Automationdirect now offers the Peninsular brand of NFPA standard hydraulic cylinders. Unlike other suppliers, our hydraulic cylinders are in stock and ready to ship to you - no long lead times for made-to-order cylinders. These double-acting cylinders are fabricated to very strict tolerance specifications from the highest quality materials. Many bolt-on mounting options allow for installation flexibility and replacement of existing cylinder installations.
Peninsular hydraulic cylinders offer the features needed for most common applications:
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• Available bore sizes: 1-1/2”, 2”, 2-1/2”, 3-1/4”, 4”
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Servo motors and gear units from SEW-EURODRIVE
Servo motors and gear units offer a high degree of dynamics and performance with a compact design, making them excellent for confined spaces. Multiple frame sizes and torque ratings makes them the perfect fit in material handling, hoist and gantry
applications, and a wide variety of machine automation applications. Their modular design allows for direct gear unit mounting without adapters or couplings. Pair that with the option of single-cable technology and you’ve got a flexible, precise servo drive solution.
VIEWPOINT
5 | Necessity: The catalyst for innovation in the manufacturing industry
Here are six ways your manufacturing team can become more innovative and drive forward
INSIGHTS
7 | What are the trends in asset management?
Asset management is more forward-looking now, incorporating digital technologies and sustainability in the plans
SOLUTIONS
12 | Open gear lubricants' slow, steady evolution
How do you lubricate a 120-ton gear the height of a four-story building that sits outdoors or in a dusty plant environment, while meeting safety, environmental and operating cost constraints?
23 | 2023 Lubrication Guide
SOLUTIONS
31 | How oil sampling helps maintain a healthy compressed air system
Lubricant is the lifeblood of heavy machinery and oil sampling can help engineers get the most of their lubricant’s utility
36 | Five best practices for electrical safety on the plant floor
Here are five electrical safety best practices, centered on a broader effort to employ a culture of safety that can help put the right safeguards in place
40 | How to adhere to lockout/tagout for electrical safety
Lockout/tagout procedures for plants, mines and manufacturing facilities can help ensure electrical safety
44 | Maintenance and safety considerations for pneumatic and hydraulic controls
Pneumatic and hydraulic controls are critical to the manufacturing industry, and implementation requires careful consideration of safety and maintenance requirements
Lubrication is a crucial part of maintaining a cement kiln. Proper lubrication of open gear drives, kiln support bearings and kiln tires play a vital role to reduce friction and wear on the moving parts of the kiln, which can help to extend its lifespan and improve overall efficiency.
Courtesy: Klüber Lubrication
The Tough Torque-Arm Family
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Find out more at info.dodgeindustrial.com/torque-arm-family
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EDITORIAL ADVISORY BOARD
H. LANDIS “LANNY” FLOYD, IEEE Life Fellow JOHN GLENSKI, President, Automation Plus
CONTRIBUTORS WANTED
Are you a subject matter expert in one of these topics? Would you like to author an article on one of the topics below? If so, please submit an idea to: https://tinyurl.com/PlantEngineeringSubmissions
• Efficient motor management
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• Expert Q&A: Hazard protection and hazardous environments
• Material handling
• Pneumatic and hydraulic controls
• Power and electrical systems maintenance
• Predictive maintenance
• Process piping
• Pumping and liquid movement
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Necessity: The catalyst for innovation
In the fast-paced world of manufacturing and industrial sectors, challenges are an inherent part of the process. Every day, leaders face hurdles that demand unique and unconventional solutions.
It is in these moments the age-old adage holds true: “Necessity is the mother of invention.” This maxim emphasizes the critical role of thoughtful and innovative leadership in driving change and finding ingenious solutions. Here are six ways to drive your company forward:
3. Encouraging collaboration: Collaboration plays a pivotal role in unlocking unconventional solutions. Innovative leaders understand that cross-functional collaboration facilitates the exchange of ideas and promotes holistic problem-solving.
1. Embrace challenges: Manufacturing and industrial plants encounter myriad challenges, such as supply chain disruptions, technological advancements, market shifts and resource constraints. These challenges necessitate a proactive approach from leaders who must anticipate, adapt and resolve them effectively.
Amara Rozgus, Editor-in-Chief
4. Leverage technological advancements: The industry is undergoing rapid technological advancements, presenting both challenges and opportunities. Innovative leaders embrace these advancements and leverage them to drive unconventional solutions. They understand the importance of staying updated with emerging technologies such as automation, artificial intelligence and robotics.
When faced with such obstacles, innovative leaders recognize that conventional methods may not suffice. They understand that embracing challenges as opportunities for growth can yield groundbreaking solutions.
2. Promote a culture of innovation: Creating a culture of innovation within a manufacturing plant is crucial for nurturing creativity and problem-solving. Innovative leaders foster an environment where employees are encouraged to question existing practices, experiment with new ideas and propose unconventional solutions. By empowering employees to think outside the box, leaders tap into the collective intelligence of the workforce, harnessing diverse perspectives and experiences to drive innovation.
5. Iterative problem-solving: Innovation often thrives through an iterative problem-solving process. Leaders encourage continuous improvement by implementing frameworks such as lean manufacturing, Six Sigma and agile methodologies.
6. Embrace sustainable practices: Sustainability is a pressing concern. Innovative leaders recognize the need to incorporate environmentally friendly practices into manufacturing operations. By embracing sustainable solutions, such as energy-efficient processes, waste reduction and the adoption of renewable resources, leaders not only address societal and environmental challenges but also uncover innovative ways to optimize efficiency, reduce costs and enhance brand reputation.
In the manufacturing and industrial sectors, necessity truly is the mother of invention. PE
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What are the trends in asset management?
Asset management is more forward-looking now, incorporating digital technologies and sustainability in the plans
Plant Engineering: What’s the current trend in asset management for industrial and manufacturing facilities?
Andreas Eschbach: Asset management as a shared service between supplier, maintenance, engineering and operations. Asset management is no longer a departmental silo but a process for which the responsibility is shared across the company and with external suppliers and customers.
Ed Garibian: Using real-time machine parameter and condition data to create rules for triggering maintenance and inspection actions. Engineering and reliability managers are super focused on not just preventive downtime, but also on creating well thought out, coordinated actions that reduce the time and resources needed for maintenance tasks and work orders.
Because the current trend shows approximately 40% of factories use predictive maintenance to reduce downtime, improve return on investment (ROI) and increase the overall longevity and efficiency of assets — and more than 50% of factories continue to use reactive maintenance strategies and preventive or proactive maintenance — asset and materials management software is evolving to help create a smarter factory by using machine learning (ML) to intelligently increase asset uptime levels, improve maintenance productivity and enhance workforce safety and compliance.
Paul Lachance: The world events of the past five years — including the U.S. and China trade war, COVID-19 pandemic, war between Ukraine and Russia, etc. — have radically altered the global industrial and manufacturing landscape. These, combined with the already-in progress fourth Industrial Revolution, have left us in uncharted territory in terms of efficiently managing our asset
and facilities infrastructures. There are numerous uncontrollable factors like inflation pressure, a skilled workforce shortage and supply-chain issues and organizations need to control costs and stay profitable despite these challenges. Industry 4.0 technology, combined with best-practice methodologies, give these companies the best chance to compete and grow. Smart organizations will embrace the digital transformation to remain competitive.
Danielle Newsome: Digital transformation is a key initiative in most facilities and will continue to trend as companies strive to capture and leverage their information to make data-driven decisions. Using your data to your advantage allows you to transform from a reactive to a more proactive environment, which ultimately helps to reduce your maintenance, repair and operations spend, right sizes inventory and reduces unplanned downtime. Companies want simple, standardized and digital solutions that make it easy to realize quantifiable value.
PE: What future trends should engineers, plant managers and designers expect for asset management?
Danielle Newsome: Government regulations focused on environment, social and governance (ESG) efforts will be more than just a trend that plant managers need to be prepared for. ESG initiatives will encourage sustainable practices within a plant by driving innovation and allow for new opportunities to reduce costs, improve efficiency and reduce waste. Proper risk management and compliance practices will need to be implemented to avoid costly mistakes that could involve significant monetary penalties.
Sustainability goes hand in hand with ESG efforts.
—Paul Lachance Industrial Operations Technology Evangelist On behalf of Brightly Software Cary, North Carolina
—Danielle Newsome Global Product Specialist, Repair and Inventory Services Rockwell Automation Sarasota, Florida
Preventive maintenance and repairs are two things that can be done to prolong the assets you have and achieve your sustainability goals. As consumers demand more sustainable production, plant managers will be at the forefront of optimizing operations to reduce waste and emissions in line with ESG goals. Effectively and accurately communicating the sustainability of your manufacturing will be an important part of brand loyalty and the buying process for consumers.
As companies begin to understand how to use AI, as well as the rapid advancement and growth of the technology, we can expect AI to be a disrupter to asset management. With the workforce skills gap and personnel shortages in manufacturing expected to remain for several years, more companies will turn to AI to bridge the gap within asset management. Maximizing the potential of AI will require facilities to have accurate data collection and analysis.
Paul Lachance: Embracing industrial digital transformation is critical. You don't have to do it all at once —and I'd recommend that you start slow, recognize value/ROI and then ramp up. But it is crucial to get started. Cultural adoption of this amazing technology is essential. If you have a low digital IQ in your organization, start by researching and learning.
There are numerous promising technologies already available that will continue to have a major impact over the next several years. Harnessing data from your plant floor and facilities is an easy starting point and you can leverage low cost, easy to deploy sensors (using IoT). These sensors will enable your assets/facilities to automatically tell you when they need maintenance.
Andreas Eschbach: Emergence of the digital twin as an integral part of asset care and operation. Artificial intelligence (AI) and industrial internet of things as well as open standards such as SysML will help drive the management of assets through the asset life cycle, from engineering through to the supply chain and operations, with a digital thread throughout.
PE: Describe the successes from using programs and systems that incorporate asset management.
Ed Garibian: A properly deployed and automated maintenance and asset performance management strategy produces lower operations costs and minimizes production stoppages, reduces the cost of asset ownership and provides overall increases on the return on asset investment for any organization. A quality deployment will also conserve valuable
skills and human resources and provide advance notification when supplies or other resources will be needed.
Andreas Eschbach: Transparency through digitization means productivity and safety for many in operations. This due to applications that provide greater visibility into asset performance from sensor and operations technology-based data. The asset is no longer a black box.
Danielle Newsome: Reliability often means many different things to plant personnel. Regardless of the reliability tool set, process or strategy used by the plant, the end goal is the same: Understanding the failure and finding the solution that will correct and eliminate machine equipment downtime. Effective tools, like CMMS, can accomplish the reduction of downtime. Using a CMMS will allow you to analyze failure data, inventory usage and work order analysis. Because plant personnel may lack the resource bandwidth to perform all these functions, partnering with an expert can be an effective strategy to find the “Why?” and implement the correct strategies to improve operational performance throughout the plant.
Paul Lachance: As a consultant who supports numerous manufacturing organizations, I am witnessing all aspects of manufacturing transformation by harnessing the amazing capabilities of Industry 4.0. Every historical software category from enterprise resource planning, enterprise asset management/CMMS, manufacturing execution, quality, supply chain, etc. are being influenced by IoT, AI/ML, blockchain, augmented/assisted/virtual reality, 3D printing and more. Each of these hardware and software technologies is showing success with the appropriate application. PE
Llumin asset management and predictive maintenance computerized maintenance management system software example. Courtesy: Llumin
Thank You
In 2023, Atlas Copco celebrates our 150th anniversary. From the United States compressed air and gas team, we want to say a heartfelt ‘thank you’ to all our employees, customers, and suppliers who have been part of our journey –we could not have achieved it without you! As we pass this milestone, our unwavering commitment is to continue to provide innovation which empowers our customers to grow and drive society forward.
GEAR LUBRICATION AND MAINTENANCE
Nancy McGuire, Albuqerque, N.M., STLE
Open gear lubricants' slow, steady evolution
How do you lubricate a 120-ton gear the height of a four-story building that sits outdoors or in a dusty plant environment, while meeting safety, environmental and operating cost constraints?
CObjectives Learningu
• Learn about the different of lubricants and what their strengths and weaknesses are.
• Learn how lubricants can make an impact in a manufacturing and production facility.
ement plants, paper mills, mineral ore processing plants and other large industrial operations rely on huge rotary drums to heat, grind or otherwise process raw materials into salable products. The giant-sized gears that turn these drums cannot be housed practically inside a gearbox, so they are often exposed to outdoor temperature extremes or environments that are dirty and dusty. Open gears must stand up under heavy loads and operate round the clock, often over a span of decades. The lubricants that keep them running are formulated to stand up to demanding conditions while meeting economic and regulatory demands, reducing operating costs and keeping downtime and equipment failures to a minimum.
lower maintenance costs and increased reliability. However, this is a long-term change with a long lead time, he added.
Change has been slow in the open gear field, but it is happening, said STLE member Larry Ludwig, chief chemist and technical director at Schaeffer Manufacturing, St. Louis. The biggest changes have been in lubricant formulations, including transparent fluid lubricants and polymer additives that increase the viscosity of oil-based lubricants. Health and safety concerns regarding possible carcinogens and solvent fumes are driving a shift away from asphaltic formulations, he added.
On the hardware side, automatic spray or immersion systems have largely replaced manual lubricant application (see Figure 1). Manual application was messy, irregular and hazardous for the workers, Ludwig said. Some applications like mining shovels, kilns and sugar mills now use direct-drive electric motors (powered from the electrical grid or by an onsite generator) for some components. However, he said, running large open gears with electric motors isn’t efficient because of the size of the motor required, and the gears still require lubrication.
1: Manual application of lubricant to the teeth of an open gear. Courtesy: Klüber Lubrication/STLE
Open gear lubricants are changing because machinery and industries are changing, said Jonathan Venditti, global market manager for the chemical industry at Klüber Lubrication, München, Germany. Many companies want to move away from open gears in favor of directdrive and gearless drive systems when they install new machinery because of their
The demand for open gear lubricants for specific applications depends largely on the demand for certain end products, which, in turn, is affected by constraints (e.g., raw material supplies and regulatory requirements) and initiatives (e.g., government-funded efforts and corporate strategies), said STLE member Darren Lesinski, technical director of marketing services for TotalEnergies Marketing USA, Inc., Linden, N.J. In the U.S., paper and cement making applications are going strong, he said. Government-funded infrastructure and power station initiatives are helping to drive cement making. Aluminum and iron production are ramping up in the U.S. and China. In Europe, some countries are returning to coal mining to make up for recent disruptions in petroleum and natural gas supplies.
FIGURE
Open gear lubricants have been affected “across the board” over the past few years, Lesinski said. “Not just from an application standpoint but the environmental concerns of certain chemistries that are utilized in open gears, and the logistics issues that we are experiencing post-COVID-19.” He cites examples of issues such as those posed by the war in Ukraine and disruptions in mining industry production, aluminum and steel processing industries and power generation. “So it’s evolving. It’s pivoting in a different direction as far as what’s available now, as far as chemistries.”
Selecting a lubricant
Open gear lubricant manufacturing is a medium to small industry sector compared to that for other lubricants, said STLE member Anoop Kumar, senior staff scientist, Chevron Products Co., San Ramon, Calif., and president of NLGI. As with any other type of gear system, selecting an open gear lubricant depends on gear size and design, operating load and temperature range and method of lubricant application.1 Open gears come in many sizes, up to several meters in diameter, and they often rotate at slow speeds (e.g., about 10 rpms), so they require viscous lubricants, Kumar explains.
The old way of lubricating open gears, Kumar said, was to fill a sump with a semifluid lubricant. The girth gear — the large gear encircling a rotating drum, driven by one or more pinion gears (see Figure 2) — would pick up the lubricant as it rotated and carry it up and around. This method was messy and wasteful, he said. The asphaltic lubricants commonly in use were viscous and drippy, and they attracted dust and dirt. The sump method eventually gave way to manual brush application of heated asphaltic lubricants. However, this was not only messy but also hazardous for the workers applying the lubricants to the moving gears. Today’s lubricant systems are automated, usually intermittent spray applications using a timer. In some cases, older systems can be retrofitted with automated sprayers, which enable operators to adjust the amount of lubricant, using only the amount needed for effectiveness.
For vertically moving gears, the spray nozzles can be contained in a covered box that delivers an atomized, directed spray to the surface of the girth gear as it passes through the box, Kumar said. This type of gear assembly requires fluid lubricants.
FIGURE 3: Oil lubricants can be applied using bath (splashing), circulation or spray systems. Courtesy: Lubrilog/STLE
FIGURE 2: Two pinion gears drive the girth gear on this double-drive cement ball mill. Courtesy: Lubrilog/STLE
ENGINEERING SOLUTIONS
Although it’s more difficult to design similar enclosures for horizontal gears like those used in shovels, it is possible. In these applications, greases with a harder consistency (NLGI 1 and 2) have generally been found to be more suitable, he explains.
Type 1 gears require grease lubricants, said Ludwig. These bidirectional gears, used for mining shovels, excavators and drag lines, need constant replenishment and a lubricant that adheres well to the surface of the gear. Type 2 gears require liquid
FIGURE 4: Comparison of various types of open gear lubricants. Courtesy: Klüber Lubrication/STLE
or semiliquid lubricants, applied using an intermittent spray or immersion system. These gears, which move slowly in only one direction, are used for mills, cement kilns and other processing equipment.
Most gear manufacturers work with lubricant manufacturers to ensure that lubricant formulations meet the manufacturer’s specifications for a given gear design, said Jean-Philippe Merlo, technical manager at Lubrilog SAS (a division of TotalEnergies), Romans-sur-Isère, France. The main lubricant requirements are high viscosity (which depends on operating temperatures and the method of lubrication), the proper types and amounts of extreme pressure (EP) additives and solid lubricants (depending on the type of lubricant, operating speeds and temperatures and defects on active gear flanks) and specified ranges for test results. Standard tests include FZG tests (a measure of an oil’s ability to provide resistance to scuffing and wear), four-ball weld tests, four-ball wear tests and Timken OK load rating (which measures how well EP additives are performing).
In addition, lubricant formulations for routine operations must be free of abrasive components. The choice of a lubricant formulation depends on the operating conditions of the rotary drum but also on a customer’s habits, Merlo said. “For good advice, you have to know the gear set and, above all, do not make the choice by comparing technical data sheets alone. A technical approach is imperative,” he said.
Once the OEM has set their specifications, additional factors influence the choice of a lubricant type. In many countries, including those in the European Union, lubricants containing bitumen are banned. Oils, compounds and greases are available for spray, bath and circulation lubrication systems, Merlo said (see Figure 3), and any of these lubricants can be used as long as they have the needed oil viscosity or NLGI grease consistency. The main factors influencing the choice of lubricant include the type of machine (slow-rotating like a cement kiln or fast-rotating like a mill, for example), the operating temperatures, the method of application and the maintenance protocol.
The condition of the gear also is a consideration when selecting a lubricant. Gears can continue to operate even if they have some amount of scuffing, pitting or other damage, Ludwig said. Temporarily using a lubricant with a higher viscosity, switch-
5: Many open gear customers rely on black greases, which contain molybdenum disulfide or graphite EP additives. Courtesy: Klüber Lubrication/STLE
ing from oil to grease or increasing the amount of lubricant can allow a damaged gear to remain in operation until it can be repaired. Switching from oil to grease is a stopgap measure, he notes, and the gear must be cleaned before switching back to oil.
These stopgap measures, however, require a great deal of caution, because using the wrong type of lubricant or keeping a badly damaged gear in operation can actually hasten equipment failure. Keeping open gear-driven equipment in operation is a high priority, he said. Facility managers might be tempted to keep things running regardless, but pushing a gear to the point of failure can be very expensive. An hour of downtime can cost as much as $175,000 in lost production, Ludwig said, and stopping operations, performing repairs and bringing the equipment back online can take on the order of 100 to 150 hours.
Asphaltic lubricants
Open gear lubricants fall into three major categories: asphaltics, greases and oils (see Figure 4).
Asphaltic lubricants are thick and adhesive. They provide good protection, but in a dusty environment like a cement plant, they also attract dust and other contaminants that can scuff gear surfaces or clog spray nozzles. Asphaltic lubricants contain bitumen, a dense, viscous hydrocarbon product that comes from crude oil refining residues. Originally, using bitumen in lubricants was a good way for oil refineries to monetize this residue, Venditti said, but issues
FIGURE 6: Transparent lubricants enable automated or manual condition monitoring while the gear is in operation. Courtesy: Klüber Lubrication/STLE
Insightsu
Lubrication insights
uSynthetic lubricants are slowly gaining ground over asphaltics and black greases.
uAutomated lubricant application and condition monitoring can increase a gear’s reliability and worker safety.
uOptimal operation depends on the quality, design and condition of the gear set; lubricants that fit the operating conditions; and regular evaluations and maintenance.
FIGURE
ENGINEERING SOLUTIONS
associated with asphaltic lubricants can add to operating expenses for lubricant customers. For example, he said, used asphaltic lubricants are classified as hazardous waste, which adds to the expense and complication of disposal.
For outdoor open gear operations in cold climates (e.g., mining or cement making), lubricant pumpability and adhesion are major concerns. At low temperatures, asphaltic lubricants can flake off of the gear, especially if they have lost some of their base oil, said Kumar. Older asphaltic lubricant formulations rely on large amounts of volatile solvents to keep them from becoming too viscous in cold weather and to keep the lubricant liquid as it is being applied to the gear. However, some solvents pose flammability concerns, he adds.
Some solvents also pose concerns for worker safety. Before regulations and company health and safety rules came into play, manufacturers of asphaltic lubricants used chlorinated solvents and other volatile organic materials. “You would just approach the barrel and your nose would become itchy. Your contact lenses would feel like they were melting in your eyes,” Venditti said. Now, the solvents are safer, he adds, but a mechanic working near a gear on a hot day might notice an odor like diesel fuel or paint thinner.
Diluents have largely replaced solvents in newer asphaltic formulations; the diluent content can be about 10%-30%. Diluents take much longer to evaporate, often 12 to 24 hours, compared with about 15 minutes for solvents. Wear protection levels may be reduced while the diluent is evaporat-
ing, so the lubricant is sprayed onto the girth gear, which has more surface area and rotates more slowly than the pinion gear. This gives the diluent time to evaporate before it comes into the contact zone with the pinion gear. Because diluents never completely evaporate, Venditti said, they lower the viscosity of the lubricant, so these lubricants never reach the theoretical maximum viscosity of the pure asphaltic material.
One drawback to applying the lubricant this way is that the lubricant is only in contact with the pinion gear for a small part of the rotation cycle. Most of the time, the lubricant is exposed to the dusty air inside the plant as it completes the rotation cycle on the surface of the girth gear. Fresh lubricant must be sprayed onto the girth gear often enough to avoid dry spots in the contact zone and to wash out any contaminants that might accumulate.
Another way of keeping asphaltic lubricants flowing in cold weather is to use a heating blanket and heat tracing cables (for temperature control) from the lubricant drum to the injection or spray point. Semisynthetic lubricants are more fluid than asphaltics, and they might not require the use of a heating blanket, Venditti said, which reduces energy costs.
Asphaltic lubricants are still used in some countries because of their low initial cost, Ludwig said. However, the European Green Deal currently being implemented could place restrictions on asphaltic lubricants and the solvents they contain for health, safety or environmental reasons. In the U.S., he adds, restrictions on asphaltics pertain mostly to marine applications, including onshore cranes in ports and cranes and winches aboard ships. Open gear lubricants also are sometimes used as wire rope dressings, where the lubricant is in direct contact with the water, which makes it even more important to ensure that these lubricants are environmentally benign.
Venditti cautions that many of his company’s customers are very conservative, and they continue to rely on the supposedly greater protection provided by “the black stuff ” (i.e., asphaltic lubricants). However, he cites his company’s research and development efforts, including test rig data, which demonstrate that biodegradable oils like esters and plant-based lubricants provide a very good coefficient of friction, high adhesiveness to the gear and a high degree of protection.
FIGURE 7: (Left) Stroboscopic monitoring of the lubricant spray pattern while the gear is in operation. (Right) Stroboscopic image of a pinion gear. Courtesy: Lubrilog/STLE
Grease lubricants
One way to achieve wear protection without the problems presented by asphaltics is to use semifluid grease lubricants. The grease thickener keeps the lubricant on the gear, which eliminates the need for tackifying additives. Even better, the grease does not have to have an extremely high viscosity, so the base oils can come from mineral, synthetic or semisynthetic sources. Solid additives used in greases form a barrier between the pinion and the girth gear, offering more complete protection in the contact area. All of these factors help to reduce the cost of buying and using grease lubricants, Venditti said.
Most open gear greases are NLGI grades 0 or 00, said Kumar. Grease lubricants for open gears mostly use aluminum complex thickeners because these are best for sprayable greases. However, other thickeners, including lithium soaps, clay or polymers, also are used. Polymer additives increase adhesiveness, and high-viscosity (3,000-40,000 centistokes) bright stock oils provide the needed lubricity.
Grease lubricants are especially useful in applications that require solid EP and antiwear additives. However, these additives are one reason that grease lubricants are less biodegradable than oils, said Ludwig. Reducing the amount of solid additive in a grease formulation is one way of making a more biodegradable product, but sufficient additives must be used to maintain the desired performance.
Unlike oil lubricants, which are often transparent, open gear greases tend to be opaque and black because graphite and molybdenum disulfide are the most commonly used solid EP additives (see Figure 5). These EP additives also protect against wear under severely heavy shock loads. Some customers prefer black greases, Kumar said, because the color indicates the presence of solid lubricants. Because opaque greases prevent direct observation of the gear surface during operation, he said, it is important to perform routine condition monitoring of the wear pattern on the gears.
Black greases are less common than they once were, Merlo said. Fewer open gear lubricants contain bitumen, and the use of black aluminum complex greases containing graphite also is declining, as more and more operations shift toward white greases.
Grease lubricants form a tacky protective film on gear teeth, which helps to reduce accumula-
tions of dust on the gear, and they don’t clog spray nozzles as badly as asphaltics do. However, greases can be hard to pump, especially in cold weather. Their main advantages are homogeneity, even distribution of the solid additives and good protection. Greases also stay on the gear surfaces longer than oil lubricants, which not only reduces the volume of lubricant that needs to be applied but also reduces the amount of used product that needs to be recovered for disposal. In the event of a failure of the lubricant application system, greases can allow a gear to run for a longer time without incurring damage.
Grease lubricants also are relatively inexpensive for a mineral-based product, Venditti said. Greases with aluminum complex soap thickeners and other similar thickeners also offer superior resistance to water washout and improved protection against corrosion, he adds.
‘ Open gear lubricants are changing because machinery and industries are changing.’
Oil lubricants
Oil-type open gear lubricants are increasing in viscosity, Merlo said, because of the high loads typical of today’s open gear operations. These high-viscosity oil lubricants, many of which contain synthetic base oils and additives, are a good alternative to asphaltics or greases, but they must be suited to the demands of gears that are not enclosed in a gearbox. The industrial applications that use open gears can have enclosed gearboxes between the pinion and the electric motor that drives the pinion, Venditti said. These gears can be lubricated continuously because the lubricant is contained within the gearbox. In contrast, girth gear lubricants are replenished by spraying the gears intermittently. Lubricant tackiness and high viscosity are essential to keeping the lubricant on the gear and avoiding dry spots. He explains that even though the pressure at any given point of an open gear is no greater than the pressure on gears in a closed gearbox, the same lubricant cannot be used for open and closed gears because of the differences between continuous and intermittent lubricant application.
ENGINEERING SOLUTIONS
FIGURE 8: Biodegradable lubricants lessen the harmful effects of spray lubricants on the surrounding environment. Courtesy: Klüber Lubrication/STLE
Transparent synthetic oil lubricants are gaining popularity because they allow operators to observe the gear surfaces while the gears are in operation to ensure that the lubricant is distributed completely and evenly (see Figure 6). In addition, they provide better performance than most of the greases traditionally used, Merlo said. Advantages of transparent lubricants over asphaltics include better characteristics for the same viscosity (and availability in a wide range of viscosities), no need to use solvents, less accumulation of contaminant particles near the root of the gear tooth and ease of application and cleaning. Transparent lubricants also have a viscosity index advantage—they maintain their characteristics over a wider temperature range than asphaltics. In addition, they present less risk to machine operators and to the environment.
Using a transparent lubricant allows operators (or video cameras) to monitor spray patterns while the gear is in operation. Because a gear may be rotating at about 10 meters per second, some monitoring systems use a strobe light to illuminate the contact area (see Figure 7). This produces a slow-motion effect that makes the evolution of the spray pattern easier to see, Ludwig said.
Transparent lubricants also make it possible to use continuous or intermittent video monitoring to watch for problems like pitting, scuffing or polishing in the early stages, Venditti said. An operator or
service representative can perform a visual inspection through an access door if unusual vibrations signal a potential problem. Inspecting a gear during operation not only provides information about the source of the problem, but it also eliminates the need to stop the equipment to perform the inspection, which reduces downtime.
Heavy oils can be used to lubricate medium to large girth gear drives. The viscosity for typical open gear semisynthetic lubricants runs between 4,000 to 8,000 centistokes, Venditti said. These lubricants can save energy by operating without the use of heating blankets at temperatures as low as -5 °C (23 °F), much lower than for asphaltics or greases.
Although oil lubricants aren’t as adhesive as asphaltics, they don’t require solvents or diluents, so they can be applied more frequently. Because high-viscosity oils, which are most likely semisynthetic formulations, don’t use diluents, they can be sprayed directly onto the pinion, where they are most effective. You can spray fresh lubricant onto the pinion gear every three minutes, Venditti said, “so you use less lubricant and more often, and then you get closer to the lubrication regime of an enclosed gearbox.”
More frequent lubricant spraying onto the pinion gear is an advantage, but it’s also a requirement, Venditti said. The girth gear generally lasts about 20-30 years, while the pinion gear generally lasts no longer than about five to eight years (you can extend this using hardened materials like carbides, he said). The pinion gear spins faster and operates at a higher temperature than the girth gear, which helps with cold-weather lubrication, but it also shortens the gear’s lifetime, he said, because friction resulting from insufficient lubrication can lead to overheating.
Venditti cites a field test in an ore processing facility in which a specialty open gear lubricant reduced the temperature of a pinion gear by 30 °C (86 °F) compared with an asphaltic lubricant. He notes that it was difficult to document any energy savings during this test because the customer kept the power level constant and increased the amount of production. However, the lubricant was successful in addressing the customer’s main priorities: reducing the operating temperature and reducing micropitting wear at the pitch line of the gears.
Polymer additives help a synthetic lubricant provide a hydrodynamic film without the use of asphaltics, and synthetic lubricants have less tendency than asphaltics to build up in a gear, Ludwig said. Synthetic lubricants have good pumpability at low ambient temperatures without the need for solvents, and they hold up well at the high temperatures typical of mills and cement kilns. Synthetic esters have less tendency to oxidize at higher temperatures than do heavy vegetable oils, and they also are more pumpable at low temperatures than vegetable oils.
Performance additives tend to last longer in synthetic lubricants, and they can provide a lower coefficient of traction, which results in less energy required to rotate the gear, Ludwig said. Using synthetic lubricants doesn’t eliminate the need to periodically clean the gears, but cleaning is much easier for these formulations than for asphaltics or greases, an advantage that is not lost on the workers assigned to this unpleasant task.
Venditti notes that different base oils are being investigated for open gear applications—including water-based lubricants, polyethylene glycol, polyalkaline glycols (PAGs) and esters. These lubricants act as coolants, reducing friction by enhancing the coefficient of friction, which helps to reduce the operating temperature of the mechanical components. Semisynthetic waste products are not considered hazardous, so you can recycle them (and sometimes get paid for it), he said.
The disadvantage to using gear oils rather than semisolid open gear greases is the limitations to their viscosity and their tendency to leak, Kumar said. However, thickeners and viscosity modifiers help with this. The decision to use oil or grease lubricants depends on the application and performance required, he adds.
Environment and regulations for lubrication
“Everybody’s talking about environment, social and corporate governance factors (ESG) and lowering carbon,” Kumar said, which is leading many industry sectors to consider more environmentally sustainable feedstocks, processes and products. However, he said, conventional products may have the advantage in performance and price, which requires industries in general to evaluate their priorities when deciding how to balance these fac-
tors. Also, there’s not a clear-cut path for disposing of gear greases, Kumar said, adding that disposal depends mostly on local regulations, and greases are complicated to recycle.
A drive toward greater sustainability and less polluting practices, driven by company initiatives and government mandates, is behind some of the current changes in machinery and lubrication. Because most equipment that uses open gears is located outdoors, spray lubrication “goes everywhere,” including into the surrounding environment, Venditti said (see Figure 8). To make sure that this practice does not run afoul of anti-pollution initiatives, researchers are actively looking into biodegradable lubricants, based on plant materials. One challenge is that oils derived from plant matter tend to have low viscosity, but some companies, including Venditti’s, are developing products that overcome this challenge.
Research efforts on plant-based polymers and biodegradable formulas, including synthetic ester compounds, are particularly interesting to operations like marine applications that have a high potential environmental impact, but mining operations are moving in this direction as well. OEMs also are starting to look at biodegradable lubricants when they set their specifications, Ludwig said. Spills involving biodegradable lubricants must still be reported to the relevant government agency, but because they are considered less persistent in the environment and they are easier to clean up, fines may be lower than for other types of lubricant, or the fines may be waived entirely. That’s one reason that biodegradables, which are initially more expensive, may save money in the long term, while offering the same performance as other lubricants, he said.
Some specialized areas require formulations that meet strict health, safety and environmental regulations. For example, open gear mills for food products—sugar processors, for example—drive a demand for more sophisticated lubricants to meet H1 regulations and other regulatory requirements.6 Marine and freshwater applications, including canal locks and hydropower plants, require open gear lubricants that will not pollute the surrounding water.
Open gear lubricants are moving away from asphaltics and chlorinated solvents; “Asphaltics are high maintenance,” Lesinski said. Depending on the application, he adds, customers can choose to use grease and synthetic lubricant technologies such
‘ Although oil lubricants aren’t as adhesive as asphaltics , they don’t require solvents or diluents, so they can be applied more frequently.’
FIGURE 9: Scuff marks on the surface of a gear tooth.
Courtesy: Schaeffer Manufacturing/STLE
ENGINEERING SOLUTIONS
as products containing perfluoropolyether (PFPE) and polytetrafluoroethylene (PTFE). These products are environmentally cleaner than asphaltics, and they provide a better return on investment and total cost of operation, he said.
Maintenance and repair
Large open gears mounted on industrial machines like grinding mills, kilns and debarking drums (which remove the bark from logs) have a service life that can span up to 40 years. However, it is not uncommon for poor maintenance practices or contamination to reduce open gear service life to as little as eight years, Venditti said. Thus, new project installations and replacement of damaged gears ensure a continuing demand for purchase and installation of new open gears.
OEMs are developing their metallurgy to produce more robust gears that require less frequent cleaning and repair than older gears. Nevertheless, because of the long lifetimes of open gear equipment, lubricant manufacturers must provide a range of legacy products to cover a broad range of OEM requirements for lubricants, cleaners and solvents. “Most of our portfolio hits most applications, but sometimes an OEM will require tweaks to a formulation,” Lesinski said.
Periodic maintenance of lubricant application systems ensures that they function properly, which reduces downtime. Some operations monitor vibrations and temperatures to catch problems in the early stages, but regular gear inspections are still necessary. Regular visits during normal operations from a lubricant supplier’s representative provide opportunities to prevent problems before they occur by identifying lubricant system deficiencies and optimizing lubricant application.
OEMs generally provide recommendations on maintenance procedures and scheduling as a condition of their warranties, but operations managers usually keep up with routine maintenance as a matter of course. “It’s part of the culture to keep the equipment running,” Ludwig said. During maintenance, a representative from the lubricant supplier is typically on site to make sure the lubricant is being applied properly, he added. The supplier’s representative can help with troubleshooting problems and offer guidance on lubricant application and the direction and timing of the spray, and they can help track down the root cause of an equipment failure.
The direction the industry is going in is a cradle-to-grave approach, Lesinski said, going beyond just selling chemistries or lubricants to the customer. Lubricant manufacturers support customers by being present at the customer’s facility for changeouts and repairs.
Routine maintenance depends on the country in which the operation is located, Merlo said. Different regions take different approaches to maintenance. However, customers who regularly schedule plant visits from a lubricant supplier’s technical representative find valuable information in the technical reports they receive after these visits. During a site visit, the technical representative observes the quality of the lubrication and the condition of the open gear set.
Merlo said that technical reports often contain information on the plant conditions that the technical representative encounters during a site visit, along with a comparison with conditions observed during previous visits. The reports also advise actions to be taken to ensure the best and safest use of the gear set. These specialist reports supplement the site visits from a plant’s technical department, and they assist the maintenance manager in making decisions.
Every phase of open gear operations requires a different type of lubricant, Venditti said. When a new gear is put into operation (or during an emergency situation requiring diagnosis of a problem), a colored priming lubricant reveals the contact pattern between the pinion and the girth gear.
Some OEMs and service companies use a running-in fluid, which contains a chemical etching compound, during the first week to month of operations to remove asperities and metalworking marks on the gears and match the pinion to the girth gear,
FIGURE 10: Special repair lapping lubricants, which contain abrasive components, must be applied by qualified technicians.
Courtesy: Lubrilog/
Venditti said. Then, they switch to another type of lubricant for use during normal operations.
Other types of lubricant use abrasives or etching compounds to repair scuffed areas after mishaps like a mechanic dropping a screwdriver or bolt into the contact area or an undetected interruption in the lubricant application that causes the gears to run dry for a day (see Figure 9). “You need to know what you’re doing with this; otherwise, you can cause even more damage to the gear,” Venditti said.
Merlo and Lesinki agree — lubricants used for normal operations should never contain abrasives. Special lubricants containing abrasives can be used for making repairs, “but never by the customer, always by a technician with special training and always after performing a damage analysis,” Merlo said (see Figure 10).
Still other formulations are required for operations in remote locations, Venditti said. These operations sometimes keep an extra gear in storage as a backup, because waiting for a replacement gear to be shipped to the site would cause an unacceptable amount of downtime. The spare gear is often stored outside, so it requires a protective coating containing anticorrosion agents to keep it in good condition, ready for the day when it is put into use.
Insurance companies require open gear equipment to be cleaned and inspected every year or two, Venditti said, and specialized gear cleaning formulations help with this task. Cleanup can require as many as five mechanics working for several days using dry ice and copious amounts of solvent to clean the lubricant and contaminants off the gears. “It’s really painful and disgusting for the team,” he said, but he adds that other cleaners on the market can reduce the time and effort significantly.
Lesinski notes that environmentally friendly volatile organic compound (VOC)-free cleaning solvents are available for routine maintenance. When used properly, environmentally friendly solvents are low impact with respect to skin contact and inhalation.
“Asphaltics take a lot of solvent to clean,” he said. The move away from asphaltic lubricants and toward VOC-free solvents and cleaning solutions reduces the amounts used, which not only is better for the environment, but it saves money as well.
Several publications from the American Gear Manufacturers Association (AGMA) offer guidelines on industrial gear operation and maintenance. For
‘
Periodic maintenance of lubricant
application systems ensures that they function properly, which reduces downtime.’
example, AGMA 919 covers the basics of condition monitoring and diagnostics for gear units and open gears. ANSI/AGMA 9005-F167 offers general guidelines for lubricating enclosed and open industrial gears, including baseline engineering specifications for the type and amount of lubricant used, based on pitch line velocity, the diameter and face width of the gear, its metallurgy, rotation speed and mode of lubricant application (e.g., brush or spray).
Long-term benefits for long-term operations
Effective lubrication and maintenance might not provide direct energy savings in the short term, Merlo said, but it offers other cost-saving benefits. Because a significant amount of energy is required to manufacture girth and pinion gears, keeping them in service longer offers indirect energy savings. Operations also can reduce equipment failures and downtime by extending the life of the gear set.
Reducing friction reduces the amount of energy needed to turn the gears, and it reduces heat production and prevents defect formation that can accelerate wear. Some customers find that they can use less lubricant by using spray applications, he adds, but the main saving comes from keeping the gear set in service longer. For an open gear on a rotary drum, he said, the fundamental points are the quality and design of the gear set, sufficient lubrication and regular technical follow-ups.
What’s more, operations that work with a good service company find it easier to maintain open gear equipment, Venditti said. “Open gears are still on the market,” he adds. “They will not disappear tomorrow.” PE
Nancy McGuire is a freelance writer based in Albuqerque, N.M. Reprinted with permission from the December 2022 issue of TLT, the official monthly magazine of the Society of Tribologists and Lubrication Engineers, an international not-for-profit professional society headquartered in Park Ridge, Ill., www.stle.org. STLE is a CFE Media and Technology content partner.
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How oil sampling helps maintain a healthy compressed air system
Lubricant is the lifeblood of heavy machinery and oil sampling can help engineers get the most of their lubricant’s utility.
Lubrication is a crucial element in the efficiency and life-expectancy of any piece of equipment with moving parts. Lubricants have many functions, but their main purpose is to form a protective barrier between the metal surfaces of critical machine components. Over time, the lubricant in the machine breaks down to where it can no longer protect the machine. At this point, the lubricant must be changed, and the machine must be filled with a fresh batch of lubricant. This is often referred to as the drain interval.
Optimizing the lubricant’s drain interval is not an easy task without the proper tools and knowledge. The safest — and most accurate — way to monitor and analyze the lubricant’s drain interval is oil sampling. Oil sampling is analogous to a person going to the doctor and getting bloodwork completed. It is a snapshot of the oil’s health in the machine at that moment.
Done routinely, oil sampling is one of the best predictive maintenance tools a service manager can use to keep the compressor running reliably. To some, oil sampling may seem like a complicated process. With any luck, this article provides some helpful insights into the oil sampling process from filling the sample bottle to what to look for on the sample report.
FIGURE 1: Oil sampling provides a snapshot into the health of an air compressor. Regular sampling can help prevent costly downtime. Courtesy: Hitachi Global Air Power
Cody Leatherman, Hitachi Global Air Power, Indianapolis
ENGINEERING SOLUTIONS
Choosing the right lubricant is critical
Before trying to maximize the lubricant’s drain interval, it is important to understand how to select the best lubricant for the compressor and why lubricants degrade overtime. Most of the time, lubricant selection is determined by the manufacturer of the equipment. If it’s the engineer’s choice, selecting a high-quality lubricant provides a strong foundation for the life of the compressor. A poor lubricant choice can cause premature wear and increased temperature and pressure on internal compressor parts resulting in lower efficiency and decreased life span.
The two primary criteria for selecting the best lubricant are viscosity and function.
Viscosity is the most vital characteristic of any lubricant. Viscosity is a measure of a lubricant’s resistance to flow and is often referred to how “thick” or “thin” the oil is. If the viscosity is too high, the lubricant will not flow though the compressor properly causing high temperatures and wear. A lubricant with a low viscosity will prema-
‘ Optimizing the lubricant's drain interval is not an easy task without the proper tools and knowledge.’
turely degrade and will not create a strong enough barrier between moving parts. The proper viscosity is scientifically calculated by measuring and determining various factors such as bearing clearances, internal temperatures and pressures.
The second primary factor of selecting the best lubricant is function. The main function of any lubricant is to reduce friction between moving surfaces. However, equipment such as an oil flooded rotary compressor demand the lubricant to serve multiple purposes including lubricating the bearings, creating an airtight seal and removing the heat generated from compression. Other specialty lubricants are formulated to hold contaminants in suspension, clean or strip metal surfaces of any past varnish, or provide cushion between components under high stress. Not all lubricants are created equal and unexpected breakdowns are expensive. Always begin the lubricant selection process by referring to the equipment’s service manual and selecting either the recommended lubricant or a high-quality equivalent product.
Main lubricant breakdown causes
When a lubricant reaches the end of its useful life, it is no longer capable of protecting equipment components. Users are often searching for what is causing the lubricant to breakdown. The answers are quickly identified when analyzing an oil sample report. Oxidation is the primary mechanism of lubricant degradation and is the reaction of the lubricant molecules with oxygen. Oxidation creates several negative effects such as increased oil viscosity, acid formation and varnish. The chemical reaction between a lubricant and oxygen cannot be avoided, but the progression can be delayed by using the correct lubricant with the appropriate additives.
Contaminates such as moisture, dirt and residual used oil also can influence a lubricant’s deg-
FIGURE 2: Varnish on an air compressor’s rotors can occur when the wrong lubricant is used or if the lubricant isn’t changed at regular intervals. Oil sampling can help identify when it is time to change out the lubricant. Courtesy: Hitachi Global Air Power
radation rate. Contaminated lubricants can be a significant contributor to related equipment failures. Solid contaminates are abrasive and score metal surfaces. Moisture will alter the load handling ability of a lubricant. Moisture also increases the rate of oxidation.
Residual used oil left in the compressor from the last oil change will increase the rate of lubricant degradation. It is important to drain as much used oil out of machine as possible before adding fresh oil into the system.
Additive depletion is another cause of degradation. Lubricant additives are chemical compounds that improve the lubricant performance. Most additive packages in lubricants are designed to be sacrificial and are used up during the life of the lubricant.
Four oil sampling best practices
The most effective predictive maintenance programs include an oil sampling program to monitor lubricant conditions and identify any potential threats to the equipment. Oil sampling helps maximize asset reliability and bring cost savings to a company’s bottom line. In order to receive the most out of an oil sampling program, it is valuable to implement a few best practices in the oil sampling technique.
1. Proper sampling techniques include running the compressor up to normal operating temperature before taking the sample. An oil sample should never be taken while the lubricant is cold. This will help to ensure the oil is well mixed with no idle particulates or water.
2. Preparing a clean area for the sampling is also a best practice. The fluid sample valve must be clean and free of debris before draining the sample into a clean new bottle.
3. The most important step in the oil sampling process is recording all the data about the sample. To aid in the oil sample report analysis, it is best to record accurate information about the sample such as type of lubricant, hours on oil, compressor hours, serial number of the machine and the date of sample.
4. Consistent oil sampling frequency is vital to any good maintenance program. Predicting a failure with oil analysis is about having the opportunity to witness the root causes or symptoms as they
develop. Consistent sampling frequency allows the maintenance professional to investigate historical trends and monitor how the lubricant is responding to its environment over time.
Once the sample is taken, it should be sent for lab analysis as soon as possible. Prompt analysis can provide time to act before expensive repairs or unplanned downtime occur. Maintenance professionals can determine what action is needed once the oil sample report is received. The next steps are not always crystal clear from the oil sample report, but looking for a few simple results can help provide a suggested course of action.
Sample analysis 101
Once in the lab, viscosity is the most common test run on lubricants because it is the most important property. If a lubricant does not have the right viscosity, it cannot perform its functions properly. Viscosity is measured with a viscometer, which consists of a constant temperature bath and capillary tubes. Industrial oils are identified by their ISO viscosity grade (VG). Most common ISO viscosity grades for an air compressor are ISO VG 32 and ISO VG 46. The viscosity of the oil sample is compared to the lubricant’s baseline or the test results of a virgin sample of the lubricant. An increase in viscosity is often caused by oxidation or contamination. If the viscosity of the lubricant is outside the limits set by the laboratory, change the lubricant in the machine immediately.
Elemental spectroscopy is the examination of concentration of the expected and unexpected
• Understand the causes of lubrication breakdown.
• Learn about the process and benefits of oil sampling.
• Learn what is in an oil sample report and what can be identified in an oil sample analysis.
FIGURE 3: Example of what happens to air compressor rotors when lubricant has failed, and the compressor is running on water. Courtesy: Hitachi Global Air Power
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elements in the oil. Elemental spectroscopy is a test used to determine the parts per million (ppm) of wear metals and lubricant additive metals in the oil sample. Wear metals are those metals that originate from an internal component of the compressor. The oil sample is “burned,” causing light to be emitted at frequencies unique to each element being measured. The intensity of light is measured and converted to a concentration, typically parts per million. Wear metal analysis is used to detect machine wear at early stages before the problem becomes catastrophic. Typical wear metals include iron, copper, lead and tin, all of which are common in shafts, gears and bearings.
Acid number (AN), which is commonly referred to as total acid number (TAN), is an indicator of oil condition. It is useful in monitoring acid buildup. Oil oxidation causes acidic byproducts to form. High acid levels can indicate excessive oil oxidation or additive depletion and can lead to corrosion of internal compressor parts. Acid number is tested by titration to detect the amount of acidic byproducts in the oil sample. Acid number should increase gradually over the useful life of the lubricant. A sudden increase indicates the lubricant is no longer capable of resisting oxidation.
Moisture is one of the most destructive contaminants faced by maintenance professionals. Overall tolerance of moisture depends on the lubricant and application. It is generally beneficial to keep moisture contamination at the lowest level possible. Moisture can be prevented by running the compressor at the recommended operating temperature.
Physical contaminants are also reported on the oil sample report; they are abrasive and are detrimental to internal compressor parts. Particle counting is considered an important proactive tool.
Particle size and number are counted by an automated particle counter. The results of the particle count are reported out as an ISO cleanliness code. An ISO cleanliness code consists of three numbers which provide a standard for the amount and size of the particles in the oil sample.
Every laboratory has their own format and conventions for the oil sample report, but it should always state the machine and lubricant condition. Interpretation of oil analysis requires attention to detail and persistence. The professionals at the laboratory are a good place to start with any questions. Equipment manufacturers also have experts on staff that can answer questions and provide insight about the machine and the lubricant properties of interest. With the information provided by the sample report, the engineer can identify and rectify any issues before they become a costly headache.
A compressed air system is not only a capital expenditure, but it also is a vital component in the company’s overall process. When air power is down, the entire factory usually is, as well. Keeping a machine running starts with using the right lubricant and ensuring the lubricant is doing the job it is intended for. A routine oil sampling program is the only safe way to maximize the lubricant drain interval and keep the compressed air system — and processes — up and running to keep the compressed air system running for years to come. PE
Cody Leatherman is product manager of consumable products at Hitachi Global Air Power, where he is responsible for lubricant and filter product lines. Leatherman spent 11 years in the lubricant industry in numerous positions. He holds a Bachelor of Science degree in Chemistry from Wabash College and a Master of Business Administration from Indiana State University. Leatherman resides with his family in Indianapolis, Indiana.
u
Insights
Oil sampling insights
u Oil sampling can help engineers keep their compressed air systems running efficiently by ensuring the lubrication hasn’t gone bad. If it does go bad, it can lead to severe repair issues or downtime.
uProper oil sampling techniques such as good data recording and ensuring the lubricant is at a proper temperature can help the engineer get the most accurate assessment on how the lubricant is performing.
FIGURE 4: Air compressor rotors that have been properly maintained with the correct lubricant.
Courtesy: Hitachi Global Air Power
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Five best practices for electrical safety on the plant floor
Here are five electrical safety best practices, centered on a broader effort to employ a culture of safety that can help put the right safeguards in place
Electricity is one of many safety hazards in the plant. It is ubiquitous and nearly everyone has access to it and, as such, the risks can be wide-ranging and sometimes even downplayed. After all, without electricity a plant cannot operate. However, electricity’s presence poses a safety risk.
According to the Occupational Safety and Health Administration (OSHA), electricity is one of the “Fatal Four” leading causes of fatalities in the workplace.
Electrical hazards on the plant floor abound. Electric shock, burns (electrical or thermal contact), explosions, electrical fires and indirect haz-
ards (like falls) are all present and pose a real threat to employees. Most often, the causes of electrical accidents can be traced back to unsafe equipment due to aging, improper usage or faulty installation; workplaces made unsafe by the environment; and unsafe work practices.
OSHA’s efforts over the past 50 years have helped to decrease worker deaths and injuries — including such incidents resulting from electrical hazards — by more than 60% of what they once were. And yet, more than 5,000 people still die at work every year and another 3.6 million suffer a work-related injury.
Instead of viewing workplace safety through the lens of employee behavior and OSHA compliance, many organizations are building safety into the fabric of their company culture and prioritize the health and safety of employees.
These organizations understand the role they play in keeping their employees safe — on the plant floor and beyond — and are making specific investments to support the overall health and safety of their teams. Adopting this type of “people-first” strategy with safety at the forefront demonstrates to employees that their health and well-being is taken seriously and their employer is not simply trying to check off a list of necessary regulation requirements.
This level of commitment can have a significant ripple effect, increasing overall employee engagement, job satisfaction and a sense of community. Ultimately, this can help to strengthen the overall culture of an organization and given consumers’ socially conscious mindset in 2023, this type of initiative has important external implications as well.
FIGURE 1: Electricity poses a unique safety risk given it is used to power virtually everything on the plant floor. Courtesy: Wesco
FIGURE 2: Electrical hazards can hide in plain sight. Implement a “find and fix” approach and let the employees be the eyes and ears of the manufacturing facility. Courtesy: Wesco
Building a strong culture of safety takes buy-in from all levels of the organization. But regardless of where an organization may be in working to build a better culture of safety, understanding how to keep employees safe from electrical hazards on the plant floor is something that can be done and built upon for the future.
Here are five best practices to consider implementing immediately to ensure everyone on the plant floor is reducing their risk of electrical incidents.
1. Empower employees to be your eyes and ears
One of the simplest things to do to combat risks associated with electrical hazards and build a broader safety program is to implement a “find and fix” approach. This strategy empowers workers to serve as eyes and ears on the plant floor.
As a first step, coach workers on the details of what they are looking for so they can identify hazards that they may not have recognized otherwise. From there, outline a clear path for how hazards are to be communicated and handled when an issue is identified.
The “find and fix” mentality also allows employers to demonstrate their commitment to safety. When employees raise concerns over a hazard that has been identified, it gives the employer an opportunity to move swiftly to correct the issue and improve the overall safety of the operation.
2. Do not
skimp on critical equipment electrical safety checks
There are several considerations pertaining to equipment that should be followed to help secure the safety of the plant floor:
• Ensure the use of electrical protection devices. Electric equipment and installations have internal and external faults that can cause damage to people or other equipment. A “fault” is an abnormal condition caused by equipment failures such as transformers and rotating machines, human errors
‘ Many organizations are building safety into the fabric of their company culture and prioritize the health and safety of employees. ’
and environmental conditions. To avoid the faults (short circuits or overcurrents), enclosures, fuses, circuit breakers and ground fault circuit interrupters or other electronic protection devices can be used to help ensure an unnecessary amount of current doesn’t pass through. Equipment and systems should also be grounded to help control voltage within predictable limits.
• Personal protective equipment (PPE) is still in style. According to data from the U.S. Bureau of Labor Statistics, more than 200 fatalities occur each year due to contact with electrical current. Before approaching electrical equipment and installations, make sure workers have the right PPE for the job. For example, proper arc-rated clothing is the best form of protection when performing live electrical work. Without the proper attire — such as hearing protection, face shields and leather footwear — risks are higher for serious injuries. One of the most important lines of defense when it comes to electrical safety is rubber goods. Rubber goods can include gloves, sleeves, boots, blankets, line hoses and more. OSHA upholds and enforces the way electrical work can be performed based on the standards issued by the ASTM F18 Committee.
u
Objectives
• Learn how a “find and fix” mentality can mobilize workers to identify electrical safety hazards before they become problematic.
• Know why you cannot skimp on equipment safety checks.
• Understand how training and communication play a critical role in putting a culture of electrical safety into action.
ENGINEERING SOLUTIONS
• Identify and label machine and equipment hazards. Safety labels are critical to warn of potential hazards on electrical panels, connected equipment and the surrounding areas. These labels typically include a safety message with a more detailed description. For instance, it might be known where an arc flash can occur, so labeling equipment with proper warning signs and instructions reduces risk.
Clear markings will help to easily identify potential danger zones and prepare workers for a plan of action should an incident occur.
Beyond labeling potential hazards, ensure that mobile equipment is not stored in hazardous environments or in a line of where employees walk. Confirm that all cords are in a cool, dry space and out of the way of where employees are moving throughout the plant floor.
3. Only employ experts to deal with electrical systems
‘ The NFPA 70E definition explicitly calls for the individual to have received safety training specific to the electrical hazards they may face. ’
Many employees often do things that fall outside of their specific job description or role in the spirit of helping the team or company out. Normally, this is a great trait, except when it comes to things where associates are not qualified for the sake of the safety of ourselves and others. Plant engineers and managers do not see people who aren’t doctors offering to do “simple” medical procedures; there’s a reason for that. While that example seems obvious, trying to perform electrical repairs as a maintenance employee without electrician qualifications or certifications can be just as dangerous.
The word “qualified” is articulated differently in NFPA 70E: Standard for Electrical Safety in the Workplace compared to how it is used in other OSHA standards. According to NFPA 70E,
“A qualified person is one who has demonstrated skills and knowledge related to the construction and operation of electrical equipment and installations and has received safety training to identify the hazards and reduce the associated risk.”
Unlike the OSHA definition of “qualified,” the NFPA 70E definition explicitly calls for the individual to have received safety training specific to the electrical hazards they may face.
This is just one example of why workers often get too close to live electrical components under the guise that they are “qualified” to proceed when in fact they are not. Remember that the employer, not the training course or instructor, must designate an employee as “qualified.” Clear communication on what scenarios are safe and are not in regards to a given electrical system must also be laid out ahead of time.
4. Lean on training to consistently reinforce electrical safety culture
Ensuring proper training is completed for electrical safe work practices, lockout/tagout, shock and arc flash hazard assessments and job hazard analysis is required by OSHA and NFPA 70E. These cannot be viewed as checkbox activities. Workers need to understand that the training provides them with the skills necessary to maintain a safe work environment, but to also return home safely.
Two specific types of important training include:
• OSHA training: OSHA can issue criminal penalties in cases of extreme negligence on the part of the employer in the event of an employee injury or death. Recently, the operator and six management officials of a corn mill were indicted by a federal grand jury — in a case involving an explosion that killed five workers and injured 15 others — on nine criminal counts, including two counts related to willful violations of federal workplace safety standards for grain handling.
These kinds of incidents are preventable. Implementing a safety and health program can help ensure a manufacturing company follows applicable OSHA regulations to help prevent injuries and deaths and reduce the risk of penalties.
• Arc flash hazard training: Electrical workers face many dangers on the job, but few are more devastating than an arc flash. This electrical release of energy can be hotter than the surface of the sun, producing an explosion with the force of eight sticks of dynamite. It is estimated that 10 arc flash incidents involving more than one death occur every day in the U.S. But these troubling facts aren’t
FIGURE 3: Ensure equipment is not stored in hazardous environments or in an area where employees frequent along the plant floor. Courtesy: Wesco
always enough to convince those involved to take the right precautions.
Before starting to address the issue on the job site, be sure to conduct a risk assessment for both arc flash and shock dangers. NFPA 70: National Electrical Code recommends arc flash tests every five years. Arc flashes threaten personnel safety and companies face lawsuits, fines, equipment damage, facility downtime and lost production. Minimize risks with proactive training and testing.
To engage employees in these trainings, consider safety awards for individual locations based on activity or training topic and incorporate related key performance indicators to actively engage workers and encourage participation. Prioritizing and incentivizing training demonstrates a company commitment to creating a culture of safety.
Advances in safety training will also give employers the ability to create consistent safety cultures across multiple locations and provide the tools that improve compliance and reporting. Virtual reality, for example, has great potential to change how training is delivered and change the training experience as a whole, making conducting training themselves even safer. By delivering virtual training, employees will not be exposed to the conditions that they need to be trained in, so training can be conducted in a safe place in an interactive way.
5. You cannot overcommunicate about electrical safety
Although many companies promote a commitment to safety, if the topic is not included in ongoing, strategic discussions among key stakeholders, this notion of commitment could ring hollow. Company priorities will change over time and focusing on the safety and security of workers should represent a core company value and be integral to every strategic discussion. This includes weaving in the notion of safety throughout key communications with plant floor workers.
Here are a few examples of how that can be done:
• Identify opportunities to include safety-related updates, best practices and lessons learned in an internal newsletter or weekly email communication to keep workers apprised of new guidelines and underscore a company commitment to build-
ing and sustaining a culture of safety. Having timely access to information can increase the reach and coverage of safety programs and decrease the overall cost of those programs.
• Be clear about existing workplace challenges teams may face. Engaging associates in this process will help effectively address red flags in a timely and thoughtful manner, ensure swift remediation and help avoid any future missteps related to known issues.
• Implement tools to report near misses and leverage data to help continuously improve. Regular safety walkarounds across all locations can help more accurately track and analyze near misses and apply lessons learned to ensure the safety and security of all workers.
In today’s business environment where global competition is fierce and skilled labor is a challenge, there should be no greater priority than ensuring the safety and security of workers. Electrical systems do pose a unique risk given they are used to power virtually everything on the plant floor.
However, through a companywide effort to build a culture of safety and a practical approach to training, equipment and personnel, organizations can provide the framework needed to ensure electrical hazards are minimized and employees are safe. PE
Scott Dowell is Senior Vice President and General Manager, Industrial and CIG, at Wesco. He has more than 25 years of experience and leads the strategy, execution and growth of Wesco’s industrial, automation, institutional and government end-user business throughout the United States.
4: Many organizations are building electrical safety into the very fabric of their company culture as they prioritize the health and safety of all employees.
Courtesy: Wesco
Insightsu
Electrical safety
uElectrical safety hazards abound on the plant floor. But how do you protect employees from a risk that is a necessity to the work that needs to be done?
u By implementing five things and adhering to OSHA and NFPA requirements, electrical safety can be achieved.
FIGURE
ENGINEERING SOLUTIONS
ARC FLASH AND ELECTRICAL SAFETY
Nick Schiltz, Grace Technologies, Davenport, Iowa
How to adhere to lockout/ tagout for electrical safety
Lockout/tagout procedures for plants, mines and manufacturing facilities can help ensure electrical safety
Performing lockout/tagout (LOTO) safely requires the answer to one question: Is there voltage? NFPA 70E: Standard for Electrical Safety in the Workplace requires an absence of voltage test to verify an electrically safe work condition. The traditional process requires electrical equipment that could pose arc flash and shock hazards to comply with NFPA 70E Article 120.5: Process for Establishing and Verifying an Electrically Safe Work.
Lack of adherence to NFPA 70E is one of the Occupational Safety and Health Administration’s (OSHA) most cited violations each year, but some industries have more challenging electrical safety obstacles than others.
ing safety, the U.S. National Institute for Occupational Safety and Health (NIOSH) Office of Mine Safety and Health Research (OMSHR) conducted a study between 2000-2009. The study included three things:
• A direct review of mining industry occupational injury data compiled by OMSHR.
• An interpretation of the narrative descriptions available for the injuries (from OMSHR data).
• A separate examination of fatal electrical injuries. During this time period, 865 electrical injuries were reported, with 39 of those being fatalities.
• Understand how to avoid Occupational Safety and Health Administration citations for lockout/tagout by making compliance easier.
• Learn how the electrical safety by design philosophy can mitigate risks and increase productivity.
• Review a perspective of one of the most extreme environments for electrical safety.
Mining workers often face unique electrical hazards compared to most industries that requires a unique approach to electrical safety. These challenges make the mining industry one of the most dangerous to perform routine electrical maintenance tasks due to the extremely harsh conditions that personnel operate within. Exposed wiring and cables necessary to power mining operations are also hindered by wet and damp climates and require the utmost care for electrical safety precautions. Dust and gases generate a combustible and deadly combination that can quickly turn small electrical accidents into deadly fires or explosions.
Mining electrical safety hazards by the numbers
When electrical hazards began to present themselves as one of the greatest threat to min-
The U.S. Bureau of Labor Statistics reported that 1,573 workplace fatalities between 2003 and 2009 had an electrical cause and an estimated 18,260 nonfatal electrical injuries, resulting in days away from work, occurred over the same period. The NIOSH OMSHR study concluded,
“There were 125,594 mining injuries reported to Mine Safety and Health Administration (MSHA) for 2000 through 2009 and electrical was the 10th most frequently listed cause, with 853 injuries. Of the 853 mining electrical injuries for that period (those with the cause listed as electrical), 39 were fatal, making electrical injuries the sixth most prevalent cause of death in mining.”
Of these injuries, 42% among them were electricians and mechanics. Contractor employees had a much greater chance of an electrical injury being fatal than did mine operator employees due to their unfamiliarity with the equipment and/or industry. Routine electrical and machine maintenance/repair activities were involved in 69% of electrical injuries. The investigators identified the top three root causes for fatal electrical injuries as:
‘ Lack of adherence to NFPA 70E is one of the Occupational Safety and Health Administration’s (OSHA) most cited violations each year. ’
• Missing or inadequate LOTO.
• Failure of power system components.
• Contact of overhead electrical power lines by mobile equipment.
In 2019, three electrical-related fatalities occurred that prompted the MSHA to issue an alert on electrical hazards. According to MSHA, these fatalities occurred when:
• An electrician contacted an energized component of an electrical circuit while adjusting the linkage between the disconnect lever and the internal components of the panel that supplied power to the plant feed belt motors.
• A contract electrician contacted an energized conductor while working inside a fire suppression system's electrical panel.
• An electrician contacted an exposed energized connector while troubleshooting a flooded bed scrubber motor circuit onboard a continuous mining machine.
As part of the alert issued by MSHA, the administration offered electrical safety best practices consisting of the following:
• LOTO circuits before working on electrical equipment.
• Do not rush. Never work alone. Talk to coworkers and confirm if a plan is safe.
• Identify and control all hazardous energy sources before conducting any task and follow safe work procedures.
• Train miners on equipment they may use.
• Electricians must know how to de-energize and disconnect electrical systems and equipment.
• Always troubleshoot without power first.
The MSHA alert’s best practices, while necessary to raise alarm, offered nothing new in terms of an employer’s and a qualified electrician’s responsibility when it comes to The Control of Hazardous Energy (OSHA 29 CFR 1910.147). This faithful reminder is simply a condensed and informal outline of the steps for performing LOTO. When LOTO is performed correctly, electrical hazards that may result in injuries or fatalities should be mitigated. However, that is not always the case.
FIGURE 1: A qualified electrician taking a voltage reading using a voltage test station permanent electrical safety device and his portable test instrument.
Courtesy: Grace Technologies
ENGINEERING SOLUTIONS
FIGURE 2: A portable test instrument with meter probes inserted into a ChekVolt permanent electrical safety device's high impedance protected test points. Courtesy: Grace Technologies
How can you avoid electrical safety citations?
Two of the top 10 most cited OSHA violations are related to the control of hazardous energy and the use of electrical work practices. These are covered under the following OSHA regulations:
• CFR 1910.147 covers the servicing and maintenance of machines and equipment in which the unexpected energization or startup of the machines or equipment or release of stored energy could harm personnel.
Insightsu
Electrical safety
uElectrical safety hazards can be minimized by having a proper lockout/tagout (LOTO) procedure, and by following NFPA 70E requirements.
uElectrical safety incidents are among the highest in the mining industry. Power and electrical system accidents were cited frequently.
• CFR 1910.333 covers the safety-related work practices to prevent electrical shock or other resulting injuries from direct or indirect electrical contact when work is performed around the electrical equipment and circuits.
Failure to perform proper mechanical or electrical LOTO can lead to electrocution, electrical shock, arc flash and other hazards. In addition to OSHA fines and penalties, these hazards often result in lost time wages, compensation claims, permanent disability and fatalities.
In 2020, the U.S. Bureau of Labor Statistics reported 126 electrical fatalities in the United States alone, 94% of which were from private industries. The BLS also reported 2,220 nonfatal electrical injuries involving days away from work, a 17% increase from the previous year.
Permanent electrical safety devices (PESDs) are developed through safety by design to mitigate the risks of electrical exposure that result in fatalities and injuries by substantially improving personnel safety and productivity in mechanical and electrical LOTO procedures. PESDs also assist facility personnel by providing preventive measures for integral and repetitive electrical maintenance tasks.
In 2022, OSHA revealed that The Control of Hazardous Energy standard was the sixth most violated citation, receiving 2,175 violations in 2022, 505 more than in 2021. The following is a breakdown of each of those violations:
How the electrical safety by design philosophy mitigates risks
Electrical safety by design works to confront common LOTO procedural and implementation issues, user error, compliance and productivity by providing innovative safety solutions that mitigate or eliminate various task risks. When properly incorporated into a facility’s Electrical Safety Program, through-door voltage indicator and test point PESDs inherently reduce risk by providing a safer and more efficient method of performing verification of hazardous energy isolation. In addition, PESDs are designed to improve the ease of compliance with NFPA 70E and OSHA energy isolation principles.
In mining sectors, a small spark may result in a deadly combustion. Contractor electricians unfamiliar with equipment would benefit from PESDs providing a safer method of performing LOTO. Voltage presence LED indication will warn personnel when hazardous energy is present, preventing accidental contact. The return on investing in electrical safety will provide increased safety, reduced downtime and peace of mind. cse
Nick Schiltz is a Content Specialist for Grace Technologies.
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ENGINEERING SOLUTIONS
PNEUMATIC AND HYDRAULIC CONTROLS
Cameron Rodger and Trevor Gauthier, Hedgehog Technologies Inc., Burnaby, British Columbia; and Derek Puzzoli, Seahawk Robotics Inc., Burnaby, British Columbia
Maintenance and safety considerations for pneumatic and hydraulic controls
Pneumatic and hydraulic controls are critical to the manufacturing industry, and implementation requires careful consideration of safety and maintenance requirements
Pneumatic and hydraulic controls have a variety of applications for the manufacturing industry. Part movement and manipulation, cooling, shaping and forming can be automated with continued advancements in digital communication and control.
Furthermore, new opportunities to take advantage of hydraulics and pneumatics have presented themselves with ongoing technological advances in the field. As these technologies become more prevalent in manufacturing, it is important to consider the safety, regulation and maintenance requirements of these systems to ensure safe and efficient operations.
Safety considerations
Objectives
• Understand the safety considerations for pneumatic and hydraulic systems.
• Learn about the maintenance recommendations for pneumatic and hydraulic systems and their components.
• Review how pressure regulation is vital to the overall maintenance of these systems.
Pneumatics and hydraulics play a critical role in many manufacturing processes and as such, it is critical to understand the risks of these systems so that they can be addressed properly. One of the key safety considerations is the potential for fluid leaks. Pneumatic systems rely on compressed air and leaks can lead to sudden changes in pressure that can cause equipment failure or even injury to workers.
To minimize these risks, it is recommended to use high-quality components, particularly for hose fittings and couplings and to implement regular inspections of these components to identify and repair leaks before they pose a hazard.
Pneumatic controls typically use highly compressible gasses, such as air or nitrogen, which can rapidly expand when released to the surroundings in the event of a leak. This risk can be reduced by implementing a fail-safe to shut down the system in the event of a sudden pressure loss. However, it is important to understand the risks of pressurized fluids before implementing a pneumatic system in a manufacturing plant.
Pneumatics safety and maintenance
The low compressibility of hydraulic fluids helps to make these systems safer to work with at high pressures. While pressure is less of a concern with hydraulics, fluid leaks can still cause harm to both workers and the environment. A leak in a hydraulic line could result in injury to workers caused by exposure to a toxic substance and the fluid may seep into the ground or evaporate, causing an environmental hazard.
Similar to pneumatics, the use of high-quality equipment combined with regular inspection will reduce the risk of leaks. An additional mitigation strategy is to create physical barriers, such as troughs that will act to catch and contain any fluid that may leak out of hydraulic lines.
Another safety consideration is the potential for system failure; pneumatics and hydraulics rely on pressurized fluid to operate and a loss of pressure can cause equipment to stop working
‘ A leak in a hydraulic line could result in injury to workers caused by exposure to a toxic substance and the fluid may seep into the ground or evaporate. ’
or malfunction. A common mitigation strategy for system failures is to implement redundancies, which are backups for critical components that allows for the system to continue working while a failed component is replaced, reducing the risk of injury and minimizing downtime.
It is also important to consider the potential for physical harm when working with pneumatic and hydraulic systems. These systems are often implemented to move large objects quickly and precisely and as a result they can generate large amounts of force over short intervals. Entrapment is a potential risk in this situation; clothing or limbs can be caught in the moving parts of the mechanism, which can cause serious injury or death.
Workers must be trained to properly use and maintain pneumatic systems to minimize the risk of injury. Proper training, including hands-on training with the specific pneumatic systems in use, can help workers to understand the potential hazards and take the necessary steps to stay safe. This can include training in following the proper safety guidelines and regulations, using proper protective equipment and following lockout/ tagout procedures to prevent accidental activation of equipment during maintenance or repair.
Maintenance requirements
While safety considerations are critical to the successful implementation of hydraulic and pneumatic control systems, it is also important to consider the maintenance requirements of these controls during their design and installation.
Poorly maintained pneumatics and hydraulics will be more prone to failures, any of which can create a potential hazard in the plant. The first consideration in this vein is regular inspection of components. With a proper inspection plan, leaks and jams can be spotted before they become an issue and repaired.
Other maintenance considerations for pneumatic and hydraulic controls are:
• Lubrication: Pneumatic equipment requires regular lubrication to ensure proper operation. Without proper lubrication, components will undergo increased wear and can seize, causing further damage and requiring lengthy shutdowns to repair or replace. The lubrication schedule should be based on the manufacturer's recommendations and the specific conditions of the manufacturing plant.
• Cleaning: Pneumatic equipment should be kept clean to ensure proper operation. This includes removing dust and debris from the equipment and cleaning the air filter. Excessive dust on or around the moving parts of pneumatics can make its way into the seals and cause a leak or premature failure.
• Replacement of worn or damaged parts: Worn or damaged parts should be replaced as soon as possible to ensure that the system is operating safely and efficiently. If damaged parts are left unrepaired, they can cause further damage leading to more expensive repairs down the line.
Continued on page 48
FIGURE 1: Pneumatic and hydraulic systems in a manufacturing plant setting.
Courtesy: Hedgehog Technologies Inc.
ENGINEERING SOLUTIONS
Continued from page 45
• Air filter replacement: Regularly replace the air filter to ensure that the compressed air is clean and free of debris. Clean air is essential to the proper operation of pneumatics, as dust can clog valves and damage seals.
• Monitor the pressure: The pressure in the pneumatic system should be checked regularly to ensure that it is at the correct level. Modern pneumatics typically make use of real-time pressure monitoring through programmable logic control. If pressure is too low, the system may act with too little force or too slowly to perform its task effectively. If the pressure is too high, it can result in lines, valves and seals leaking.
• Check for leaks: Regularly check for leaks in the system and repair them as soon as they are detected. As discussed above, leaks in pneu-
matics and hydraulics can cause several safety and maintenance issues throughout the plant.
• Keep accurate records: Keeping accurate records of the maintenance performed on the pneumatic system will help ensure that all necessary maintenance is performed on schedule.
• Follow manufacturer's recommendations: Always follow the manufacturer's recommendations for maintenance, including lubrication, cleaning and replacement of parts.
A proactive approach to system inspection and maintenance can save a plant on more costly repairs caused by faulty equipment in the future, as well as protect workers from injuries caused by failures. Implementing these practices early and working with the manufacturer to determine the best approach will ensure the best performance and value to the plant for a given control system.
Pressure regulation
Pressure regulation is an important aspect of pneumatic controls, the primary purpose being to control the amount of compressed air delivered to pneumatic actuators and other components, ensuring that they operate at the correct pressure. This helps to maintain consistent and accurate performance, while also reducing the risk of equipment failure and injury to workers. Some common methods of pressure regulation include:
• Mechanical pressure regulators: Mechanical pressure regulators are relatively simple and reliable, using a spring-loaded piston and a diaphragm to control the flow of compressed air. They can be prone to wear and tear over time.
• Electro-pneumatic pressure regulators: Electro-pneumatic pressure regulators use electrical signals to control the flow of compressed air. They are more precise and flexible than mechanical pressure regulators and can be integrated into automated control systems.
• Proportional pressure regulators: Proportional pressure regulators use electronic sensors and feedback to control the flow of compressed PNEUMATIC AND
FIGURE 2: Promoting safety for pneumatic and hydraulic systems.
Courtesy: Hedgehog Technologies Inc.
air, providing highly accurate pressure control. They are typically used in applications where precise control is critical, such as in robotics and highspeed manufacturing processes.
As with safety considerations, regular maintenance is important in the proper function of pressure regulators. All regulators require calibration and inspection at specific intervals to ensure that they continue to perform accurately and reliably. Regular maintenance can help extend the life of pressure regulators and reduce the risk of equipment failure.
What are the other maintenance risks and considerations?
A potential risk involved with using compressed air in pneumatic controls is the buildup of flammable gas. In systems that use oil-lubricated compressors, the oil can mix with compressed air and create a flammable gas mixture, which can ignite under certain conditions.
The buildup of flammable gas is somewhat inevitable in any compressed air system, but the risks can be minimized. As with other risk factors, proper maintenance of oil-lubricated compressors will reduce the risk of oil mixing with compressed air. Oil-free compressors can also be used to eliminate flammable oils from the system; however they tend to require more regular maintenance and replacement than their oil-lubricated counterparts.
Finally, proper ventilation of compressed air lines will reduce the amount of accumulated flammable gas in the system.
Temperature regulation is another consideration for the use of hydraulics and pneumatics. When the working fluid temperature fluctuates significantly from what is specified, it will cause the viscosity to change, reduce the effectiveness of seals and increase the chance of fluid degradation and contamination. These changes can lead to losses in performance, reduction in efficiency
‘ In systems that use oil-lubricated compressors, the oil can mix with compressed air and create a flammable gas mixture, which can ignite under certain conditions. ’
and equipment failure. The seals used throughout hydraulic and pneumatic control systems are sensitive to temperature and significant deviation from the manufacturer's specifications will reduce the performance of the seals and increase the risk of failure. Something as seemingly harmless as a worn-out O-ring can lead to much more significant failures and potential injury if left alone.
There are methods of regulating the temperature in these systems, such as heat sinks and cooling mechanisms, as well as temperature sensors to monitor system temperature. With compressed air, it is
also important to implement an air-drying system, which will remove moisture from the air and reduce the risk of condensation in the lines.
Corrosion in pneumatic systems is influenced by a few factors. Corrosion can occur as a result of exposure to moisture, acids or contaminants being present in the system. A few common methods of mitigating this are:
• Air drying: Like temperature regulation above, dry air will limit the moisture present in the system, reducing the risk of corrosion
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‘Corrosion is less of a concern in hydraulic controls, as the operating fluid serves to lubricate the system and provides a barrier to corrosive substances.
• Lubrication: In addition to reducing wear, lubricants can create a barrier to protect components from corrosive substances.
• Materials selection: As with other fields, materials selection plays an important role in postponing corrosion in pneumatics. It is important to consider materials that will both be compatible with the manufacturing environment and the controls system
• Positive pressure: Holding positive pressure in the pneumatic system will ensure that contaminants are forced out if any leaks should form.
Different operating fluids will also affect the rate of corrosion. In pneumatics, the most common operating fluids are air, nitrogen and carbon dioxide. Corrosion is less of a concern in hydraulic controls, as the operating fluid serves to lubricate the system and provides a barrier to corrosive substances.
In summary, hydraulic and pneumatic control systems offer many benefits in manufacturing, but it is important to understand several aspects of their operation so that they can be addressed during implementation. Between safety considerations, maintenance and pressure regulation, there are any number of ways that pressurized systems can affect other areas of a plant, so proper planning and maintenance in accordance with relevant standards and regulations is essential. PE
Cameron Rodger is a mechanical engineer and Trevor Gauthier is a mechanical engineer at Hedgehog Technologies Inc. Derek Puzzoli is the owner at Seahawk Robotics Inc.
Insightsu
Maintenance insights
u Hydraulic and pneumatic systems play a large role in manufacturing processes and plants.
u Without ongoing maintenance and replacement of hydraulics and pneumatics, systems and plants would shut down, crippling a supply line or business.
Engineering innovation plays a vital role in the vitality of industrial manufacturing. You’re invited to explore the profiles on the following pages and celebrate the success stories of our participating manufacturing innovators:
• ABB Motors and Mechanical
• Assured Automation
• AutomationDirect
• Camfil Air Pollution Control
• Dewesoft
• Digi-Key Electronics
• Dodge Industrial
• Flexicon
• Flowserve Corporation
• Lubriplate Lubricants
• Motion
• SEW-Eurodrive
• Spiroflow
Assured Automation Announces New Thermal Shutoff Valve Series
Thermally activated Thermal Shutoff Valves (TSVs) are critical components in refinery, terminal, and distribution safety systems. Thermal activated shutoffs work like fuses in the piping that carry extracted fuels. When a fire occurs, the fuel flow is shut down, preventing the fuel from feeding the fire.
TSV Series thermal shut-off valves combine a fire-safe ball or butterfly valve with a pneumatic actuator and the FM approved FireChek ® valve to form a dedicated standalone thermal shut-off valve that will close (or open) at a given temperature (165 ̊F standard). This alternative to fusible link valves can be tested and reset without the need to replace any hardware.
The valve is held open by charging the actuator through a Schrader (check) valve. There is a clearly labeled gauge to indicate the proper pressure range to maintain.
TSV’s have passed both Mil-std-810G humidity and vibration testing procedures through an independent third party. The TSV’s patent pending design can be manually vented for annual valve cycling. FireChek ® can also be tested and reset on site. All TSV assemblies are individually tested by a qualified technician in our ISO certified facility after assembly.
Direct drive technology improves reliability, reduces maintenance, runs quieter and saves energy
ABB offers high-torque, direct-drive, motor solutions for cooling tower applications by combining technologies of the field-proven and power-dense laminated-frame RPM AC motor with a permanent magnet rotor design and the matched performance of an adjustable speed drive.
ABB’s Baldor-Reliance ® Cooling Tower Direct-Drive motors provide the benefits of variable speed control while eliminating the costs and time required to maintain traditional gearboxes or belted transmission systems. The motor couples directly to the cooling tower fan and is controlled by an AC drive to provide optimal speed and performance that results in quieter operation and reduced energy consumption.
The RPM AC synchronous permanent magnet motor uses a laminated finned frame construction to provide a highly efficient, compact package with flange mounting dimensions that can replace right-angle gearbox and jack shaft installation in conventional cooling towers.
This same technology is offered in power-dense, foot-mounted designs that can replace belt and sheave applications where more vertical mounting space is available. Derived from one of the toughest motor platforms used in the most demanding industrial applications, the RPM AC motor is the perfect solution for operation inside a tower’s hot and humid environment.
Several stock models are available to fit common cooling tower parameters. Custom configurations for motor and matched variable speed drives are also available through ABB’s RPM AC Cooling Tower Wizard configurator tool. Like many ABB motor solutions, Cooling Tower Direct Drive motors include provisions for ABB Ability Smart Sensors for condition monitoring and are backed by our global service and support network.
A well-recognized name in the industrial automation market, AutomationDirect provides quality products with FREE award-winning in-house sales and technical support. AutomationDirect provides customers with quick order and delivery through an online store and toll-free number. Prices on most products are well below the industry average and a 30-day money-back guarantee is offered on nearly all items.
With close to 35,000-part listings, new products include Stahlin Enclosures, WEG rolled steel motors, Wenglor proximity sensors, Endress + Hauser capacitance level switches and Swivellink mounting systems. The company also offers the CLICK PLUS PLCs, DURApulse drives, enclosures, circuit protection, cut-to-length cable, pneumatic supplies and more.
The state-of-the-art headquarters facility near Atlanta is designed throughout for maximum performance. The majority of items are in-stock and ready for fast shipping; orders over $49 ship for FREE. Some exclusions apply.
The company provides online tutorial videos through their web store at www.automationdirect.com as well as their YouTube channel. They also provide FREE online PLC training to anyone interested in learning about industrial controls. A Customer Forum utilized by tens of thousands of automation professionals provides peer support on technical and application questions.
AutomationDirect’s customer support team has been rated top-notch by its customers and has received numerous industry accolades/awards for providing the best service and support on various products. To ensure their service and support remains superior, they continuously survey customers and have consistently outranked other suppliers.
For an in-depth look at products offered, visit: www.automationdirect.com.
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Safely Collecting and Containing Combustible and Toxic Dusts
Camfil APC is the world’s leading manufacturer of industrial dust and fume collection systems. The company’s flagship product is the Gold Series X-Flo industrial dust collection system. It handles all kinds of toxic and combustible dusts/fumes, including fine, fibrous and heavy dust loads, and features high capacity filter cartridges that are safe and easy to change out.
Combustible Dust Collection
Camfil APC compliance experts can recommend dust collectors with explosion venting and isolation equipment that satisfy all OSHA and NFPA guidelines. Camfil offers a full range of technical services to test dusts and analyze specific operating conditions. They carry a variety of products to mitigate dust collector explosions, including explosion vents and ambient fume collection systems with HEPA grade filters.
Toxic Dust Collection
Pharmaceutical and chemical processing industries require systems that can safely collect toxic dusts, potent compounds and active ingredients. The Gold Series Camtain® collectors are ideal for high-efficiency filtration that doesn’t require re-use. They protect workers from exposure and combustible dust risks. The Quad Pulse Package collector is compact enough to be placed on the production floor or suite. It includes a secondary HEPA filter and uses a segmented cleaning process to keep the primary filter cartridge operating continuously.
Replacement Filter Cartridges
In addition to equipment, Camfil APC offers a full range of replacement filter cartridges using HemiPleat® technology that fit most other dust collector brands. Replacing standard filters with HemiPleat filters increases any dust collector’s performance, and the filters last much longer.
Industry-Leading Customer Support
Camfil filtration experts help customers improve the air quality in their facility. They make site visits to evaluate the dusts, assess needs and recommend the most cost-effective equipment to solve problems and comply with OSHA and NFPA standards. Most Camfil dust/fume collection systems feature extended filter life, easy filter change-out, energy efficiency, and a 12-year warranty.
Manufacturing Excellence and Testing Services
The corporate headquarters in Jonesboro, Arkansas includes a state-of-the-art test lab to simulate full-scale testing, including ANSI/ASHRAE Standard 199 testing. This testing provides comparison data on emissions, pressure drop, compressed air usage, energy consumption and emission readings, taking the guesswork out of equipment selection to help identify the best dust collection equipment, size and design for each specific application.
Why the future of Logging and Control systems are defined by you, often without you realizing it.
It’s all about the focus
Focus is defined by many things. One of them is ‘paying particular attention to.’ At DEWESoft we pride ourselves on using that word to describe two key aspects related to our approach to designing and developing data acquisition and control systems. We focus on what you tell us you need or want, then we focus our attention on delivering it, how you wanted or needed it. DEWESoft design devices for you and wholly based on you.
Our goal is to take advantage of the latest technologies, newest techniques, and latest trends to create tools that guarantee accuracy classes second to none, out of the box software that can be set up short periods of time.
systems can real-time data at high as fifteen million per second per Our systems using EtherCAT communication technology provides the ability data to real-time
controllers that will ensure a true closed loop control mechanism for your application. This includes the ability to communicate to third party devices via a multitude of protocols such as MQTT, OPCUA, Modbus TCP, Serial and CAN. Our systems depending on the protocol allow the ability to stream data to an SQL database or Historian for further data analysis and management.
With our latest addition to the DEWESoft product family, the OBSIDIAN® data acquisition system with an on-board Linux based real-time operating system, as well as the capability of being switched to, what we refer to as, ‘standard mode’. This means that the system can be used as a standalone headless data acquisition system or ‘in-the-loop’ controls using EtherCAT as the primary protocol. With the OBSIDIAN® EtherCAT only a single cable is required for streaming many tens of channels. With the addition of our built-in Wi-Fi you don’t even need to be tethered to a host PC and can even operate your system from your mobile phone or tablet using our Android/IOS App.
Accelerating Progress Through Innovation
Digi-Key is committed to continual innovation and a recent invention and patent exemplify the innovative spirit running throughout the company.
Last year, Digi-Key was awarded a U.S. patent for a tray designed to transport and store electronic components. The tray was invented by Digi-Key engineers Shane Heinle and Reid Landsrud who set out to create a safer and more efficient way of transporting broken pack integrated circuits. The trays are a quarter of the size of the industry standard JEDEC trays allowing for a smaller packaging and shipping footprint for smaller quantity items, as well as a reduced environmental impact.
After inventing the tray, Digi-Key worked with fellow Minnesota companies Holland Molds of Wadena, Minn., RTP Company of Winona, Minn., and CCI of New Hope, Minn. to assist in commercial production of the tray.
“To me, everyone at Digi-Key is an engineer, and we have to make things work every single day,” said Shane Heinle, senior supervisor, ESD program control for DigiKey. “This is truly a local product from idea to production that is having global implications for our customer base.”
“It’s amazing the amount of packaging we save by using this smaller tray which offers the exact same benefits as the standard larger tray, just right-sized for the number of components we ship often,” said Reid Landsrud, supervisor, resident maintenance technician for Digi-Key. “We are able to send components in a smaller shipping box, with a smaller moisture barrier bag, a smaller amount of desiccant and a lower shipping cost; decreasing shipping and packaging prices and lessening the environmental impact.”
Innovative ideas are a constant at Digi-Key, from frictionless interactions to next-generation solutions. All indications are that 2023 is shaping up to be a good year of new product development for our engineering customers as well. We look forward to the continued innovation of our customers and we work together to accelerate progress.
For more information, please visit the Digi-Key website.
Control Unplanned Downtime, Don’t Let It Control You
Dodge ® Industrial has launched the newest condition monitoring platform. OPTIFY™ is easy to use and provides overall health status of assets remotely—letting you know when maintenance is needed before it’s too late. The free platform offers a unique digital advantage by seamlessly combining Dodge Industrial Internet of Things (IIoT) products and robust data analytics with industry-leading expertise, allowing you to reduce downtime, improve reliability, and operate safely.
The advanced platform’s integrated notifications provide warnings on decreasing health status of assets, allowing you to schedule maintenance before a problem occurs and the system goes down— saving valuable time and mitigating unforeseen expenses. OPTIFY is an advantageous solution for tracking key performance parameters in your operations to make betterinformed decisions in real-time.
Advanced analytics
You can customize views to compare data trends across different periods of time. Fast Fourier Transform (FFT) analysis provides a comprehensive look into equipment health to evaluate unique machinery issues.
Intuitive interface, alerts, and alarms
Easily manage your plant and assets through the streamlined interface. The comprehensive dashboard displays asset health with color-coded status indicators, and integrated notifications alert you to immediate actions needed to keep operations running smoothly.
Conditions monitoring and remote accessibility
The platform allows for like-asset comparison and historical data collection—both built-in features that don’t require separate portals. You can access the platform anytime, anywhere through a browser or mobile app.
Dedicated support
Access to industry-leading and USbased customer service is available at your fingertips when you need it most.
Get started with OPTIFY at dodgeoptify.com !
Flexicon stand-alone bulk handling equipment to engineered, plant-wide systems
Flexicon provides an unparalleled level of service through its administrative, engineering and manufacturing capabilities on four continents, and extensive worldwide network of Applications Engineers and factory-direct Regional Sales managers—a unique consolidation of bulk handling specialists with hundreds of years of combined experience.
An extensive research and development program continually sets new standards for bulk handling equipment performance with entirely new designs, product improvements and equipment that complies with chemical, food, dairy and pharmaceutical requirements nationally and internationally.
Flexicon’s design engineering staff devises efficient solutions to the most unusual problems with highly custom equipment, endowing the company with a depth and breadth of bulk handling experience unequalled by any other manufacturer.
Equipment overview
Flexicon is a world leader in the design and manufacture of bulk handling equipment and custom-engineered and integrated plant-wide systems that transport, discharge, fill, weigh, blend, deliver and/or feed a broad range of powder and bulk solid materials.
Products range from individual equipment to automated systems that source bulk material from interior and exterior plant locations, transport it between process equipment and storage vessels, weigh it, blend it, feed it to packaging lines, extruders, molding machines and storage vessels, and load it into railcars and trailers.
Choose from a broad range of reliable, high performance equipment:
• Flexible Screw Conveyors
• Volumetric Feeding Conveyors
• Tubular Cable Conveyors
• Pneumatic Conveying Systems
• Bulk Bag Fillers
A separate Flexicon Project Engineering Division manages largescale bulk handling projects across the chemical, mineral, food, dairy and pharmaceutical industries worldwide.
• Bulk Bag Dischargers
• Bulk Bag Conditioners
• Weigh Batching Systems
• Manual Dumping Stations
• Drum/Box/ Container Dumpers
Supervised by dedicated Project Managers, these custom-engineered, automated systems integrate Flexicon equipment with bulk handling and process equipment of other manufacturers including:
• Gravimetric/Volumetric Feeders
• Silos & other storage vessels
• Dryers/Coolers
• Mixers/Blenders
• Screeners
• Crushers/Grinders
• Packaging Machines
• Other bulk processing equipment
Basic, stand-alone machines to automated plant-wide systems, all Flexicon equipment components are backed by Flexicon’s Lifetime Performance Guarantee.
Continuous growth required the company to recently double the size of its US headquarters.
Achieve
sustainability goals and lower total cost of ownership with a holistic flow control approach.
To help businesses rise to the challenges of decarbonization and energy reduction targets, Flowserve has developed the Energy Advantage Program (EAP). The program incorporates proven engineering expertise, an innovative datadriven optimization of flow loop operations and defines a mutually-agreed-upon set of commitments to reduce efficiency costs and/or achieve carbon and efficiency goals.
Within the EAP, Flowserve performs engineering analysis, project management, and execution of aftermarket upgrades, tailored to the industry, application, and other site variables. The plant operator’s commitment is the collaboration on data, process information, and implementation.
Quantified Sustainability Impact
Implementing the Energy Advantage Program allowed the petrochemical operator to achieve:
• Combined power consumption reduction by approximately 3810 MWh per annum.
• Estimated annual savings from reduced energy consumption of $230,000.
As an example, Flowserve partnered with a petrochemicals plant operator to optimize energy usage of a cooling water system with five parallel VS3 pumps (rated 600 kW each) connected to a cooling tower in an open system. Flowserve was tasked with minimizing energy consumption across all operating scenarios — from reducing operational risks of having to operate all installed pumps to meeting the duty requirements and maintaining the existing electric motor and drive train, discharge head and motor frame.
• Approximate CO2 savings of 2285 metric ton per annum.
• Increased redundancy (5oo5 to 4oo5 operation).
• Increased reliability through higher NPSH3% margin
Flowserve’s EAP team implemented validation testing for open channel flow measurements to benchmark a dynamic system model for the different operating scenarios. This allowed new duty conditions to be defined for the pumps to achieve optimal energy efficiency at a system level. Following a data-driven analysis on the complete flow loop, Flowserve determined the most cost-effective, impactful upgrade was to retrofit the CW pumps with a custom hydraulic end. The improvements were validated through CFD analysis and factory tests prior to final on-site validation of the savings.
In addition to the petrochemical industry, Flowserve’s EAP is already helping companies realize measurable results in a wide variety of industries and applications — coal-fired power plants, pipeline, steelworks, and nuclear, just to name a few.
CLICK HERE or scan the QR Code to get in touch with Flowserve’s EAP engineering team to find out how we can help you achieve sustainability goals and lower TCO with an enhanced holistic flow control approach.
Predictive maintenance yields greater productivity, reliability, and savings.
Anglian Water, one of the largest water utility providers in the UK, was facing increasing pressure to improve the reliability of their equipment and to implement a reliability-centered maintenance approach. RedRaven, Flowserve’s predictive maintenance service, proved to be an effective a solution for this new initiative. After a one-month trial, Anglian Water increased RedRaven deployment to eleven pumps at four sites. Anglian Water further expanded the RedRaven deployment to monitor clean water and recycled water operations for up to nine hundred sites over a five-year period.
During commissioning of the live system, the Flowserve Monitoring Center (FMC) noticed high vibration values on one of the pumps. The system integration engineer went back on site to conduct additional analysis with a handheld vibration analyzer. Given the alert from the FMC, he chose to investigate further, even though the pumps were working properly at the time of inspection. Anglian Water is very much impressed by the following “end-to-end service” features:
• Portal: A streamlined dashboard that is accurate and detailed
• Flowserve Monitoring Center (FMC): Continuing support with clear and concise explanations
• Predictive Maintenance: Easy integration of monitoring and analytics to complement the existing pump repair agreement between Anglian Water and Flowserve
With RedRaven, Anglian Water is already changing its culture and thinking around maintenance, leading to a predictive maintenance approach with increased efficiency and reduced maintenance expenses. The solution has also enabled the company to save time and person-hours, making them more productive and effective. They appreciate the concise explanation of the analysis and the straightforward evidence provided along the way. They continue to be happy with the successful installations and recommend RedRaven to operators who are looking for next-level system performance.
Lubriplate’s Complimentary ESP Extra Services Package helps maximize your lubrication maintenance program.
A Toll Free Technical Support Hotline and E-mail
You can call Lubriplate’s technical service center toll free at 800-347-5343 for quick answers to tough lubrication questions by phone, or you can e-mail questions to LubeXpert@lubriplate.com seven days a week.
Complete Plant Surveys and Lubricant Inventory Consolidation
Complete plant surveys by Lubriplate’s professional staff of lubrication engineers are also available to determine your exact lubricant requirements and identify opportunities for lubricant inventory consolidation.
Customized, Color Coded, Lubrication Charts and Machinery Tags
Lubriplate offers color coded lubrication charts and machinery tags to help prevent lubricant misapplication and ensure that the proper lubricant is used when servicing a particular piece of equipment. Based on a complete plant survey, tags can be provided for each piece of equipment in your plant.
Lubrication Maintenance Software
Lubriplate offers a PC based computer software program that puts your entire lubrication and maintenance schedules at your fingertips. This service is based on a complete survey of your entire plant. Contact Dan Moroses (Newark office) for details at 973-589-9150.
No-Charge Follow-up Oil / Fluid and Grease Analysis
Lubriplate’s Oil/Fluid and Grease Analysis Program is offered at no-charge on all Lubriplate products. Tests include: Viscosity, Acidity, Contamination (% sediment and % moisture,) Spectrochemical (PPM of wear metals and additives) ISO Cleanliness (optional). An interpretation of the results is included along with suggested actions to take.
In Plant User Lubrication Training Programs
We offer training programs tailored to fit your needs. These educational training sessions focus on all facets of machinery lubrication and are not a sales presentation. Seminars are graphically presented with PowerPoints and other support material. Available on-site at your facility or in a local conference room. Contact us at 800-733-4755 for more information.
Lubriplate Lubricants Company Newark, NJ 07105 / Toledo, OH 43605
Bin-Picking: A New Automated Solution for an Old Manual Process
By Brody Diggins and Logan Martin, Motion Ai
One significant element of robotics in the industrial industry is efficiency. Everything revolves around uptime and the revenue stream that comes in through the products you create. Bin picking is one part that has held factories back for decades; its intricacy has impeded robots from successfully picking the correct item out of a bin of various parts. In recent years, bin-picking automation has made great strides: the process is faster and saves money in the long run with vision software and robotics.
How Our Bin-Picking
Automation Works - Before, intricate and small products were nearly impossible to sort correctly and were too expensive to attempt sorting when it could go wrong. Now, AI-driven bin picking has solved the previous sorting difficulties. It starts with a checklist of what must happen for accurate sorting. The list guides the robot on what to do and when, ensuring it only does the same action once. In this checklist, the robot precisely plans the path to search the box. A collision-avoidance feature allows the specific object to be identified, picked from the bin, and sorted correctly.
Operations - Before running these robots, the operator must learn the robotic programming for the specific task, work cell process design and correct camera setup, and complete AI training in parallel to these other factors.
The AI bin-picking solution is immune to different conditions that could impact original bin-picking systems. The camera set is not inhibited by ambient lighting.
How Bin-Sorting Solutions Improve Automation - Besides saving costs, automated bin-picking solutions will make your factory run smoother and faster than ever. The accuracy is unbeatable, few or no mistakes are made on the factory floor, and bins are sorted exponentially.
Although bin-picking solutions used to be costly, they are more accessible now that they have been simplified and are ready to be used in the factory daily.
Ready to automate your bin-picking process? Contact Motion Ai and speak to a rep today.
Image courtesy of Motion Ai.
Technology Updates and Automation Expertise from SEW-EURODRIVE
SEW-EURODRIVE — Much More Than Gearmotors
Our team of (MAXOLUTIONS) automation engineers provides the expertise, project planning, software, commissioning, and worldwide support for your most challenging motion control projects. They can serve as a valuable extension of your engineering team, reducing the stress and demanding workload. Our experts provide a solution of perfectly matched SEW components that work together seamlessly — because we designed them that way!
Complete Drive Maintenance and Management
SEW-EURODRIVE now offers a full complement of drive maintenance and management services. Our CDM ® Maintenance Management service provides a 24/7 online portal as well as a complete overview of your drive components, the condition of your units, drive usage, and service details. Plus, our new onsite Pick-Up Box Service will free up your maintenance team for other tasks. Just place your drives that need repair in the supplied box and we’ll handle the pick-up and return of your units.
MOVIGEAR® and MOVI-C® for Decentralized Installations
MOVIGEAR is the mechatronic drive system that combines the gear unit, IE4 motor, and electronics in one compact unit. Updates include fully integrated Ethernet/IP communications and digital motor integration. This advanced single-cable technology carries power, feedback information, and control signals along a single hybrid cable between decentralized devices. MOVI-C modular automation system is a one-software, one-hardware, automation platform that combines fully integrated components, control electronics and software.
About SEW-EURODRIVE
Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE, a leading manufacturer of integrated power transmission and motion control systems. SEW-EURODRIVE sets the global standard for high performance and rugged reliability in the toughest operating conditions. With global headquarters in Germany, its U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants, more than 63 technical sales offices and hundreds of distributors and support specialists. This enables SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-coast and around the world.
P: 864-439-7537
www.seweurodrive.com
Spiroflow, Cablevey, Kason, and Marion Join Forces to Offer Unmatched Innovations in the Material Handling and Processing Solutions
Spiroflow, Cablevey (Automated Handling Solutions (AHS)), Kason, and Marion (Advanced Material Processing (AMP)) have joined forces to provide cutting-edge material handling and processing solutions. Together, they offer unparalleled product portfolios and services, delivering tailored solutions to improve productivity, reduce labor costs, and increase safety.
As the industrial landscape continues to evolve, the need for innovation in material handling and processing has skyrocketed. In response to this demand, Spiroflow, Cablevey, Kason, and Marion have combined their expertise to deliver cutting-edge solutions to clients across various industries.
Automated Handling Solutions is a leading provider of advanced automation solutions and specialized material handling equipment for markets such as food and beverage, pharmaceuticals, and general industrial processing. Spiroflow and Cablevey’s combined portfolios offer innovative solutions to customers, such as hygienic dust-free conveying solutions.
Advanced Material Processing offers various material processing equipment solutions to food, nutraceutical, mineral, plastic, chemical, and biomass industries. They specialize in highlyengineered equipment and systems for mixing, drying, separation, and thermal/moisture control. Kason and Marion’s equipment is designed to meet each industry’s unique needs, ensuring efficiency and quality.
The joining of these four brands provides customers access to unmatched material handling and processing solutions tailored to their specific needs. By combining their expertise, they offer a comprehensive suite of material handling solutions, delivering superior performance and reliability.
Spiroflow Systems has been a global leader in powder handling and dry bulk solids processing for over 45 years and, along with their Automation and Controls division, provide equipment and services to manufacturers in the food, bulk material handling, packaging, paint & finishing systems, OEM equipment manufacturing, paper, film & foil, pharmaceuticals, foundries, automotive, and general industrial sectors. Spiroflow is proud to be an integral part of the AHS & AMP platform to deliver to customers worldwide.
sales@spiroflow.com • 704-766-8065 spiroflow.com
Publication Sales
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Matt Waddell MWaddell@CFEMedia.com
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Robert Levinger RLevinger@cfetechnology.com 630-571-4070 x2218
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Aaron Maassen AMaassen@CFEMedia.com Integrated Media Manager 816-797-9969
Northeast
Richard A. Groth Jr. RGroth@CFEMedia.com 12 Pine Street 774-277-7266 Franklin, MA 02038
Director of Content Marketing Solutions
Patrick Lynch PLynch@CFEMedia.com
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Marketing Consultant
Brian Gross BGross@CFEMedia.com
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Publication Services
Jim Langhenry, Co-Founder and Publisher, CFE Media JLanghenry@CFEMedia.com
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