN through two brake housings, each containing a spring applied piston. This hydraulically released disc

Intelligent compact ejectors with display

brake consists of two symmetrical cylinder housings and can be supplied with or without a mounting stand. The SKP 4 x 180, weighing 630 kg, combines two brake assemblies

Aventics aventics.com

containing a total of four pistons to deliver braking force of up to 453 kN.

Aventics is expanding its range with intelligent compact ejectors. The new ECD (Ejector Compact Display) series consists of four product versions: ECD-BV, ECD-SV, ECD-IV and ECD-LV. Equipped with a special nozzle, these compact ejectors ensure more efficient vacuum generation. When operated at the optimum pressure of 4 bar, air consumption is reduced by 15% compared to a product without this technology. The new ECD ejector series is suitable for handling metal and other nonpermeable workpieces, as well as pastries and other slightly porous products.

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HF Fully Loaded AdF (FPW) 09-17_9x10.875 8/11/17 12:34 PM Page 1

FULLY LOADED

Optimize performance. Reduce energy needs.

Save space. Cut installation time. Increase reliability.

Specify a HydraForce customized hydraulic control solution for your machine. Using our state-of-the-art manufacturing technology, we’ll meet your precise requirements. And we’ll deliver fast turnaround as well as free engineering assistance from design to production.

For more information on our custom solutions, visit hydraforce.com, or contact us at Sales@hydraforce.com

hydraforce.com Lincolnshire, IL, USA 847-793-2300

Birmingham, UK 44 121 333 1800

Changzhou, China 86 519 6988 1200

São Paulo, Brazil 55 11 4786 4555

© 2017 HydraForce, Inc.

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PRODUCT WORLD

Custom packaging suction cup COVAL coval-inc.com

Current to pneumatic (I/P) transducers AutomationDirect automationdirect.com

The FPC (FlowPack Cup) series suction cup is a

NITRA NCP series electro-pneumatic transducers

universal suction cup

convert a 4-20 mA current signal (I) from a PLC

for all types of FlowPack

or other controller to a linear pneumatic output

packaging. This ultra-

pressure (P). Used in paper and paper converting,

flexible packaging will stick

food and drug, petrochemical, HVAC, textile,

to the product, regardless

and energy management industries, NCP series

of shape or material. As a

I/P transducers provide reliable and repeatable

result, it is able to handle very high production rates. The series is based on three innovations: thin and wavy flower-shaped lips that perfectly mold to the packaging; internal cleats that allow for optimized vacuum while preventing crushing and strengthening the hold; and fittings with a lateral vacuum distributor that prevent loss in efficiency. Available in food-grade silicone and with a plastic insert that meets FDA and CE standards, they come in two sizes: round, Ă˜60 mm or elliptical, 120 x 100 mm.

operation of pneumatic valve positioners, valve actuators, air cylinders, damper and louver actuators, web tensioners, clutches, and brakes.

These NITRA I/P transducers are rated for installation in NEMA 4X (IP65) environments and approved for hazardous locations. The NCP series I/P transducers are available in output pressure ranges up to 120 psig for industrial pneumatic and process control applications.

Professional O-ring tool kit C. Otto Gehrckens (COG) cog.de New 5-piece O-ring tool set made of high-quality stainless steel is available for the assembly and disassembly of O-rings. The high-quality stainless-steel instruments consisting of a pointed tool, removal lever, push and pull tool, as well as a flat-headed removal tool, are precisely machined and provide effective aid with almost all assembly and disassembly tasks.

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For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com

Post-compensated, sectional, load-sense valve Muncie Power Products munciepower.com A 33 gpm nominal flow rate valve, the L125’s inlet is capable of a maximum of 40 gpm and its work sections a maximum of 26.4 gpm.

The L125 has good flow sharing parameters and multiple spool flow options. Electrohydraulic and manual shift versions are available. The L125 post-compensated, sectional, load-sense valve is suitable for the utility, agriculture, snow and ice, and refuse markets in addition to specific applications such as truck-mounted cranes, forestry cranes and plow and spreader functions.

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PRODUCT WORLD

Hydraulic sensors for OEM mobile and industrial applications Webtec webtec.com The new J1939 CAN pressure sensors are intended for mounting on a test point or onto the CT range of J1939 CAN turbine flow meters to provide a convenient digital solution for the measurement of pressure, flow and temperature on pumps, valves and hydrostatic transmissions, for example. The CT flow meter can be installed anywhere in the hydraulic circuit for production or development testing, commissioning and monitoring of control systems. Flows from 1 to 1500 lpm (0.25 to 400 US gpm) can be measured at up to 480 bar (7,000 psi). Pressure sensors can also be offered with measurement capability up to 1,000 bar (14,400 psi). Moreover, with the addition of a manual loading valve on the flow meters, further test scenarios can be simulated and monitored, such as pump efficiency.

High performance hose Eaton eaton.com Eaton has expanded its hydraulic hose portfolio with the release of its GH681 hose series, a one-wire braided hose qualified to 1 million impulse cycles. This highperformance hose provides customers with durability in harsh environments.

Standard EN857 Type 1SC hoses are qualified up to

200,000 impulse cycles. The GH681 exceeds this standard by 5 times and is designed to withstand the toughest applications. This durability helps decrease maintenance costs, improves safety and minimizes downtime.

The GH861 hose is used as part of a hydraulic system,

working under pressure to transfer oil to the cylinders in mobile machinery like tractors, lifters, sweepers and agricultural equipment. It is also used for industrial applications such as presses to connect moving parts.

Self-contained electrohydraulic actuator Rexroth boschrexroth.com This self-contained electrohydraulic actuator reduces space and weight by eliminating external piping for heavy-duty loads.

The system

does not require an external power unit.

All oil is enclosed in the cylinder, accumulators, pump and the valves. It is servomotor driven, so only consumes energy when needed.

It pairs all the functions known from servodrives with the physical

advantages of fluid power technology such as high power density and robustness. The standardized sub-assemblies—hydraulic cylinder, control block and motor/pump group—form the basis for these linear axes. The leak-free fluid circuit requires only a very small amount of hydraulic fluid. The system is virtually maintenance-free and the fluid medium service life corresponds to that of the axis.

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Friction cup product line extension Piab piab.com Available in four sizes, the new BXF family comprises a total of 36 cups. Featuring additional bellows, the cups offer an improved level of compensation performance. They are easy to program for de-stacking applications, where rack positions of sheets or other objects might vary slightly. Offering extra flexibility, BXF bellows ensure friction cups are forgiving when they pick objects. They eliminate the need for expensive and cumbersome spring brackets/plungers to be fitted on ejectors or robot end-of-arm tools, for simpler and less expensive installations.

Bent-axis motors Linde Hydraulics lindehydraulics.com Variable displacement (CMV) and fixed displacement bent-axis motors (CMF)—are characterized by high power density and speed. For use in agricultural and construction machinery, they use standardized interfaces, which can be quickly and easily integrated into existing systems without the need for adaptors. Both are available as standard and plug-in versions for use in confined spaces.

With high-speed capacity up to 7,200 rpm, they offer displacement ranges between 60 and 215 cc, nominal pressure of 450 bar, and maximum pressure of 500 bar. The first sizes will be the CMF80 fixed displacement motor with 80 cc and the CMV115 variable speed motor with 115 cc, accompanied by electroproportional controls.

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| courtesy of Accumulators Inc.

COMPONENT FOCUS

How do accumulators improve system performance?

Ken Korane • Contributing Editor

Hydraulic accumulators are pressure vessels that store and discharge energy in the form of pressurized fluid. In essence, potential energy is stored in a compressed gas and released on demand to force oil from the accumulator and into the circuit. Here are some important benefits accumulators provide, and how they make hydraulic systems better.

Energy storage. One of the most essential functions of accumulators is their ability to store energy. Particularly in cyclic or varying operations, the accumulator discharges in times of high demand and recharges during periods of low demand. One example is in plastic injection-molding machines, where high pressure and clamping force are only needed for a short segment of the entire manufacturing process.

Accumulators are often used to supplement pump flow during peak demand. Without an accumulator, the pump and motor must be sized to handle peak power requirements—even if maximum power is only required momentarily. With an accumulator, the system can be sized for average demand. This, in turn, permits a smaller pump that recharges the system during periods of slack demand. It also means a smaller motor, and a total system that demands less energy, generates less heat and costs less.

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Emergency backup. Accumulators can maintain a high-pressure charge almost indefinitely and serve as an emergency power source should a machine lose electric power or a pump fail.

Properly sized units can provide the necessary flow and pressure to retract a cylinder, close a valve, open a mold or move a machine to a safe position until power is restored or the malfunction is corrected.

Accumulators can also safeguard the lubricating film in critical bearings that must have a constant oil supply. If a lubricant pump fails, the accumulator maintains pressure until the machine stops or a secondary pump restores flow.

Vibration and shock reduction. Pumps, especially piston and gear types, generate pressure pulsations in hydraulic circuits.

Sizable pressure spikes in hydraulic circuits are fairly common,

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COMPONENT FOCUS

Piston Accumulator

Bladder Type Accumulator

from connectors and joints, and lower maintenance costs.

An accumulator also reduces overall hydraulic-system noise levels and the transmission of fluid-borne noise to adjacent mechanical structures that can, in turn, resonate. The result is quieter machines and happier operators.

Leakage compensation. Some hydraulic systems must maintain pressure and force when there is no motion or flow, such as holding a loaded cylinder in an extended position or a keeping a clamp closed for extended periods. In such cases, users often shut down the system to save energy.

An accumulator can maintain constant pressure even if fluid slowly leaks internally past piston seals or valve clearances. Only when circuit pressure drops below preset limits does the pump fire up and recharge the accumulator.

“One of the most essential functions of accumulators is their ability to store energy.”

too. Quick deceleration of large cylinders, impacts from excavator buckets and sudden valve closure can generate pressure spikes. And hydraulic fluid readily transmits shocks and pulsations through hose and tubing, and that can wreak havoc with downstream components.

Mounting a small accumulator near the outlet of the pump can absorb pulsations, minimize vibration and provide smoother operation.

Adding an accumulator into the return line of machines can mitigate shocks and cushion the effects of “water” hammer to prevent damage to the sensitive components.

Curtailing system shocks will extend component life, reduce leaks www.fluidpowerworld.com

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Temperature compensation. Swings in ambient temperature or machine operating conditions can cause hydraulic-fluid temperature to fluctuate, and that affects overall system pressure. An accumulator can compensate for temperature-related pressure differences in a closed hydraulic system. Accumulators minimize the effect of pressure changes by adding or reducing the amount of fluid in a circuit.

Faster response. Bladder and diaphragm accumulators have virtually instantaneous response and can quickly supply fluid to fast-acting servo and proportional valves and improve their performance.

Accumulators can also immediately meet peak flow requirements; help keep pressure constant in systems using variable-displacement pumps; and provide force compensation in continuous processes, such as rolling materials that offer varying working resistances, which ensures consistent output and improves productivity and quality.

FPW

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