fluid power world october 2015

October 2015www.fluidpowerworld.com

PAGE 40

Pneumatic system guidelines for success p.64Select the right motor for your hydraulic applications p.50 Reliability in industrial hydraulics p.56

Today’s engineer needs to understand the complexity of modern systems, from fuel consumption to load sensing.

Not your grandfather’s loader

Modern mobilehydraulics:

COVER_FPW 10-15_FINAL MG.indd 1 10/5/15 10:01 AM

HOW TO REDUCE STRESSTOMPKINS QUICK DISCONNECTS &

LIVE SWIVELS

Reduce the stress on both you and your equipment with Tompkins Live Swivels and Quick Disconnects. Our Live Swivels prolong the life of hose by reducing the eects of torque, twisting, kinking, and bending stress. Our Quick Disconnects are designed to connect

and disconnect lines seamlessly; without the use of tools. Both product lines available in a variety of sizes to help you, and your machines, remain stress-free.

800.255.1008 | tompkinsind.com/stressreduction

Tompkins 10-15.indd 1 9/30/15 12:41 PM

the #1 value in automationOrder Today, Ships Today!

* See our Web site for details and restrictions. © Copyright 2014 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405

With AutomationDirect’s new special-purpose,push-to-connect pneumatic ttings, it’s easy toadd the components you need to any circuit,at any location. These small, highly-ef cient ttings are mounted inline without any tools required,making installation a breeze!

Research, price, buy at: www.automationdirect.com/pneumatic-parts

NITRA QUICKEXHAUST VALVES• NITRA quick exhaust valves

have a technopolymer body andnickel-plated brass valve insert

• Pressure range of 7 to 150 psi• Normal ow is from inlet to outlet

ports, reversing ow from outlet isdirected to exhaust port

• Ideal for use with pneumatic actuatorsthat require a very fast stroke speed

NITRA FLOWCONTROL VALVES • Elbow meter-in, meter-out and

inline pneumatic ow valvecon gurations

• NPT and BSPT (R) threadsavailable

• Tough thermoplastic bodies,stainless steel tube grippingclaws, nickel-plated threadswith pre-applied Te on sealant(O-ring on #10-32 and M5 threads)

• Release rings are color coded todifferentiate between meter-in and meter-out

• Working pressure: -29.5” Hg to 150 psi• Working temperature 32 to 140°F (0 to 60°C)

NITRA HANDSHUTOFF VALVES • 2 and 3-way, locking and

non-locking manual shutoffvalves with technopolymerbody and nickel-plated brassinternal parts

• Union straight manual hand valves with thermoplastic (PBT) body and stainless steel tub gripping claws

• Technopolymer body• NITRA miniature pressure regulators

allow adjustments to downstream air pressure in a range of 15 to 120 psi

• NITRA pressure gauges have metal gauge housings and offer a range of0 to 170 psi

• NITRA pressure indicators have arange of 29 to 145 psi with your choiceof green or orange indicators

Starting at:$11.75(PMU14A)

NITRA PRESSUREREGULATORS / GAUGES /INDICATORS

Starting at:$8.75

Starting at:$8.25

Pneumatics made easywith Push-to-Connect inline ttings

Starting at:$11.25(HVU14-12)

1510-FluidPowerWorld-PneumaticsInline-MAG.indd 1 8/31/2015 10:09:18 AM

AutomationDirect 10-15_FPW.indd 1 9/30/15 12:43 PM

F l u i d L i n e s

Kids, education and fluid powerYou’ll likely notice that most issues of Fluid Power World have a particular focus on students and fluid power education. While it’s common to see “students are our future” type statements in most any industry, I think we can all admit that getting kids—heck, even college engineering students—interested in hydraulics or pneumatics is a big challenge. Fluid power is a mature industry that doesn’t capture the mainstream media’s imagination of what engineers do the way that bridge building or rocket designing might. There’s been a big STEM push that’s been picked up by the media the past couple of years, and many people and schools are getting into the idea. We need to realize that we have some real avenues into the discussion. LEGO didactic kits are affordable, great ways to introduce children to the concept of pneumatics. Maybe a tax-deducta-ble gift of some of the kits to your local elementary school would get the ball moving in your community. Maybe your company will even match the funds? And we all know that robots can incorporate fluid power actuation—and what kid isn’t fascinated by real life robots? (Mine sure are!) I was blown away by my visit to Dean Kamen’s FIRST Robotics championship in St. Louis this spring. It was great to see some fluid power companies (both manufacturers and distributors) sponsoring teams and providing equipment. We understand the importance of encouraging fluid power education, and we cover it extensively in every issue, including our Training, Association Watch and Research & Development columns. Our Safety and Maintenance departments often have education-oriented topics, as well. This month, you’ll find an insightful feature story written by Assistant Editor Michelle DiFrangia that takes a look at the state of fluid power education, examining programs that have been undertaken by schools, universities, manufacturers and distributors, and even our industry associations. The National Fluid Power Association actively wants to work with companies that have their own events—like Parker Hannifin’s Chainless Challenge, and we’d love to play a role, too, in promoting these events to the wider community. I remember sitting at the NFPA Annual Conference earlier this year, and a map went up showing where fluid power companies were donating time and money to educational causes. There were some embarrassing gaps, including in my own state of Ohio, home of a lot of fluid power manufacturers, users and expertise. We need to fill in the map. How are you going to help this school year?

2 FLUID POWER WORLD 10 • 2015 www.fluidpowerworld.com

Paul J. HeneyEditorial Director

[email protected]

On Twitter @DW_Editor

QUALITY HYDRAULICHOSE & ACCESSORIES

HYD

RA

ULIC

HO

SE

& FIT

TIN

GS K

uriyama of A

merica, Inc. S

eptember 2

01

2

Kuriyama HydraulicsEDITION 1209

HYDRAULIC HOSE,FITTINGS & ACCESSORIES

KHHCA0912

THE ASSOCIATION FOR HOSE ANDACCESSORIES DISTRIBUTION

EDITION 1207

KuriKrimp™ Crimpers & Accessories

Introducing our New and Improved!

A Complete Line of Thermoplastic Hydraulic Hose and Fittings

WATCH FOR MORE NEWPIRANHAFLEX ™ PRODUCTS

COMING SOON!

The “Piranhaflex” trademark contained in this publication is a trademark of Kuriyama of America, Inc.

EDITION 0313

13-KOA-36367_collateral_PiranhaflexCatalog.indd 1 3/21/13 3:12 PM

NEW! Kuriyama Hydraulics Catalog• Includes new Piranhaflex™ Plus Series

thermoplastic hydraulic hoses.

• New Piranhaflex™ 100R18 and twin line thermoplastic hydraulic hoses.

NEW! KuriKrimp™ Crimpers & Accessories Catalog• New improved Die Kages for protection and storage

of dies for the KD100 series crimpers.

• New KD4-600 and KD4-1000 series crimpers for crimping larger ID industrial hoses.

NEW! Piranhaflex™ Non-Conductive Hydraulic Hoses• Piranhaflex™ Plus Series PFP354NC nonconductive hose for medium pressure lines on utility equipment.

• Piranhaflex™ Series PFAN388NC non-conductive hose; complies with ANSI.92.2 for vehicle mounted pressure lines on boom trucks and cherry pickers.

Phone: (847) 755-0360 | Fax: (847) 885-0996360 E. State Parkway • Schaumburg, IL 60173

[email protected]

www.kuriyama.com

Kuriyama Hydraulics

Editorial 10-15 FPW_Vs3 MG.MD.indd 2 9/30/15 12:38 PM

HOW DO I KNOW IF I’M TALKING TO AN ENGINEER OR A SALESMAN?

THE ENGINEER’S CHOICE™

Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer?

Our customers would. That’s why they collaborate directly with our world-class team of Smalley engineers—experienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox® retaining ring or constant section ring for your precision application.

Smalley wave springs reduce spring operating height by 50%, saving space and weight, fi tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.

Visit smalley.com for your no-charge test samples.

HOW DO I KNOWIF I’M TALKING TO AN ENGINEER OR A SALESMAN?

THE ENGINEER’S CHOICE™

Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer?

Our customers would. That’s why they collaborate directly with our world-class team of Smalley engineers—experienced professionals whose only focus is helping you specify or design the ideal wave spring, Spirolox® retaining ring or constant section ring for your precision application.

Smalley wave springs reduce spring operating height by 50%, saving space and weight, fi tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and stainless steel.

Visit smalley.com for your no-charge test samples.

Smalley wave springs reduce spring operating height by 50%, saving

fi tting tight radial and axial spaces. We offer more than 4,000 stock sizes in carbon and

smalley.com for your no-charge

reduce spring operating

Coil SpringSmalley Wave Spring

38139_Smalley_BrandAd_FluidPowerWorld.indd 1 9/3/15 9:50 AMSmalley 10-15 FPW.indd 3 9/30/15 12:45 PM

OCTOBER 2015 • vol 2 no 5 • www.fluidpowerworld.com

WTWH Media, LLC6555 Carnegie Ave., Suite 300, Cleveland, OH 44103Ph: 888.543.2447 • Fax: 888.543.2447

EDITORIAL

Editorial Director Paul J. Heney [email protected]@dw_editor

Managing EditorLeslie Langnau [email protected]@dw_3DPrinting

Senior EditorMary [email protected]@dw_marygannon

Associate EditorMike [email protected]@wtwh_Michael

Assistant EditorMichelle [email protected]@wtwh_michelle

Contributing EditorJosh Cosford@FluidPowerTips

Director, Creative ServicesMark Rook [email protected]@wtwh_graphics

Visual Design ManagerMatthew Claney [email protected]@wtwh_designer

Graphic Designer/Production CoordinatorMargaret [email protected]@wtwh_meg

Traffic ManagerMary Heideloff [email protected]

Director, Audience DevelopmentBruce Sprague [email protected]

SALES

VP Sales

Todd Tidmore

512.626.8263

[email protected]

@wtwh_ttidmore

VP, Business Development

Michael Ference

408.769.1188

[email protected]

Key Account Manager

Jim Powers

312.925.7793

[email protected]

@jpowers_media

Regional Sales Manager

Tom Lazar

408.701.7944

[email protected]

@wtwh_Tom


Neel Gleason

312.882.9867

[email protected]

@wtwh_ngleason


Courtney Seel

440.523.1685

[email protected]

@wtwh_CSeel

Business Development

Michelle Flando

440.670.4772

[email protected]

@mflando

NEW MEDIA/WEB/

BUSINESS DEVELOPMENT

Web Development Manager

B. David Miyares

[email protected]

@wtwh_webdave

Web Development Specialist

Patrick Amigo

858.603.2984

[email protected]

@amigo_patrick

Video Manager

John Hansel

[email protected]

@wtwh_jhansel

Video Coordinator

Joshua Jones

[email protected]

@wtwh_josh

Business Development

Manager

Patrick Curran

[email protected]

@wtwhseopatrick

Online Coordinator

Jennifer Calhoon

[email protected]

@wtwh_jennifer

4 FLUID POWER WORLD 10 • 2015

2011- 2015

FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into disputes with or between any individuals or organizations.

FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or publication. Every effort is made to provide accurate information. However, the publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

FLUID POWER WORLD does not endorse any products, programs, or services of advertisers or editorial contributors. Copyright© 2015 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval systems, without written permission from the publisher.

SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions, 1 year: $125; 2 years: $200; 3 years $275; Canadian and foreign, 1 year: $195; only U.S. funds are accepted. Single copies $15. Subscriptions are prepaid by check or money orders only.

SUBSCRIBER SERVICES: To order a subscription or change your address, please visit our web site at www.fluidpowerworld.com

FLUID POWER WORLD is published by WTWH Media, LLC, 6555 Carnegie Avenue, Suite 300, Cleveland, OH 44103.

www.nfpa.com

Marketing Team LeaderStacy [email protected]@wtwh_scombest

Marketing CoordinatorCarli Evilsizer [email protected]@wtwh_carli

Marketing and Events CoordinatorNicole Loepp [email protected]@wtwh_nicole

Marketing and Events CoordinatorJen Kolasky [email protected]@wtwh_jen

Marketing CoordinatorLexi Korsok [email protected]@medtech_lexi

HYDRAULIC FLANGESAND COMPONENTSAND COMPONENTS

* SAE 4-BOLT

* FLANGE ADAPTERS

* STAINLESS

* SAE, JIS, DIN

WWW.MAINMFG.COM/flg

[email protected] PH: 800-521-7918

3181 Tri-Park DriveGrand Blanc, MI 48439

Request MAIN's catalog

A US Manufacturer

'MAIN' ADVANTAGES

"Serving Industry for 55 years"

* METRIC PORTS

* SPECIALS

MAINMAINmanufacturing products, inc

Experience - 55 years of hydraulic experience

Assistance - MAIN's engineers are part of the SAE, NFPA, and ISO committees

Availability - Standards & Specials in stock

CONNECTIONS WITHINTEGRITY

TOMPKINS FLANGES AND NO BRAZE FLANGE ADAPTERS

Pressure-tested and designed for extended use, our no braze adapters provide unmatched reliability in a variety of configurations. Leaks are a

non-issue due to one-piece construction and meet Code 61 and 62 specifications. In addition, Tompkins carries a full-line of threaded and

weld flanges, as well as split flange kits.

800.255.1008 | tompkinsind.com/flanges

Staff Page_Fluid Power World 10-15_Vs1.indd 4 10/1/15 12:11 PM

• Industry leading customer service

• 23 different displacement sizes

• Both gerotor and roller gerotor designs available

• High quality and performance

• High efficiencies across a broad torque range

• Ideal for industrial and mobile applications

Muncie Power Productswww.munciepower.com

POWER TAKE-OFFS - PUMPS - MOTORS - CYLINDERS - VALVES - RESERVOIRS - HOSES - FITTINGS - FILTERS

Call 800-367-7867 to learn more.

REASONS WHY YOUR NEXT LOW SPEED HIGH TORQUE MOTOR SHOULD BE A MUNCIE POWER PRODUCT

Muncie Power 10-15.indd 5 9/30/15 12:52 PM

20


ON THE COVER Modern mobile machinery, such as loaders, require in-depth understanding of complex hydraulic systems. Photo credit istockphoto.com.

40

D E PA R T M E N T S

02 Editorial 08 Korane’s Outlook

10 Research & Development

14 Association Watch

18 Distributor Update

20 Energy Efficiency

22 Design Notes

28 Training 31 Fundamentals

34 Maintenance

38 Safety

84 Component Focus

86 Product World

88 Ad Index

50

56

Oct

ober

201

5 Contents | v o l 2 n o 5 | f l u i d p o w e r w o r l d . c o m

10

F E AT U R E S

MOBILE HYDRAULICSModern mobile hydraulics:

Not your grandfather’s loaderToday’s engineer needs to understand the complexity of modern systems, from fuel

consumption to load sensing.

HYDRAULIC MOTORSSelect the right motor for

your hydraulic applicationsAlthough hydraulic pumps are more often

talked about in system design, choosing the motor must come before pump selection.

INDUSTRIAL HYDRAULICSReliability in industrial hydraulics

The key to a reliable hydraulic system lies in keeping it cool, clean and dry.

PNEUMATICSPneumatic system guidelines

for successFollowing these design rules will

ensure a successful machine automation application.

EDUCATIONStudents today, engineers tomorrow:

Our future lies in their educationRecognizing the need for immersive learning, manufacturers, distributors and associations

are working toward getting students excited about careers in fluid power.

64

72

64

Contents_FPW 10-15_Vs4 MG.indd 6 10/1/15 9:30 AM

NFPA/JIC Tie Rod Cylinders • Hydraulic and Pneumatic • 1½” up to 24” bore • Interchangeable with all brands

Custom Welded Cylinders • Hydraulic and Pneumatic • 1½” up to 50” bore, with strokes exceeding 300”

Heavy Duty Mill Cylinders • Hydraulic and Pneumatic • 1½” up to 50” bore, with strokes exceeding 300”

As we continue to grow, we remain committed to accessibility. We want our customers to know they can call us anytime. Accidents are never convenient, which is why we offer emergency services 24 hours a day, 365 days a year.

Yates 10-15.indd 7 9/30/15 12:53 PM

The stock market’s pressure on hydraulics

Whether you closely follow the stock market or only occasionally peek at your 401(k) balance, it’s been a rough ride over the last couple months. The Dow Industri-als, S&P 500 and other major indices fell into “correction” territory—off more than 10% from highs of a couple months ago. Even worse is the beating fluid power manufacturers and OEMs are experiencing. No one knows whether more bloodlet-ting or a major rebound is in the offing. But most experts point to three culprits un-derpinning the turmoil: slowing economic growth in China, fears of rising interest rates in the U.S., and slack demand for commodi-ties that range from corn and soybeans to oil and coal. Especially on the last point, that translates to bad news for manufacturers of everything from hydraulic pumps to agricul-tural and mining equipment. Economist Eli Lustgarten of Longbow Research, a featured speaker at NFPA’s Industry and Economic Outlook Conference (IEOC) in August, agrees that fluid power demand is falling in 2015 due to sharp declines in commodity sectors and sluggish economic growth. Virtually all end markets for commodi-ty-related capital spending are under signifi-cant pressure, he said. Prices of industrial metals like copper and iron ore, currently at five-year lows, are tied to economic growth in China and India. And opposition to coal in power-generation markets continues to grow. In turn, mining equipment production and sales are soft. Excellent global crops the last two years have depressed agricultural commodity prices, meaning less cash in farmers’ pock-ets and less demand for ag equipment.

Finally, oil and gas investments con-tinue to spiral downward as crude prices remain in the doldrums. As a result, said Lustgarten, 2015 production is down 45% for large ag equipment, 50% for mining equipment and 55% for China construc-tion equipment, versus recent market peaks. The depressing news is directly reflected in the stock market. Ag leader Deere is down 19% from its 52-week high. Caterpillar and Komatsu, with sizeable footprints in mining, dropped 28 and 33%, respectively. And mining-equipment maker Joy Global has declined nearly 70%. Fluid power stalwarts Parker Hannifin (-24%) and Eaton (-28%) likewise feel the pain. Nonetheless, there may be a silver lining. For those with a long-term view, many consider stocks to be oversold. Fluid power markets may not be going gang-busters, according to economists at the IEOC, but they should hold their own with slow and steady growth. No one predicts the demise of oil, steel—or fluid power, for that matter—anytime soon. As Warren Buffett once famously said, “Be fearful when others are greedy, and be greedy when others are fearful.” With the market beat down, now may be a good time to bet on the long-term prosperity of the fluid power industry. FPW

8 FLUID POWER WORLD 10 • 2015 www.fluidpowerworldonline.com

K o r a n e ’s O u t L o o k

Ken Korane, Contributing Editor

isto

ckph

oto.

com

Korane column 10-15 FPW_Vs2 MG.MD.indd 8 10/1/15 2:24 PM

MANIFOLD WIRING MADE EASY

© Copyright 2015 Bimba Manufacturing Company. All Rights Reserved.

BIMBA BRANDS I ACRO I MEAD I MFD I PNEUMADYNE I TRD

THE SIMPLE SOLUTION FOR WIRING MANIFOLD VALVE STACKS.To learn how Bimba can help you streamline your setups, or to learn more about the Mead Manifold PowerStrip™ visit www.bimba.com/mead

Introducing the Mead Manifold PowerStrip™

• Simplifi es manifold valve stack wiring• Eliminates bundled wire sets• Uses existing DIN style solenoid connection• Features integrated circuit protection and LED indicators • Reduces installation time • Cost-effective

PNEUMADYNEPNEUMADYNE

MANIFOLD

BIM-2488 Bimba Resizes_2015_Design World_Mead MPS_070115.indd 1 6/15/15 3:29 PMBimba 7-15.indd 9 9/30/15 12:55 PM

RESEARCH & DEVELOPMENT


Setting The Standard For Solar Storage

Transportation is one of the largest segment users of energy in the U.S., consuming 30 quadrillion (quads) of BTUs a year. Making up this segment are light-duty and beyond-light-duty transportation vehicles. Light duty refers to the cars that Americans drive every day. Beyond-light duty refers to everything else, from mobile machinery to large trucks. Mobile machinery—used in agriculture,

construction, mining, and so forth—is a significant portion of this energy usage, said Zongxuan (Sunny) Sun, co-deputy director of the Center for Compact & Efficient Fluid Power (CCEFP). “In a report published by the Department of Energy, off-road (transportation) consumes about 2.4 quads per year, which accounts for 8% of the total transportation energy consumption and

17% of the non-light utility vehicle energy consumption,” Sun said. “This is even larger than even the marine or aviation markets.” Because of this, CCEFP researchers are working to secure government support and form collaborations between academia, industry and the national labs to conduct pre-competitive research in off-road vehicles. A group from the NFPA, CCEFP, Association of Equipment Manufacturers

CCEFP research aims to improve mobile hydraulic efficiency

RESEARCH & DEVELOPMENT Mary C. Gannon • Senior Editor

Professor Zongxuan Sun, co-deputy director of the CCEFP (center), works with graduate research students on the free-piston engine de-sign at the University of Min-nesota. This research project aims to create a modular design that combines the internal combustion engine and the hydraulic pump into one device.

FPW_Research 10-15_ Vs3 MG.MD.indd 10 9/30/15 2:35 PM

Intertraco (Italia) S.p.A. SUZZARA (MN) - ITALY www.intertraco.it

THE

QUAL

ITY

OPTI

ONA complete and fully compatible

hose and fittings non-skive systemfrom R1AT 1/4” to R15 2”

including wire braided, multispiral,thermo-plastic and teflon applications.

Intertraco 10-15.indd 11 9/30/15 12:57 PM

1 2 FLUID POWER WORLD 10 • 2015 www.fluidpowerworld.com www.fluidpowerworld.com 10 • 2015 FLUID POWER WORLD 1 3

RESEARCH & DEVELOPMENT

and member companies recently participated in a meeting with the Vehicles Technology Office (VTO) of the DOE to demonstrate the differences between on-road and off-road vehicles’ energy use. Clearly, the biggest difference is that in on-road vehicles, internal combustion engines are used, while most of the energy produced by off-road vehicles goes through hydraulic power. Additionally, off-road vehicles are one input (ICE) and multiple output (drivetrain and working functions) systems with different hardware architectures and duty cycles than light-duty vehicles, said NFPA’s CEO Eric Lanke. And not only are their drivetrains different, there is currently no dedicated program or offices in the federal government that fund the pre-competitive research in this area. Additionally, energy efficiency and productivity are key drivers for global competition in this area. Couple all this with the fact that NFPA’s research showed that the average efficiency of fluid power systems is only 22%, and you clearly can see there is a significant opportunity to improve efficiency in this area, said Sun. In the meeting with VTO, Sun said the group highlighted four areas for potential research, with a fifth objective being the continued support of research by CCEFP universities.

1. Efficiency of fluid power systems enabled by more efficient components, such as modular power supplies, and optimized system architectures.2. A tighter integration of fluid power systems with combustion engines, such as hybridization and Sun’s research into free-piston engines.3. Develop connected and automated off-road vehicles to improve efficiency and productivity by reducing the losses of sub-optimal operations.4. The development of systematic modeling and analysis tools to continue to develop new architectures, user interfaces, controls and connectivity.

Further details were given to the VTO

about the free-piston engine and even Caterpillar’s hydraulic hybrid excavator to give the members of the VTO real-life examples of

these efficiency improvements. The free-piston engine combines the internal combustion engine and the hydraulic pump into one device, eliminating the crankshaft altogether. A linear engine moves back and forth, working combustion energy into fluid power directly. “This device would enable efficiency improvement on both the engine side and the fluid power side,” Sun said. “Because you do not have a crank shaft, you have independent, individual modules so you could potentially place these modules at different locations of your vehicle so that you not only get improved efficiency, you also get a lot of flexibility in the design and packaging of your machine.” Caterpillar’s hydraulic hybrid excavator is already commercially available, and offers significant improvements compared with its non-hybrid version of the same size excavator. This machine uses recovered energy from the swing to load trucks while using up to 33% less fuel than Caterpillar’s own 336D machine doing the same amount of work. The CCEFP is also conducting research on a similar hybrid design, but Sun said they highlighted the Caterpillar product to demonstrate that manufacturers see the need in the industry and it’s not just a pipe dream created by professors. “We also want to show that there are commercial products on the market that clearly demonstrate that with the right technology, you could significantly reduce energy consumption and emissions,” Sun said. “I think the key really is that fluid power is a dominant method for power transfer in this field and there are significant opportunities for improving energy efficiency. The CCEFP is working together with industry members to try to promote the pre-competitive research in this area.” FPW

CCEFP ccefp.org

and other engineering topics atwww.engineeringexchange.com

Discuss This

Complete Mechatronics Motion SolutionsUnder control and in motion

Global manufacturer of process control and factory automation solutions

For more information:Call: 1-800-Go-Festo 1-800-463-3786

www.festo.com/us/mms

Toothed belt axis ELGA-RF

Integrated servo motor MTR-ECI

Mini H-Gantry EXCM

FPW_Research 10-15_ Vs3 MG.MD.indd 12 9/30/15 2:36 PM

#6825 Kurt Hydraulic Fluid Power World ad Oct 2014.indd 1 9/19/14 3:23 PMKurt Hydraulics 8-15_FPW.indd 13 9/30/15 12:58 PM

ASSOCIATION WATCHASSOCIATION WATCH


Throughout the Industry & Economic Outlook Conference (IEOC), presented by the NFPA in August, most economists echoed their thoughts from last year, saying the country, and the fluid power market in particular, is on track to round out the rest of 2015 at a slow pace and experience moderate growth rates of about 2 to 2.5% in the coming year.

Each year, the IEOC features five keynote presenters. Returning this year were NFPA favorites Alan Beaulieu, of ITR Economics; John Walker, of Oxford Economics; Eli Lustgarten, of ESL Consultants; Jim Meil, of ACT Research; and geopolitical strategist and forecaster Peter Zeihan.

With most traditional fluid power markets down and not expected to see a major comeback for several years, it would seem like a lot of gloom and doom. As all four indicated, agriculture, mining and industrial machinery will not see much growth in the coming years as those markets continue to pull

NFPA IEOC roundup: Slow growth spurred by low energy prices

Mary C. Gannon • Senior Editor & Paul J. Heney • Editorial Director

Eli Lustgarten reminded the audience at the NFPA IEOC that the U.S. is one of the bright spots in the global economy, and should continue to see stable growth for a few years. Photo courtesy of the NFPA

10 • 2015 FLUID POWER WORLD 15

back. But we should see a silver lining as lower energy prices, higher employment and non-durable goods help to pick up the slack.

One of the key statements Beaulieu made is that nothing is as bad as the press makes it out to be. As he forecasted last year, he expects 2016 and 2017 to be up, with a mild recession coming in 2019.

Oxford was, as usual, fairly optimistic. While he said he sees the short-term forecast as “deeply troubling,” he expects mid-term growth rates of between 4 and 5%. He said the U.S. economy is relatively good, with a weaker dollar hurting exporters but helping to boost consumer spending power.

Lustgarten honed in on the U.S., calling it an oasis in what is to be modest global growth, as things have started picking up and will continue for the next couple of years. As each one pointed out, the U.S. is on stable ground while other world

FPW Dept Assoc Watch 10-15_Vs4 MG.MD.indd 14 9/30/15 2:41 PM

To l l F r e e : 8 8 8 - 3 3 1 - 1 5 2 3 • w w w . b r e n n a n i n c . c o m

Use our website to search our catalog of over 30,000 hydraulic fittings, instrumentation products, clamps, valves, flanges and more. All of our products are available in steel, stainless, brass and aluminum.With an offering of more than 8,000 drag-and-drop CAD models, product data and pressure ratings at your fingertips along with knowledgeable customer service specialists standing by to answer your questions, we make it easy to specify Brennan.

RIGHT AT YOUR FINGERTIPS.

D i s t r i b u t i o n C e n t e r sAt lanta C leveland Dal las Houston800.458.1988 800.331.1523 800.443.9937 800.443.9937Los Angeles Seatt le Shanghai Toronto 800.942.5321 800.445.7107 +86 021 57390012 800.331.1523

®THE LOGICAL CHOICE

Brennan Industries 8-15 FPW.indd 15 9/30/15 12:59 PM

ASSOCIATION WATCH

10 • 2015 FLUID POWER WORLD 17The MFP Seals Logo and the X-PAC® name are registered trademarks of Martin Fluid Power Co. © 2015

FPW_MFP_HH_OCT15A.indd 5 8/25/15 2:25 PM


Discuss This

powers, such as China, Russia and Europe, struggle.

However, all four agree that durable goods, particularly those filled heavily with fluid power components, will lag behind more consumer-driven growth. But as energy prices, including oil, natural gas, and electricity, continue to stay low, said Meil, we will see a pick-up in activity as we start to “see the plus side in the energy price shock.”

Zeihan echoes these sentiments, more forcefully saying that the U.S. is a country uniquely positioned in the coming decades, which bodes well for manufacturers. Most importantly, the continual technological advances in fracking are bringing about some interesting changes. The costs are dropping and will continue to do so. Currently, prices are approaching the levels

of Middle Eastern oil production. Zeihan said that the U.S. can expect 30 years of cheap natural gas, and realistically, it’s probably much closer to 60, simply with the technology we have currently. But add on to that the fact that people drive less as they age and retire—and the bubble of the boomer generation means we’re looking at a minimum of 20 years of year-on-year decline in energy needs. He said that by 2017, we will be energy independent as a country.

Zeihan said that there are some bright spots in various industry sectors, due to this continued lowering of domestic energy prices. Ones related to natural gas are midstream/downstream production, petrochemicals, fertilizers, desiccants, plastics and moldings, paper, tires, glass, insulation, antifreeze, detergents,

cosmetics, paint, diesel, adhesives, fire extinguishers, water treatment and distribution. And ones related more directly to electricity are retail consumption, chemicals and plastics, petroleum refining, paper and paperboard, metals manufacturing, food processing, plastics and rubber, and aluminum. FPW

NFPAnfpa.com

FPW Dept Assoc Watch 10-15_Vs4 MG.MD.indd 16 9/30/15 2:48 PM

full production runs.From prototypes to

Looking for a custom hydraulic cylinder solution that outperforms any other cylinder in any fl uid power industry application? Partner with Aggressive Hydraulics for the innovation you need to succeed. Our purpose-built philosophy is the driving force behind our superior products and superior customer satisfaction.

Our design, engineering and manufacturing expertise addresses an application’s specifi c rigors, environmental challenges and exacting requirements to meet existing customer demands or solve the hydraulic cylinder needs of an untapped customer base. From one unit to full production runs, we can supply you with proprietary products that deliver a better total value, day in and day out. Ready for a new competitive advantage? Get Aggressive.

(866) 406-4100 | www.aggressivehydraulics.com | [email protected]

© 2015 Aggressive Hydraulics, Inc. All rights reserved.

Engineered to move your business.

Now that’s Aggressive!

Aggressive Hydraulics 10-15_FPW.indd 17 9/30/15 1:04 PM

DISTRIBUTOR UPDATE


Mike Santora • Associate Editor

Just about everyone is aware of the dominance of video content on the Internet. Just to be on the net at all demands that you be aware of it. The trend doesn’t show signs of slowing down either. Cisco, for example, predicts that 69% of all consumer Internet traffic will be video by 2017. If you want to stay competitive and serve your consumer base well, video needs to be a big part of your business. Distributors in the know have taken notice. Motion Industries, a distributor of industrial maintenance, repair and operation (MRO) replacement parts is already known for their popular MiHow2 series of instructional videos. Many have tuned-in for the tutorial video How to Set a Pressure Reducing Valve in a Hydraulic System. The video covers how to install an Eaton/Vickers pressure reducing valve in a hydraulic system. The video How to Select the correct Power Team Cylinder has also become a widely viewed resource for fluid power professionals. But for those looking for a shorter, more concise video experience, there is also the Tom’s ToolBox series.

Tom’s Toolbox series: Short videos, big impact

The video series follows the same format as MiHow2, but in shorter time snippets. A new video, for example, Demonstration of Milwaukee’s New Innovative Fluorescent Lighting Tester, was filmed with the help of Milwaukee. It’s a quick video shedding light on the Lighting Tester’s efficiency and uses. The video can now be viewed on the new MiHow2.com under the Tom’s Toolbox heading.

Each Tom’s Toolbox video is filmed in a workshop or appropriate off-site setting and features Motion Industries’ host, Tom Clark. The series is also available for viewing on Facebook and YouTube. Additional MiHow2 and Tom’s Toolbox videos are scheduled to be posted in coming weeks.

Motion Industries has more than 550 operations, including 15 distribution centers throughout North America and serves more than 150,000 customers from the food and beverage, pulp and paper, iron and steel, chemical, mining and aggregate, petrochemical, automotive,

wood and lumber, and pharmaceutical industries. The videos are integral to the company’s growth.

“We have outstanding relationships with our suppliers. They see the benefit of having their products represented on Tom’s Toolbox, and in most cases, can’t wait to be part of our promotional activities,” said Randy Breaux, Motion Industries’ SVP, Southern U.S. Operations, Corporate Marketing and Strategic Planning.

This is especially true for the fluid power sector of their business. “Motion is one of the leaders in fluid power product sales. Our fluid power products offering continues to expand and the expertise we provide our customers through our product specialists and branches are keys to our success in fluid power,” said Breaux. FPW

Motion Industries motionindustries.com

FPW 10-15_Distributor_Vs5 MG.MD.indd 18 9/30/15 2:56 PM

HYD1508-1708

TECHNICALCLEANLINESS

Condition Monitoring and AnalysisTechnical cleanliness is becoming increasingly important in many sectors of industry: automotive, machine tools, injection molding, mobile hydraulics, and production systems. High demand for the reduction and prevention of start-up breakdowns and for extended warranty periods is driving the need for improved component cleanliness.

HYDAC, the Solutions Provider of:Offl ine Filter Systems - OFS & OFS-AM Series• Provides visibility and traceability of data previously unavailable or

unmanaged, making true predictive maintenance a reality• Programmable cleanliness levels and automatic switch-off• Asset history management and record keeping for trending

Fluid Control Units - FCU Series• Portable service unit for measurement of particulate contamination,

water saturation and fl uid temperatures in hydraulic systems

• Cleanliness classes in accordance with ISO and SAE and/or NAS

CLEANLINESSFrom a clean component…to a technically clean system.

BOOTH #2342SEE US AT

FCU 1310

OFS-A

OFS-AM

HYD1508-1708 FPW_OctAd_FullPg.indd 1 8/19/15 9:38 AMHydac 10-15.indd 19 9/30/15 1:05 PM


ENERGY EFFICIENCY

The wet storage dilemma

Ron Marshall • For the Compressed Air Challenge

A metal products manufacturer was well aware of the benefits of large storage receivers installed on

its system of load/unload compressors. The receivers act as a quiet zone where water and lubricant can settle

out of the air before entering the system dryers. In this zone, the air is cooled—making it easier to dry. And the

significant storage reduces the compressor’s load/unload cycle frequency, which reduces the energy consumed.

The processor purchased a 1,060-gal storage tank, which was placed on the wet side of his refrigerated air dryer. All was well for many months until the maintenance personnel noticed the compressors cycling excessively. The air dryer was also performing poorly, allowing water into the downstream piping, fouling air-operated tools. An experienced auditor was called in to take a look at the system. After checking the compressor settings, the dryer and filter differential, and examining the piping, he had a look at the wet receiver condensate drain. For some reason, the automatic drain had failed. A manual valve was opened—and about 1,000 gal of water was released after draining the tank for

what seemed like hours. A failed drain had caused the tank to completely fill with condensed water over a period of time, making the receiver ineffective in improving the system. The free water that gurgled out was overwhelming the air dryer. The plant engineer was concerned, as the completely full tank was extremely heavy and could have caused mounting structures to collapse. The drain was replaced and compressor operation returned to normal. The plant now has a regular maintenance schedule to test the drains. FPW

Compressed Air Challengecompressedairchallenge.org

FPW 10-15 EnergyEfficiency_Vs2 MG.MD copy.indd 20 9/30/15 2:58 PM

NFPA Hydraulic Cylinders

TECO Technology’s Hydraulic Business Group and Hengli Hydraulics are pleased to announce that TECO Technology has become the first Hengli distributor in North America.

Let TECO Technology & Hengli offer you a high quality solution for your next OEM application.

1069 Serpentine Lane

Pleasanton, CA 94566

1045 Telegraph Street

Reno, NV 89502

19439 SW 90th Court

Tualatin, OR 97062

TECO Technology - www.tecotechnology.comHengli America - www.hengliamerica.com

Providing the Right Technology for your Application

Hydraulic Hose & Fittings Hydraulic Filtration

Other hydraulic products offered by TECO Technology are.....

Hengli-Teco ad 2015_FPW_Vs8.indd 21 9/30/15 1:07 PM


DESIGN NOTES Edited by: Mike Santora • Associate Editor

Surgical assist robot goes pneumatic

Two pneumatic cylinders are used to move EMARO forward and back-ward (200 mm); up and down has a -3 to 47° range of motion; and for rotation and right and left move-ment, EMARO moves from -90 to 90°.

first pneumatically controlled surgical assist robot.

Launched by the Tokyo Institute of Technology and Tokyo Medical and Dental University (TMDU), EMARO resulted from more than 10 years of research on pneumatic, ultra-precision manipulation. Associate Professor Kotaro Tadano of Tokyo Tech’s Precision and Intelligence Laboratory and Professor Kenji Kawashima of TMDU’s Institute of Biomaterials and Bioengineering conducted the research.

EMARO controls the endoscope by sensing the vertical and horizontal movements of the surgeon’s head through a gyroscope that is worn on the forehead. The endoscope has four degrees of freedom for movement: forward and backward (insertion and removal), up and down, left and right, and rotation. The surgeon directs this motion by controlled movements of his head and by operating switches with his feet.

Until now, pneumatic manipulation technologies have not been able to provide the smooth and continuous movement needed for highly precise control of surgical devices. Professors Tadano and Kawashima overcame this

Surgical precision saw a major technological boost in the early 1980s when robots began accompanying doctors in the OR. In recent years, minimally invasive operations have been gaining popularity over traditional surgery because of faster post-operative recovery and less scarring.

Many of these endoscope-based surgical operations present unique risks, such as camera shake or communication difficulties between the operating surgeon and the scopist. New equipment is needed to overcome these problems. At the same time, conventional motor-driven endoscope manipulating robots are not ideal in terms of operational subtlety and delicacy. That’s why Riverfield, a Tokyo-based venture company, built EMARO—the world’s

hurdle by creating an advanced model with continuous air pressure control and an original manipulation technique. Their success owes much to Tokyo Tech Professor Toshiharu Kagawa, who has had impressive results over decades of research in the field of fluid measurement and control. Two pneumatic cylinders are used for moving EMARO forward and backward (200 mm); up and down has a -3 to 47° range of motion. For rotation and right and left movement, EMARO moves from -90 to 90°. Two rotary type pneumatic actuators are used for left and right and for rotation. All actuators are driven by a five-port, spool-type servovalve.

Pneumatic driving makes it possible for robots to move gently and smoothly. It has been used extensively in industrial robots, particularly for grasping and holding objects. Moreover, the pneumatic approach makes it possible to create a compact and lightweight design; sufficient power can be obtained by injecting or extracting air through a cylinder no larger than a standard syringe—about 10 mm in diameter.

Consequently, the operating surgeon can receive clear endoscopic images without

FPW_DESIGN NOTES 10-15_Vs4 MG.MD.indd 22 9/30/15 3:10 PM

www.fluidpowerworld.com 10 • 2015 FLUID POWER WORLD 23


Discuss This

camera shake, resulting in more precise surgeries. In addition, EMARO provides haptic feedback for the user and, taking the role of a scopist, can be useful in smaller hospitals that have a shortage of doctors, allowing more patients to undergo laparoscopic surgery.

EMARO is the first in a series of surgical assist robots that will use ultra-precision pneumatic manipulation technology. Development is now underway for a system that uses the pneumatic drive design and incorporates forceps. As its primary feature, this system will be able to detect the force exerted on the forceps through air pressure, and will feed this sensory information back to the operating surgeon. This is called force sensing.

With surgical assist robots, the surgeon sits in front of a console placed off the patient and operates the controls with both hands. While observing endoscope images, the surgeon can manipulate forceps and the endoscope. With force sensing, the surgeon will feel as if he were directly working on the patient, which is likely to help improve surgical accuracy.

There are no plans to bring EMARO stateside yet, but it’s not off the table. “We have not planed this yet, but if there is a good opportunity, we will deliver EMARO to the U.S.,” said Kawashima. FPW

Riverfield riverfieldinc.com

A competitive range of metric tube fittings according to ISO 8434-1 / DIN 2353 are now available from our stock in the US and Canada.

The STAUFF Advantage:

• Highest Quality European Made Parts • Pressure ratings that surpass the requirements of the ISO standard for increased operational safety and reliability • Our premium Zinc/Nickel surface coating offers surface protection against corrosion with more than 1200 hours resistance to rust in industry standard salt-spray tests

Learn more at stauffconnect.com

[email protected]

NEW!

STAUFF

Connect

Metric Tube Fitting Technology from STAUFF.

Metric fittings are “Standard” for STAUFF.

STFF-307FittingsAd9x5_25FPW4.indd 1 9/18/15 11:56 AM


Bluetooth embedded amplifier for proportional cartridge valves goes wireless


DESIGN NOTES

If you are of a certain age, you might remember when nearly every electronic device had a cord. You also might remember having been tripped, or tangled in those wires as well. In your home, the stakes were fairly low. That’s not usually the case in the field, where they can also pose real safety concerns.

As engineers working with fluid power cartridge valves, it’s important that you’re able to get close and observe machine operation during machine setup and calibration. Configuring without wires means the end of special cables, connectors and the need for a PC in the field.

It’s easy to imagine industrial applications that would benefit from Bluetooth-configurable valves. With a 30-ft range, Bluetooth reaches places that might otherwise require climbing with programming equipment,

exposure to hazardous environments and increased time to connect and configure valves. With Bluetooth you can reconfigure installed amplifiers quickly and easily. In 2007, Sun Hydraulics introduced its first embedded amplifier products. At the time, the best communication approach was an IR link for ease of connection and electrical noise immunity. But with the explosion of smartphone usage, Bluetooth communication made its way to the top of the short list for new connectivity options. The Sun design team saw this opportunity early on; the concern was how to make it a reality.

Perhaps the biggest challenge Sun faced during the design process was how to go wireless and add better software configurability without expanding the size

of the embedded amplifier. It wasn’t until the introduction of Bluetooth Low Energy (BLE) and its effective miniaturization that Sun was able to include it in its embedded amplifiers.

For this project, Sun’s design team turned to its sister company, High Country Tek, which creates digital electronic controls for the fluid power industry. With High Country Tek’s experience designing and building totally encapsulated controllers, the Sun team was able to complete this complex product design while maintaining complete in-house control of the process.

To keep within the same form factor, they used a Bluetooth chipset and switched to a 16-bit processor coupled with a 10-bit A/D converter to enhance resolution and software configurability.

Dither settingsAnalog input rangeRamp timeSupply voltageOperating temperature range

Off, 33 to 500 Hz, in 1-Hz increments0 to 10 V, 0 to 5 V, or 0 to 20 mA0 to 65.0 sec, 1-msec incrementsUp to 32 Vdc-4 to 176° F (-20 to 80° C)

Technical Specs

Edited by: Mike Santora • Associate Editor


www.gerdau.com/specialsteel

Gerdau NitroSteel® offers superior corrosion protection and wear resistance to hydraulic cylinder rods and pneumatic cylinder tubes. Our ferritic nitro-carburizing process is a cost-effective and environmentally-friendly alternative to chrome plating.

Gerdau NitroSteel® is transforming the future of hydraulic systems.

Gerdau_NitroSteel 4-14_FPW.indd 25 9/30/15 1:10 PM

DESIGN NOTES


To account for environmental concerns, the Bluetooth embedded amplifiers were fully encapsulated for vibration, shock and environmental protection. They were also sealed to IP69K (with Deutsch DT04-6P connector) and IP65 ratings (with DIN 43650 A connector). They were CE certified, including the 30-V/m automotive standard per Directive 2009/19/EC. The amplifiers were tested on X, Y and Z axes over a frequency of 33.3 Hz at an overall level of 6.8 g for a total of four hours each. The end result was four Bluetooth Embedded Amplifiers meeting the same requirements as eight IR embedded amplifiers—all in the same form factor.

The next step was the interface for the new technology. This new version of the company’s embedded amplifier is configured by an iOS or Android app called AmpSet Blue. The app made updates easier and eliminated the need for firmware updates. Customers would no longer have to download and install updates from a website. The latest versions would be available by opting to update the app from a mobile device. The Bluetooth embedded amplifier was designed with two indicator LEDs labeled “Power/Status” and “Active.” These LEDs allow the user to determine the status of the amplifier from a distance. When the app opens, the Bluetooth scan locates the amplifiers within range and supplies a list of available amplifiers. Once they select an amplifier, the Power/Status LED starts blinking, providing visual indication of the amplifier selected, then gives further feedback regarding the real-time operational status.

The design team also added the security options you find on most other mobile apps. Features include optional password protection to limit access of the amplifier’s configuration settings to authorized users only. Plus, the amplifier has a time-out feature that disconnects after a period of inactivity. FPW

Sun Hydraulicssunhydraulics.com/bluetooth

LEDs allow the user to determine the status of the amplifier from a distance. The Power/Status LED blinks to provide visual indication of the amplifier selected, then provides further feedback regarding the real-time operational status.

Rota Engineering Ltd

Wellington Street, Bury, Manchester, BL8 2BD, UK

UK Tel: +44 (0) 161 764 0424US Tel: 972 359 [email protected]

COFFEE TEA? or

You also have a choicefor hydraulic cylinder positioning

Inside the cylinder?

• Compact, robust design

• Maintains ASAE pin dimensions

• Excellent *vibration capablity

*Tested to Mil-STD-202G

Or outside the cylinder?

• Easily field replaceable

• No expensive SS cylinder tube needed

• Ideal for steering cylinders

• Ideal for long cylinders up to 130 ft.

....OUR HALL EFFECT TRANSDUCERS GIVE YOU THE CHOICE....

Signal ElectronicsBuilt Inside

Non ContactOperation

MiniatureMounting

AbsoluteSignal

Short Length Maintains Pin to Pin Dimensions

No ExtraEnd Cap

Costs

On SiteReplaceable

Magnet Works ThroughCarbon Steel

No Deep Drilling Costs

Maintains Piston Rod and End Cap Strength


Kocsis 10-15.indd 27 9/30/15 1:11 PM

TRAINING

Aeration versus cavitation


When designing a hydraulic system, it is important to understand the difference between cavitation and aeration—and

understand the damage they can create.

As previously discussed in our April issue, it is critical to maintain proper fluid levels in the reservoir to ensure the Net

Positive Suction Head Available (NPSHA) is greater than the Net Positive Suction Head Required (NPSHR) by the pump.

Anytime the NPSHA is equal to the NPSHR, the flow instabilities in the fluid moving to and through the pump will be

affected to the point cavitation can (and will be) generated.

Imag

e:

isto

ckp

ho

to.c

om

Aeration is a process where air is circulated with, mixed with or dissolved in the hydraulic fluid. It is created when air leaks into the system through the pump seals, pipe fittings and unions, which are all areas where air leakage is common.

Aeration accelerates degradation of the fluid and causes damage to system components through loss of lubrication, overheating and burning of seals.

Cavitation, on the other hand, is the formation of gas bubbles that create vapor cavities in a liquid. It occurs when the gas bubbles in the liquid are subjected to rapid changes of pressure. This higher pressure causes the air bubbles to implode, which generates an intense miniature water hammer (shock wave). This shock wave creates significant wear as the gas bubbles implode on or near a metal surface, causing

cyclic stresses through repeated implosions. The result of these implosions will

cause surface fatigue and damage to the metal surfaces. This type of wear is called

“inertial cavitation.”Cavitation occurs when the volume of

fluid demanded by any part of a hydraulic circuit exceeds the volume of fluid being supplied. This causes the absolute pressure in that part of the circuit to fall below the vapor pressure of the hydraulic fluid. This will result in the formation of gas bubbles.

The difference between the two is in how the air is getting into the system. Cavitation is caused by NPSHA, and can be stopped by simply slowing the fluid flowing through the system. If the problem is aeration, on the other hand, you have to locate and isolate the air leaking into the system, so resolving the problem can

be more time-consuming. The damage by both is equal, however.

The following are the most common detectable symptoms that give warning of cavitation and aeration:

Abnormal noise in hydraulic systems is often caused by aeration and/or cavitation. Air in the hydraulic fluid makes a banging or knocking noise when it experiences high and low system pressures as it circulates through the system.

High fluid temperatures above 180° F (82° C) are detrimental to system operation and will damage seals and accelerate degradation of the fluid. High temperatures can be caused by anything that reduces the system’s capacity to dissipate heat (low reservoir level) or increases its heat load (air generates heat when compressed).

In addition to damaging seals and

David Marlowe • Owner/CEO • DMAR Technical Training and DMAR Business Centers USA LLC

FPW_Training 10-15_Vs7 MG.MD.indd 28 9/30/15 3:22 PM


reducing the service life of the hydraulic fluid, high fluid temperature can cause damage to system components through boundary lubrication as a result of excessive thinning of the oil film (lower viscosity index), which in turn causes full film lubrication loss.

Slow operation, or a reduction in system performance, is often the first indication that there is something wrong. In a hydraulic system, flow controls speed and response. Therefore, a loss of speed indicates a loss of flow.

Other symptoms include erratic actuator and valve movement.

Consequences of cavitation in a hydraulic system can be serious. Cavitation causes metal erosion, thus damaging the system components and contaminating the fluid. Cavitation can also cause mechanical

failure of system components. Cavitation can occur anywhere

within the hydraulic circuit; however, hydrodynamic cavitation commonly occurs at the pump. The pump suction line between the reservoir and pump should be open and not restricted. If the pump has an inlet strainer or filter, it is important to prevent it from becoming clogged. A partially closed suction valve or restricted intake line will cause the velocity of the fluid in the intake line to increase, causing the boiling temperature of the fluid to decrease as the fluid pressure goes below vapor pressure. This will vaporize some of the fluid molecules.

The following are common causes of aeration and cavitation, so monitor your system for any of these improper designs:

1. Restricted fluid flow to pump2. Loose connection or fittings on suction line 3. Low hydraulic fluid level and/or low NPSHA4. Excessive pump speed; be sure to check specifications of the pump and motor5. Incorrect hydraulic fluid or wrong oil viscosity6. Foaming oil and/or low or old oil levels7. Clogged reservoir air breather vent 8. Too low of an oil temperature 9. Damaged or worn pump

The damage caused by unresolved cavitation to a hydraulic system can be extremely expensive and cause extensive downtime. Prevent this problem with proper system design and maintenance. And always, listen to your hydraulic system. A rattling or knocking noise is not the sound of a welcome visitor. FPW

David Marlowe • Owner/CEO • DMAR Technical Training and DMAR Business Centers USA LLC

AVENTICS Quick Ship Program. Kjell Lyngstad, Director AVENTICS North American Sales, helps ensure his customers have the high-performance pneumatics they need through our Quick Ship program. It o ers a wide selection of our most popular pneumatic products, ready to ship with fast, reliable delivery that meets or beats market lead times. And standardizing on these products saves time over your system’s lifecycle.

Get the current catalog: Visit www.aventics.us/QuickShip

THE NEXT GENERATION DELIVERY SOLUTIONS

AVENTICS CorporationLexington, [email protected]

ave3292-10Ph2-HPH-dwfpD1d.indd 1 8/31/15 2:11 PM

FPW_Training 10-15_Vs7 MG.MD.indd 29 9/30/15 3:23 PM

MADE IN THE USA

Phone: 716-743-4360 Fax: 716-743-4370

Phone: 31 70 392 1063 Fax: 31 70 392 1059

Phone: 905-688-3642 Fax: 905-688-9993

www.DMIC.com1-800-248-3645

Subsea Ball Valves

DMIC’s SUBSEA / OFFSHORE COMPONENTS

THE CHOICE OF PREMIER POWER UNIT

MANUFACTURERS

“BVQW”• 316 Stainless Steel• Duplex & other

materials available• ROV Interface• Your choice of

Connection & media compatability

“FDS” / “RDS”Large supplier

for sub sea applications

Gauges for subsea use

Call For:• Valves, Subsea & Offshore• Flow control needle valves• Hydraulic Actuation

“CVH” Check Valves

• Custom manifolds• Firesafe Valves• API Certification• NACE MR-0175

DMIC 10-15.indd 30 10/1/15 12:22 PM

Pressure control: Upstream and downstream“It’s a PRV … a pressure control valve … a pressure regulator.” That’s what I sometimes hear when discussing symbols

on a hydraulic schematic, or even when examining components. The acronym PRV really drives me crazy because it

could stand for pressure relief valve or pressure reducing valve. These two types of valves aren’t the same at all. Let’s

have a quick look at the differences. You can already see some of the differences in the symbols alone.

A pressure relief valve is often connected to the main pump outlet line. When used in this location, it is there to put a limit on the maximum system pressure. It does not make the system pressure go away. Nor does it unload the pump. That is yet a different type of valve. The relief valve simply supervises the pressure value in the main hydraulic supply line as it flows from the pump and reacts to keep it under a certain value as specified by the system designer.

When the system pressure climbs close to the level of the pressure relief valve setting, the valve will begin to open. “Cracking” is a term applied often to relief valves. It de-scribes the pressure value needed to cause the smallest de-tectable opening where the valve is now passing some fluid back to tank. As the pressure value climbs higher, perhaps due to an overloaded lift cylinder, the relief valve will open farther as needed. If a lift cylinder is completely overloaded, the relief valve will be passing all of the pump’s flow to tank. The system pressure will be at its maximum. The relief valve itself is a pressure load on the system. It has at least one spring inside that is trying hard to close the valve. A pressure reducing valve on the other hand is not often found near the pump. In most cases, it will be located down-stream in the system, close to a component where pressure needs to be stepped down from a higher main system pres-sure. It may look like a relief valve, but it does not function the same.

PILOT OPERATED PRESSURE REDUCING VALVE

PRESSURE RELIEF VALVE


Carl Dyke • Hydraulics Consultant at CD Industrial Group Inc.FUNDAMENTALS

Fundamentals_FPW_10-15_Vs3 MG.MD.indd 31 9/30/15 4:00 PM

Faster_FPW_10-15.indd 32 9/30/15 1:13 PM

FUNDAMENTALS


Discuss This

If one cylinder in a metal stamping machine is there to punch and break through the stamped material, another cylinder may be used to clamp that material in place. Both cylinders may be fed by the same pump. The clamping cylinder, however, may only need a fraction of the pressure that the stamping cylinder needs. Too much clamping pressure and the material could be damaged. Or perhaps the clamping cylinders are of a light-duty design compared to the stamping cylinder. This design is common enough. The pressure reducing valve takes a higher pressure on its inlet and then creates a lower maximum pressure for the remaining cir-cuitry on its outlet. On the symbol, you see the dashed pilot line sensing and triggering on the outlet side. Another interesting fact is that most of the hydraulic circuitry that follows after a pres-sure reducing valve is low-flow or zero-flow in design. At the very least, the sub-circuit is low or zero-flow at the moments when the pressure reducing valve is actually needed, such as when the clamping cylinder is busy holding material in place. FPW

CD Industrial Group Inc. cdiginc.com


Fundamentals_FPW_10-15_Vs3 MG.MD.indd 33 9/30/15 4:04 PM

MAINTENANCE

Wet hydraulic oil is similar to damp air in that the water molecules are partially dissolved in the oil, like humidity in the air. For the most part, “damp” hydraulic oil is no real concern. Most of the time, the saturation level of water is low enough to cause little concern. But in some cases, excessive water contamination does occur, where the “humidity” of the oil reaches the saturation point. When water saturation reaches 100%, droplets can “rain” out of the oil, causing pools, puddles or other areas of localized water. Water in your oil can cause a few problems to your hydraulic system. The most common problem with humid oil is that the increased water content accelerates the oxidation rate of the fluid, lowering its life expectancy. Not only does water increase the oxidation rate of the oil itself, but you may have noticed the majority of hydraulic pumps, valves and actuators are made from iron and steel, both of which oxidize quickly in the presence of water. Not only does this cause corrosion of the internal hydraulic components, but also the corrosion itself is a form of contamination when it is released into the system.

Should water saturation levels become so high that you experience free water, you’re in for a world of hurt. Water makes a terrible lubricator, and everywhere there is no oil, you are risking rapid metal-to-metal wear. And where water loiters, the corrosion rate is further exacerbated. In the worst of cases, pooled water can freeze, and subsequently damage components. Water can be the most difficult contamination to control. You can purchase inexpensive water-absorbing filter elements, but they’re typically terrible filters that happen to suck up only free water. They can’t do

Edited by: Paul J. Heney • Editorial Director


When there’s water in your hydraulic fluid

Vacuum dehydrators, like the VUD series from Hy-Pro Filtration, remove free, emulsified and dissolved water and gas from hydraulic systems.

FPW Maintenance 10-15_Vs5 MG.MD.indd 34 9/30/15 4:11 PM

Only pay for what you really need!

HAWE Hydraulik’s directional valves are designed and manufactured with modularity in mind. With minimal installation, our vast product range couples space-saving directional valve banks to proportional controlled functions or hydraulic drive motors. There are li-terally billions of combinations to choose from, for you this means one thing: we always have the right solution for the right price!

www.hawe.com [email protected]

Smart Efficient Technology Made By HAWE Hydraulik

Integrated functionsProportional directional spool valve PSL

A demand-actuated combinationValve bank with PSL and EDL

Compact design with direct actuationProportional directional spool valve EDL

Reduced installation costsProportional directional spoolvalve PSL-CAN

solutions in every combination.

HAWE 10-15.indd 35 9/30/15 1:14 PM


MAINTENANCE

in; it’s a machine that subjects oil to a vacuum, then heats it up a bit. Less heat is required to cause the saturated oil to boil away its water, and a side bonus is that the vacuum sucks away all the humid air. The problem with vacuum dehydrators is they’re expensive, some in the realm of $20,000. Most often, your best bet is to rent them, which you can do at your local fluid power distributor. They’re the most effective way of removing saturated water—although your best bet is still to avoid water altogether. FPW

anything to remove humidity. So if you need water absorbing elements, you’re already in trouble because you’ve let it go too far. That being said, throwing a few $50 filters at the problem could be cheaper than replacing thousands of dollars worth of hydraulic oil, so it could be worth a shot. We know water will boil at 100° C (about 212° F). If you live at a higher altitude, like in Denver, your boil point is almost 10° cooler. This occurs because air pressure is lower, and it takes less heat energy for the molecules to break their bond, evaporating the water sooner than at sea level. Lower ambient pressure means lower boiling point. So what if we could take advantage of this effect and lower the boiling point of water that is saturated within oil? This is where a vacuum dehydrator comes


Discuss This

You Needed a Better Seal.

You Got It!Flaretite Seals for Flared Fittings

Available in Kits.

Make all your fl ared fi ttings:fl ared fi ttings:fl ared fi ttings:

“Leak-Free”

Make all your Make all your Make all your fl ared fi ttings:fl ared fi ttings:

w w w. f l a r e t i t e . c o m

Visit our Website for

FREE samples and

literature

Phone: 810-750-4140Flaretite, Inc.

w w w. f l a r e t i t e . c o m

1/4 _9_08flaretite.indd 1 1/15/09 9:48:20 AM

Air that moves the world.

Reliability and high performance

MODULAR FRL UNITSCOMPACT, LIGHTWEIGHT

RAPID ASSEMBLY

PATENTED BOWL LOCKING MECHANISM

INTEGRATED SOFT-START, SHUT-OFF AND TAMPER-PROOF DESIGN

www.camozzi-usa.comA Camozzi Group Company

Camozzi Solutions Air-Treatment FRLs

h&p ad for camozzi - frl - quarter page ad.indd 1 9/20/12 5:32 PM

FPW Maintenance 10-15_Vs5 MG.MD.indd 36 9/30/15 4:13 PM

Visit us at www.lillbackausa.com1629 Prime Court, Suite 400 , Orlando, FL 32809Phone (847) 301-1300

FINN-POWER Innovation, Precision, Durability...

SIDE-FEED MACHINE LINE

GENERAL PRODUCTION LINE

FINN-POWER – the industry’s choice for crimpers, skivers, hose cutters, and accessories.

SERVICE LINE

SERIAL PRODUCTION LINE

Crimping since 1973

Lillbacka 8-15 FPW.indd 37 9/30/15 1:15 PM


Mary C. Gannon • Senior EditorSAFETY

During the course of everyday operations, hydraulic hose assemblies are exposed to moisture, dirt, corrosion, high temperatures and physical impact. Continuous movement and rubbing against other hoses or equipment—often caused by machine vibrations—can erode hose covers, while non-compatible fluids can eat away at them as well. And once this outer layer of protection is gone, hose reinforcement is open to even more damage and rust. Thus, it is essential that necessary precautions be taken to protect them.

Hose protection products, such as sleeves and wraps, can be simple to use. They protect against cuts, abrasions and ultraviolet rays and resist crushing. And not only do these simple devices save hose, they help to reduce the risk of industrial injuries to employees or damage to integral hose assemblies by preventing hose ruptures in the field.

Hose protection sleevesHose sleeves are the last line of

defense in protecting people, environment and machinery against hose bursts or

leakage. They also protect hose against abrasion.

Quick assemble hose or cable protective sleeves are suitable for use

in the field or for applications where the

winding of spiral-formed products is difficult. Resistant to heat, ozone and abrasion, these sleeves contain hoses to protect operators from hose failures in close quarters. A special Python hook-and-loop design closure promotes quick and easy bundling of hose groupings; it is easy to assemble or remove.

Essentra’s line of mining safety-approved sleeves protects against any possible hydraulic hose oil leakage, ruptures or spills. Its polyamide material means this sleeve is dense, yet not bulky,

and still provides a high degree of burst resistance and abrasion protection. Effective in reducing the concentrated stream of pinhole leaks, which can be a huge but less noticeable danger, this sleeve provides excellent leakage containment. Tested and approved by M.S.H.A. (approval #M.S.H.A. IC-234/0), this mining safety-approved sleeve meets FED-STD-191 test method 5309 for abrasion resistance and ASTM D6770 for abrasion resistance of textile webbing.

Hose protection ensuressafe hydraulic designs

Here, textile sleeves protect hose from abrasion in extreme environments. Below is a sampling of hose protection products, including Essentra’s fire protection sleeve, spiral sleeve and mining safety-approved sleeves.

FPW_Safety 10-15_Vs8 MG.MD.indd 38 9/30/15 4:17 PM

A full line of fire protection sleeves has excellent elasticity for protecting or bundling hoses, tubes and cables in a variety of hostile environments. The insulation properties of the outer silicone rubber and inner knitted glass fiber provide close quartered personnel with effective protection against burns from hot hoses and reduced heat energy loss. This sleeve withstands intense radiant heat and flame of continuous exposure up to 500° F (260° C), 15 to 20 min up to 2,000° F (1090° C), and 5 to 30 sec up to 3,000° F (1,650° C). Furthermore, it can withstand repeated exposures to molten steel, molten aluminum and molten glass up to 3,000° F (1,650° C).

Additionally, hose sleeving allows for easy bundling of hose that flexes in the same direction. For safety’s sake, users should only bundle hoses of the same designs and pressure rating, so only high-pressure hose in one sleeve, while low-pressure designs should be bundled in another. Also, take care to not bundle hoses too tightly and to give a proper amount of slack so fittings and hoses will not be stretched beyond their limits. (An added benefit of hose sleeves is aesthetics, as they provide a more streamlined look to hydraulic hose on machinery.)

Hose protection wrapsHose covers are offered in a variety of styles, such as wire or flat armor spring, nylon sleeves or plastic coil sleeving. They protect against abrasion and crushing, thus extending hose life.

Essentra’s Spiralguard is suitable for hydraulic, pneumatic and industrial hose assemblies. It is radial cut from extruded tube, enabling high natural recovery

memory and flexibility to maximize hose coverage.

Manufactured in a high-density polyethylene material,

Spiralguard has high abrasion

Hose and cable sleeves (right) allow for easy bundling of similarly-rated high- or low-pressure hoses that bend and flex in the same direction. Below, left, are Essentra’s Spiral-Wrap hose protection products.

resistance, anti-crushing performance and resistance to UV deterioration. This material is also a thinner, lightweight product, but still maintains industrial strength and quality. Featuring a heavy–duty, double-beveled edge design to prevent snagging and cutting during installation, it is easy and safe to install before or after the hose assembly is mounted. A medium-duty product is available for use on applications where abrasion is not frequent, but protection is still needed.

For mining and quarrying applications, users might consider a mine-safety-approved, flame-retardant and antistatic series of Spiralguard that protects underground hose assemblies. Tested and approved by Mine Safety Laboratory, Department of Mineral Resources NSW to AS2660 FRAS Compliance (1991 International Standard: ISO6805) and in accordance with the former British Coal specification 182:1986, this line satisfies the requirements of the non-metallics scheme for use underground.

A lightweight and flexible Cellulose Acetate option is still crush resistant, but its lightweight profile will cover much more hose surface during a flexing or bending process than any other wrap. The inner core ensures flexibility, while the external profile ensures resistance to abrasion, crushing and electrical conductivity.

If weight and size are an issue, but some hose still needs protection, you could consider point-of-contact protectors. These are a more economical solution when there are few single sources of hose wear. Made out of PVC, these are durable and have a high wear factor. Point-of-contact protectors are easy to assemble and remove as they are simply assembled with a cable tie. They are used mostly on hydraulic hoses, fuel and oil lines, brake systems, wiring harnesses and battery cables, and can be used in conjunction with hose protection sleeves. FPW

Essentra Componentsessentracomponents.com

Hose wrap sleeves are common on hydraulic lines where abrasion resistance from bending is a given.


Discuss This


FPW_Safety 10-15_Vs8 MG.MD.indd 39 9/30/15 4:17 PM

Modern mobile hydraulics:Not your grandfather’s loader


Carl DykeHydraulics ConsultantCD Industrial Group Inc.

FPW_Mobile Construction_10-15_Vs6alt MG.MD.indd 40 9/30/15 3:45 PM

Modern mobile hydraulics:

M O B I L E H Y D R A U L I C S


Mobile hydraulic component and sys-tem designers have quite a challenge. Market com-petition compels them

to keep up with a lot of change and innovation over time. If we think about the advances in mobile hydraulic systems design, what are we really talking about? Is it that the machine has become more complex with highly sensitive operator controls? Are these systems sophis-ticated because of the intentional engineering to make them more efficient, accurate and reliable? Is it also that the reliability of these systems makes a significant contribution to human safety? The answer to all of these questions is yes. Let’s have a look at a few of these design parameters and the operating, maintenance and troubleshooting issues that can arise.

Safety systems require reliabilityIt is true that hydraulic systems in use on mobile and construction machines feature some of the most sophisticated circuit designs. In many cases, these machines feature braking and steering systems that must offer the high-est levels of priority function and reliability. Hydraulic accumulators are often used in the

Today’s engineer needs to

understand the complexity

of modern systems, from

fuel consumption to

load sensing.


hydraulic system must be designed to be efficient with the fuel source. Road graders are designed to save fuel. It is not necessary to heat fluid by unloading most of the hydraulic system during long travel cycles when hydraulic motion is not needed. Yet, the hydraulics must be ready to respond at the instant when the operator moves a valve lever. One way to accomplish this objective is with a load-sensing system.

Load-sensing systems are now found on a large percentage of mobile machinery, due to the efficiencies that they offer. These sys-tems use pressure feedback—directly from the work-loaded cylinders and motors—to constantly modify and control the pump’s parameters. The pump involved is generally of the

larger machines as the main flow buffer for steering and brakes. Mobile crane systems and aerial work platforms are additional examples where both high reliability and safety are paramount. A failure over the control of the boom or the stabilizing outriggers has serious implications. While electronic sensors are often involved, basic hydraulic components such as pilot-operated check valves and counterbalance valves have to function flawlessly. Manufacturers of these valves work hard to produce a spool that will not seize and a poppet design that is least likely to trap a particle on the seat during valve closure. Perfect performance for all conditions and for badly contaminated fluid is impossible, so the use of a built-in, wire-mesh filter screen is typical for the pilot ports at the least.

Production and efficiencyA wheel loader that might have one hydraulic pump dedicated to the steering function may also have a control valve to share that pump’s flow with other func-tions—such as the boom lift or bucket tilt—to achieve maximum cylinder speed when steering is not occurring. Excavators need to operate non-stop, for days and weeks while offering ex-tremely accurate and consistently repeat-able motions. The only reason to start the engine in an excavator is to power the hydraulic pumps. Therefore, the entire


“Excavators need to operate non-stop, for days and weeks while offering extremely accurate and consistently repeatable motions.”

variable displacement piston type, and the spool valves for directional and flow control appear to be typical. However, a special sig-nal hose from the valve bank to the pump controller offers a clue to the presence of the load-sensing design. A network of small passages in the valve bank (and the use of tiny shuttle valves) sends the pressure from the valve section with the highest loaded, active motor or cylinder, all the way to the pump’s controller (compensator) through that special load sense signal line. The maximum system pressure is constantly modified using the variable displacement controller on the pump. Using a variable displacement pump together with constantly adjusted maxi-mum system pressure results in less wasted fuel at the prime mover. The maximum hydraulic system pressure is constantly adjusted to be only slightly higher than what is needed at any operational moment. When directional valves are returned to the center position, blocking off pump flow to the system, the load sense line is bled down, which sets the system pressure to a low standby value of only a few hun-dred psi. Pump flow is also automatically adjusted to near zero. In this standby state, the pump demands minimal power from the prime mover.

Load sensing control for accurate flowThe load-sensing system also offers greater flow accuracy. If the hydraulic system is operating motors that turn metering and

Figure 1. A load sensing hydraulic system features a feedback signal line from the loaded cylinder to the controller on the pump.



ACCESSORIESFITTINGSASSEMBLY

BENDINGCRIMPING CUTTING DEBURRINGFILTERING FLARINGWASHINGMARKING MULTIFUNCTIONALUNITS

PRE-ASSEMBLYSKIVING TESTING

ACCESSORIESFITTINGSASSEMBLY

BENDINGCRIMPING CUTTING DEBURRINGFILTERING FLARINGWASHINGMARKING MULTIFUNCTIONALUNITS

PRE-ASSEMBLYSKIVING TESTING

O+P USA 10-15 FPW.indd 43 9/30/15 1:17 PM


mixing augers on a mobile concrete batch truck, then this flow accuracy has a direct impact on product quality. An electrical generator needs to maintain steady speed regardless of the electrical loads that it is powering. Any serious fluctuation in rotor speed could cause problems for the electrical appliances supplied by the generator. If the generator is turned by a hydraulic motor, the hydrau-lic system must have a way to correct the speed of the motor where there would otherwise be fluctuation with changes in electrical power demand. In both of these examples, as the pressure at the hydraulic motor changes, the pump responds to the signal on the load sense signal line, changing its displace-ment slightly to maintain a steady pressure drop across the flow controlling valve, thereby providing a steady flow rate to the actuator. This is a pressure-compensated, flow-controlling technique that comes built-

in with most every load-sensing system. Component and system designers have the challenge of making sure that this closed-loop control scheme can be properly tuned. Features such as load sensing add complexity to the system. If one hears a machine owner express a wish for the simpler hydraulics from a previous decade, they are also wishing for higher fuel con-sumption, and machines that were not as responsive.

Maintenance and common problemsHydraulic faults in mobile machinery have much in common with faults in any other hydraulic system. Overheating and fluid contamination are common causes for

intermittent faults as well as for component and system failures. Conducting proper inspections and carrying out basic preventative main-tenance at optimum service intervals significantly helps to reduce the frequency of failures. The setting of service intervals may need to be examined and adjusted on a seasonal basis or as work conditions change in environments where harsh usage occurs. The gathering of scheduled, careful measurements of fluid properties, system pressures, temperatures, cycle times and flow rates can help predict a problem or failure at an early stage when corrective action is still a relatively inexpensive option.


Figure 2. The pump supplies only the needed flow, with pressure at the pump outlet controlled so that it’s only slightly higher than what is needed by the loaded cylinder. Significant energy savings can be achieved.

Figure 3. With load sense systems, hydraulic motor speeds are kept steady, even as engine speed changes or as hydraulic motor torque varies.


866-821-RYCO (7926)

ISOBARIC HOSE

CONNECTING PARTNERSHIPS

MATCH YOUR HOSES TO YOUR SYSTEM PRESSURESTREAMLINE YOUR PRODUCTIONS

STREAMLINE YOUR COSTS

USE ISOBARICS

KEEP YOUR EQUIPMENT PERFORMING AT ITS BEST

Today’s equipment calls for the highest quality, robust and extremely flexible hoses. RYCO’s solution – our Isobaric hose range.

RYCO’s Isobaric hoses offer constant pressure performance throughout each range. This provides easy product selection and simplifies system design;a hose to suit all of your requirements.

The bright laylines help with product identification and selection.

RHUS-MKT 2015 Fluid Power ISOBARIC Full Page Ad 9x10.875 - 2015-07-01 v1-0.indd 1 7/1/2015 9:25:01 AMRYCO 10-15.indd 45 9/30/15 1:18 PM


This practice is known as predictive mainte-nance. A service shop’s disciplined use of pre-ventative and predictive maintenance tech-niques increases the mean time between failures (MTBF) and keeps the machinery at maximum levels of production availability. Hydraulic system problems on these sophisticated mobile machines can also be caused by previous maintenance work. This is often the case for reports of erratic cylinder or motor motions on a load-sense hydraulic system. A pump controller adjust-ment—if done incorrectly, perhaps without proper knowledge of how load-sense systems work—can be the start of a whole new problem, and possibly a safety issue as well. A replacement component installa-tion, such as a changed-out pump, can be

Figure 4. Predictive

maintenance work is critical.

the source of a new problem if the work is not done correctly. In the case of a drain hose accidentally connected to a control-ler option port on a piston pump, the now non-functioning pump controller can rack up a hefty repair bill due to extreme system overheating. One of the most common problems reported from users of one-off, custom-built, load-sense hydraulic systems is “hunting” or “surging.” That is, the motors

and cylinders under certain circumstances will be speeding up and slowing down, all while the proportional, directional valve is apparently being held at one constant flow position. This is not unusual if the machine design has not been tested for all possible operational conditions. Adjustments to the system may have to be made to accommo-date a unique accessory or implement to be connected to the machine’s auxiliary ports. In some cases, the operator of a mass-



Fabco-Air solves problems. Let us help! www.FABCO-AIR.com

Providing best-in-class products, solutions, and support in the pneumatics industry

1958Putting mechanical elements in their place

since

Air Prep

Slides

Cylinders

Grippers

Multi-Power®

Sensors

Valves

RotaryActuators

Crimpers

Rod Locks

Moving something? Linear Slides give you precise, non-rotating motion!

Fabco-Air 10-15.indd 47 9/30/15 1:20 PM



produced machine may find a way to put the hydraulic system through its paces in a way that was not the intent of the manufacturer—and in doing so, causes faults and wear that were not at all expected. It is not always pos-sible for the original equipment manufacturer to lock out this type of harsh usage; thus, a series of faults and problems to troubleshoot will arise.

Even more complexity: Learning is not optionalWe have glimpsed into the precise nature of valve design and the use of load feedback to dynamically adjust a pump controller, but we haven’t covered all of the technology that makes for a sophisticated, modern hydraulic system in a mobile machine. As was men-tioned earlier, electronics certainly play a role. Quite often, an engine speed sensor informs a control module about excessive engine load, with that same module then sending an elec-trical signal to the displacement controller on the largest pump. The pump is automatically downsized while the engine is under excessive load to prevent an engine stall. This is only a basic explanation of a horse-power limiting control, as was the explanation for the load-sense control scheme. However, they do serve to illustrate that there are care-fully specified design parameters at work on modern mobile machines. These parameters, while appearing a bit narrow at times from an operator’s perspective, are meant to improve fuel economy—or they are there to make the machine motions smoother or more accurate. Without a doubt, the overlapping systems compel a machine maintainer or troubleshoot-er to deepen their understanding of the overall engineering goals. FPW

CD Industrial Group Inc. cdiginc.com


Discuss This

Hose, tube and pipe cleaning and sealing solutions.

For heavy duty markets including

Construction, Mining, Marine,

Off-Shore, Hose & Tube Assembly

Hose, Tube, Pipe Cleaning & Sealing Solutions

Say goodbye to caps & plugs. Now there’s a better solution!

Clean Seal System

Durable heat-shrink seal • Quick, clean, easy process • Universal fitShort capsules available to conform to 90° fittings

LEARN MORE at www.ultracleantech.com

Advancing Contamination Control.Hand-held heat guns and diffusers available.

Clean Easy. Seal Easy.

1274 Highway 77, Bridgeton, NJ 08302 U.S.A800-791-9111 • 856-451-2176 •Int’l +1 856-391-3262Email: [email protected]

Visit us atBooth #1361COP2

21-24 / OCT / 2015SANTIAGO, CHILE


Veljan Hydrair 10-15.indd 49 9/30/15 1:56 PM


Although hydraulic pumps are more often talked about in system design, choosing the motor must come before pump selection.

Bent-axis piston motors feature pistons placed at an angle to the drive shaft, rotating the shaft as fluid enters the motor.

FPW_Hydraulic Motors 10-15_Vs4 MG.MD.indd 50 9/30/15 4:22 PM

H Y D R A U L I C M O T O R S

(continued on 58)

right motor

The ideal in hydraulic system design is to match overall efficiencies to the

application performance expectation. This requires the designer to first match the

motor, then the pump to a specific system performance expectation. Whether the

requirement is to do something within a specific time frame, or in handling a given

amount of load, the design of the entire system will change depending on the mo-

tor selected.


Select the

for your

A hydraulic motor is a hydraulic actuator that, when properly connected into a hydraulic system, will produce a rotary actuation. This can be unidirec-tional or bidirectional depending on the system design. Motors are similar in design to pumps only where a pump

takes a rotary actuation to move hydraulic fluid out of the unit, whereas a motor will take flow into itself and put out a rotary actuation. The motor selection comes first in the process because application design best practices require that you start with the

hydraulic applicationsJustin Wheeler • CFPHSC-Series/Bent Axis Project ManagerHydraulic Pump Div. Parker Hannifin


52 FLUID POWER WORLD 10• 2015 www.fluidpowerworld.com

requirement, then work back to the prime mover—the pump that will put the fluid power into the mo-tor selected to deliver the performance goal. Each motor type—gear, vane, in-line piston, bent-axis piston and radial piston—has a specific performance profile. So, knowing the application performance requirement and which motor type best meets the objective is the first step. Then it’s necessary to evaluate the cost of your motor options along with the degree of complexity you want for the overall system. In the end, it all goes back to the application’s performance expectations. Some have severe duty cycles, while others do not. If, for example, you consider running a low-efficiency, lighter-duty motor into a higher-duty cycle application, the life of the motor will be less than the life of a higher-duty cycle motor that is designed to operate in those types of environments. It is important to understand what operating pressures and flows are required for the motor selected to achieve the application perfor-mance expectations. Each motor type has its own set of applications where they are a better choice than others. For ex-ample, if a small gear motor designed to operate at a max of 3,000 psi and 1,000 rpm is put into an ap-plication that requires it to run consistently at 3,000 psi and 1,000 rpm, the motor will be running in a “corner” overstressed condition and have a reduced life—even though it is technically within its ratings.


The better motor choice would be a motor with higher ratings that will live longer in the application. Granted, there is a greater cost in going with a higher rated motor. The final decision always will depend on what is required in terms of application perfor-mance and motor life versus where you want to be with cost.

How motors are ratedMotors are rated by displacement, with displacement defined as the volume of fluid that it takes to rotate the shaft of the motor once. The common rating units are cubic inches per revolution (CIR), or cubic centimeters per revolution (CCR).

Motors are also rated by torque—the amount of twisting force the motor can deliver. The common measurements of torque are inch-pounds (in.-lb) and Newton-meters (Nm). The torque of a mo-tor is a function of motor displacement and system pressure. Starting torque is the torque the motor can generate to turn a load when starting from a stop. In general, starting toque is the lowest torque rating of a hydraulic mo-tor due to inefficiencies.

Stall torque is the maximum torque the motor will generate before it stops rotating. Sometimes this is also referred to as running torque. The rotational speed of the motor shaft is measured in units of rotations per minute (rpm). Motor speed is a function of hydrau-lic input flow and motor displacement. Pressure is generated by resistance to hydraulic flow. The more resistance, the higher the pressure. Common measurement units are pounds per square inch (psi), kilo Pascal’s (kPa) or bar.

Common motor classes and typesGenerally, hydraulic motors are placed into one of two classifications: high speed, low torque (HSLT) or low speed, high torque (LSHT).

Gear motors come in two varieties—the gerotor/geroller or orbital and external spur gear designs. Orbital styles are classified as LSHT motors; however, some do exist with the HSLT classification. They consist of a matched gear set enclosed in a housing. When hydraulic fluid is moved into the motor, it causes the gears to rotate. One of the gears is connected to the motor output shaft, which produces the motor's rotary motion. Key features include:

Vane motors and their operation principal. Parker's vane motors feature a balanced design.

FPW_Hydraulic Motors 10-15_Vs4 MG.MD.indd 52 10/1/15 11:57 AM


Piston motors offer extremely high mechanical efficiencies, up to 97 to 98%.

• low weight and size• medium pressures• low cost• wide range of speeds• wide temperature range• simple design• wide viscosity range

Applications include mobile hydraulics, agri-cultural machinery to drive conveyor belts, dispersion plates, screw conveyors or fans. Their biggest drawback is that they have a higher noise level.

Vane motors are typically classified as HSLT units. However, larger displacements will fall into the LSHT range. Hydraulic fluid enters the motor and is applied to a rectangular vane, which slides into and out of the center rotor. This center rotor is connected to the main output shaft. The fluid being applied to

the vane causes the output shaft to rotate. Parker’s vane motors feature a bal-anced design where the inlet and outlet ports of the motor are applied to sections of the vane cartridge that are 180° apart from each other to ensure that the hydrau-lic forces are always in balance inside the motor. Key features include:• low noise level• low flow pulsation• medium pressure • high torque at low speeds• simple design• easy versatility• vertical installation friendly

They are used in both industrial applica-tions, such as screw-drive and injection molding, and mobile applications such as agricultural machinery.

Visit us at: www.PrinceHYD.com

Cylinder Manufacturing Capabilities:

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

• Strokes up to 50’

• Operating pressures up to 6,000 PSI

Features:

• Integrated linear position sensors

• Special materials for high strength / weight savings

• Integrated valves for load-holding & counterbalance

• Internal Cushioning options for deceleration of motion

• Multi-stage telescopic

Custom Cylinder Manufacturing Capabilities.....

Prince Mfg 6-15_5.indd 1 7/30/15 4:12 PM



the pistons, which are contained in a cylinder barrel. The pistons are at an angle to the drive shaft, which means that the piston will rotate the shaft as fluid enters the motor. They can be both fixed and variable displacement. In a variable-displacement bent-axis motor, the cylinder barrel is rotated between maximum and minimum displacements. The command signals to change the displacement can be electrical, hydraulic or a combination of both. They are best known for high perfor-mance, high pressures, high speeds and volumetric mechanical efficiencies in the 97 to 98% range. The also offer quick reaction and precise control. These motors are suit-able for applications that require a signifi-

Piston motors come in a variety of designs with both LSHT and HSLT classifications.

In-line piston motors are classified as HSLT. Hydrau-lic fluid enters the motor and is applied to a series of pistons inside a cylinder barrel. The pistons are pressed against a swash plate, which is at an angle. The pistons push against this angle, which causes the rotation of the swash plate that is mechanically connected to the output shaft of the motor. The swash plate can be a fixed or variable angle. Variable angle motors can have their displacements adjusted between a maximum and minimum setting. The command signals to change the displacement can be electrical, hydraulic or a combination of both.

Bent-axis piston motors are classified as HSLT. They are similar to inline motors except that the piston barrel is at an angle in relation to the swash plate. Hydraulic fluid enters the motor and is applied to

cant amount of power. They are used to drive mobile and construction equipment, winches, ship-cranes and all kinds of heavy-duty hydraulic equipment for offshore and onshore operations.

Key features of in-line and bent-axis piston motors: • higher speeds • higher efficiencies• can be fixed or variable displacement • multiple controls to adjust displacement • wide range of speeds• high power density

Radial piston motors, such as Parker's Calzoni motors, feature pistons arranged perpendicular to the output shaft.


FPW_Hydraulic Motors 10-15_Vs4 MG.MD.indd 54 10/1/15 11:58 AM

10 • 2015 FLUID POWER WORLD 5 5

Radial piston motors are LSHT classified. These motors are designed with pistons arranged perpendicular to the output shaft. Typically, the pistons will ride against a cam, which is mechanically connected to the output shaft. The pistons will force the cam to rotate as hydraulic fluid enters the motor. These motors are capable of producing high torques at low speeds, down to half a revolution per minute. Applications include caterpillar drives of dragline excavators, cranes, winches and ground drilling equipment. In general, these motors are fixed displacement. However, some versions will allow for variable displacement. They accomplish this by limiting the number of pistons that can receive hydraulic fluid. Other versions change the internal geometry of the cam the pistons are acting against.

Key features of radial piston motors: • higher output torques• lower output speed• smoother output speed at low speeds (no “cogging”)• simplification of system design by reducing or eliminating gearboxes or other mechanical ratios that would need to be used in the system

Motor selection considerationsAll of the following questions are important to answer when selecting a hydraulic motor:• What are the performance needs of the application?• What is the load and amount of break away and running torque needed?• What is the shaft speed and horsepower?• What is the operating pressure and flow?• Is displacement fixed or variable?• What is the operating temperature?• Is there any leakage potential?• What noise level can the application handle?• How reliable is the motor design?• What type of controls will be used—mechanical or electronic?• Is ease of installation critical?• Is ease of maintenance necessary?• What is the bearing type and expected life?• What is the expected motor life?• Is it open or closed loop?• What kind of contamination potential is there?• What certifications and approvals are needed?

Proper hydraulic motor selection starts with the expected performance required by the application, then works back to the prime mover—the pump. Then it is necessary to evaluate the cost of your motor options along with the degree of complexity you want for the overall system. FPW

Parker Hannifinparker.com

Quick

Supplied air is fed through the system’s pressure protection valve and a simple “T” from the

air seat to the air valve.

& Simple I n s t a l l a t i o n

Fully Installed

Installing the valve onto the seat bracket

Operating the P.T.O. and Dump

DAV 1229PTO and Hoist

feathering

air valve

Tel: 716.853.7996 • Fax: 716.853.8003571 Howard Street, Buffalo, NY 14206

www.delhydraulics.com

DEL Hydraulics 7-15_Vs3.indd 1 6/17/15 5:04 PMFPW_Hydraulic Motors 10-15_Vs4 MG.MD.indd 55 10/1/15 11:58 AM


I N D U S T R I A L H Y D R A U L I C S

industrial

Josh Cosford • Contributing Editor

Reliability in

The industrial hydraulic environment is a piece of cake compared to what the mobile hydraulic industry is put through. Industrial hydraulics are typically cleaner, more temperate and better outfitted with luxuries, such as coolant systems and advanced contamination removal equipment. Still, if the industrial hydraulic envi-ronment is so peachy, why do so many machine failures occur, especially as related to the reliabil-ity of their hydraulic systems?

Hydraulic systems—yes, even on mobile ma-chines with terrible ambient conditions—can be extremely reliable as long as they’re designed and maintained with reliability in mind. It just so

The key to a reliable hydraulic

system lies in keeping it cool, clean

and dry.

hydraulics

FPW_Industrial Hydraulics_10-15_Vs5 MG.MD.indd 56 9/30/15 5:03 PM


Desiccant breathers help control moisture through adsorption and prevent particulate from entering reservoirs during air exchange. Also, water-absorbing filter elements remove free water from hydraulic oils down to fluid saturation point. Photo courtesy of Hy-Pro Filtration

FPW_Industrial Hydraulics_10-15_Vs5 MG.MD.indd 57 10/1/15 11:40 AM

The industrial machine environment provides the environment and resources to ensure hydraulic machines are extremely reliable, but even the most stable machine environment cannot compensate for a poor machine design. Intelligent and well-engineered hydraulic design should be a top consideration for any machine, regardless of environment. The three primary factors to be designed into a hydraulic machine are the control of the three types of contamination: heat contamination, particle contamination and water contamination.

Keep it cool Controlling the temperature of the industrial hydraulic machine is generally quite easy, and when considered from a design phase, over-

INDUSTRIAL HYDRAULICS

happens that industrial environments are often conducive to ensuring machines have everything they need to run reliably. The stationary nature of the industrial environment allows for permanently installed equipment that helps keep hy-draulic systems cool, clean and dry. Regardless, industrial hydraulic systems aren’t immune to issues related to reliability, and it’s quite unfortunate because that doesn’t have to be the case. Industrial hydraulics still overheat, still have contamination issues and they still have moisture related failures.


Vacuum dehydrators, such as the VS1 from Hy-Pro Filtration, are portable machines that heat oil and apply a vacuum to remove dissolved, emulsified and free water in oil.

Brazed plate heat exchangers (above) help remove a great deal of heat with low coolant flow. Water-cooled shell and tube exchangers (left) are also popular for their efficient cooling capabilities. Photos

courtesy of Thermal Transfer Products, an API

Heat Transfer Co.

heated oil should never be a factor reduc-ing reliability. The stable ambient tempera-ture of the plant environment ensures oil is typically within its ideal range of operating viscosity. When an industrial hydraulic machine overheats, the cause is most often generated internally from either poor design or a failed heat-generating compo-nent, such as a pump or relief valve. When hydraulic oil overheats, it loses its lubricity—in addition to the damage it suffers from oxidation. As hydraulic oil rises in temperature, its viscosity reduces


Fluidyne 10-15.indd 59 9/30/15 1:57 PM



inversely proportionate to that increase in temperature. When viscosity is critically low, the oil can no longer maintain a boundary layer of lubrication, and metal-to-metal con-tact and wear is imminent. Next to particle contamination, heat is the second most common cause of hydraulic component failure. A hydraulic circuit designed with ef-ficiency in mind is also one designed to run cool. An efficient hydraulic system makes best use of input horsepower by convert-

ing more of that energy into useful work, rather than wasting it. Energy wasted in the conversion to hydraulic energy is turned to pure heat. For example, a pump that is 80% efficient, and being run with 10-hp input, will produce 2 hp of pure heat. This 2 hp worth of heat will have to be removed from the hydraulic system. By choosing a pump with 90% efficiency, the heat load generated will be halved. On top of choosing efficient components, the circuit should be designed to reduce heat load, although that is a topic unto itself. If an industrial hydraulic machine is not designed with optimal efficiency, its environment still allows for a great place to run a reliable machine. Because of access to electrical resources, efficient and powerful forced-air electric coolers can be perma-nently installed to keep oil within its optimal temperature range. These liquid-to-air cool-ers can also use thermostatic control of oil to maintain a range of optimal temperature and viscosity.

Filter carts, such as this FC series, feature two DFE rated Hy-Pro spin-on elements in series to condition hydraulic fluids with two filter passes with each pass through the filter cart.

“Next to particle contamination, heat is the second most common cause of hydraulic component failure.”

Should a hydraulic system be par-ticularly inefficient or massive enough to generate high heat waste, running a liquid-to-liquid cooler may be required. Because cooling water can remove heat from hy-draulic oil with much more efficiency, high heat loads can be removed from a relatively small cooler, which is important if plant real estate is at a premium. Shell and tube coolers are common and efficient, but the brazed plate cooler is the king of this realm. The brazed plate cooler design provides a high surface area for heat transfer to take place, allowing a lot of heat to be removed from a small cooler with relatively low cool-ant flow. The downside to any liquid-to-liquid cooler is that it requires an expensive cool-ing infrastructure, with plant-wide plumb-ing, filtration systems, cooling towers and/or chillers. Most large plants take advantage of this type of process and cooling equip-

ment, so the addition of a liquid-to-liquid cooler will be seamless. If your plant is without the cooling systems in place, you will have no choice but to use a forced air cooler. Regardless of the option you use, what’s important to the reliability of your hydraulic system is to prevent the fluid from overheating.

Keep it clean Particle contamination is often cited as the cause of most hydraulic equipment failures. The high pressure of hydraulic systems can force particles between and against tiny clearances, which under normal circum-stances, would never cause a problem. This is why ultra-high pressure hydraulic systems require ultra-high quality filtration. But every hydraulic system needs filtration on some level, and I can tell you I’ve never seen a machine with too much of it. The industrial environment has the pri-mary advantage of real estate. In a mobile application, for example, the machine often does not have the space or weight capacity to add multiple stages of high-quality filtra-tion. However, industrial floor space is of-ten available to add large filtration systems, such as basket or bag filters. These filters can hold massive volumes of particulate, and although they’re not often highly fine, they can trap the bulk of the contamina-tion to prevent the finer filters from being clogged quickly. These filters can be used as the first stage in an offline kidney loop, where a second high-efficiency filter is used to achieve target oil cleanliness. The kidney loop, or offline, filtration system is typically only seen in the indus-trial domain. It contains a separate pump/motor group whose sole position in life is to circulate oil through a filter (and sometimes


hydraforce.comLincolnshire, IL, USA 847-793-2300 Birmingham, UK 44 121 333 1800 Changzhou, China 86 519 6988 1200

Discover the difference.For more details or engineering assistance

visit hydraforce.com/hyperformance.htm, orcontact us at [email protected].

SUPERIOR PERFORMANCE IS A GIVEN.HYPERFORMANCE IS EARNED.™

HyPerformance™ high pressure cartridge valves are in a category all their own.This comprehensive line features over 150 cartridge valves that have been testedto meet the rigorous NFPA T2.6.1 standard. The robust cavity design increasesreliability and ensures valve retention in demanding applications. Simply put, theyoffer the highest level of performance in the industryand are certain to power your application forward.

Hanover, GermanyNovember 10-14, 2015Stand 16C07

HF HyPerformance AdF (FPW)_10-15_9 x 10.875 9/1/15 11:28 AM Page 1

Hydraforce 10-15.indd 61 9/30/15 1:58 PM




a cooler, as well). Hydraulic systems with kidney-loop filtration systems are often the cleanest around, because their filter element quality can be extremely fine with no concern for backpressure related to high flow, as can be seen with return line filters. The extra pump and electric motor require extra space, plumbing and an electrical connection, which is easier to come by in a plant. Another benefit to the extra space available to industrial machines is the capacity to use pressure filters. A pressure filter is sometimes used in mobile machin-ery, but the space and cost don’t always allow it. When taken advantage of, the pres-sure filter prevents downstream contami-nation-related failures due to either pump disintegration, or during periods of high dirt ingression to the reservoir. Although

they cannot prevent a pump failure, such a failure will not damage the downstream components. When particle contamination is protected against, the industrial hydraulic machine really never should see a reliability problem.

Keep it dry Where industrial hydraulic systems are absolutely superior to their mobile hydrau-lic cousins is in regard to the prevention and elimination of water contamination. Because of the stable environment and lack of rain, free water intrusion is rare within a manufacturing plant. If it exists, it’s typically in the form of humidity, or during cata-strophic failure of a liquid-to-liquid cooler. I’ve been in enough plants to know they’re hot and humid in the summer, which is sometimes enough to allow humid-

ity to make its way into hydraulic fluid, allowing water to dissolve into the liquid straight from the air. When water satura-tion within oil becomes high enough, the oil performance can be reduced, which is in addition to the accelerated oxidation of steel hydraulic components, such as pumps and valves. Humidity can be reduced from hydrau-lic oil by way of desiccant breathers, which act as a water absorbing barrier between the volume of air in the reservoir and the humidity in the ambient air. As the tank breathes in air, it must pass by the desic-cant material, pulling away moisture and leaving the tank air dry. These desiccant breathers are large and relatively expensive, and must be changed much more frequent-ly than traditional filter-breather caps. Should water contamination be exces-

www.hunger-hydraulics.com • +1.800.248.9232

Complete Hydraulic SolutionsYour One Source for

New and Rebuild at our Ohio Facility

Assembling 37k lb. Cylinder

Doosan DBC130 Boring Mill

Thread Milling 3”- 8 holes 60” Swing Lathe

Doosan Puma 300LC

Rossford Facility

Over 70 years experience

Hunger Hydraulics C.C., Ltd.

63 Dixie Highway

Rossford, Ohio 43460

Phone: +1.419.666.4510

Fax: +1.419.666.9834

[email protected]


sive to the point of free water, water absorbing filter elements can be added to the system. These filters are often high-micron elements with lower efficiency in removing particles. They will absorb free water as it passes through, but they’re limited in the volume that can be trapped before they themselves become clogged. Often during times of water contamination removal, multiple filter elements must be used to get the majority of the water out of the oil. It should be noted that water absorbing elements can only remove free water and provide no protection against humidity. To remove humidity from oil, special machinery is required. The vacuum dehydrator is a machine, often on a large, wheeled cart, which can be trucked around the plant to any system requir-ing its attention. It will circulate the oil in the reservoir, just as with a kidney-loop system. It heats the oil while at the same time applying a vacuum. The heat and reduced local pressure allow water to boil at a low temperature, and the vacuum pulls the moisture away. This system can remove both dissolved and free water. Just as you would imagine, the vacuum dehydrator is expen-sive, bulky and requires an ac power connection, so it generally exists in the industrial realm alone. But the value of maintaining dry oil is often overlooked, so few plants use them. Dry oil has better lubricating properties, oxidizes less and is more stable over an extended period. As you can imagine, dry oil is absolutely required when reliability is a primary concern in the industrial environment. The reliability of any hydraulic system is improved when particle, heat and water contamination are controlled. Because of the mega-dollar value of some industrial machines, often costing millions of dollars, the extra investment of protection systems should seem like a no-brainer. With the resources available to some industrial plants, reliability should never be a concern. FPW



Discuss This

LunchBoxS E S S I O N S

Continuous, Just-In-Time Hydraulics & Electrical Training

Learn ONLINE, ANYWHERE, ANYTIME, with interactive industrial

training from CD Industrial Group Inc.

CD Industrial Group Inc.1·866·628·3224

[email protected]

lbs.indd 1 2015-09-25 1:58 PM


P N E U M A T I C S

Pneumatic cylinders are a popular way to clamp, position and transfer parts in

automated equipment. They also offer one of the simplest ways to achieve mechani-

cal motion and fixturing of parts (Figure 1). However, some common problems can oc-

cur when designing and applying pneumatic actuators and cylinders—and air prepara-

tion devices such as filters, regulators and lubricators.

Following these design rules will ensure a successful machine automation application.

Pneumatic system guidelines for success


Pat PhillipsProduct ManagerFluid Power & Mechanical ProductsAutomationDirect

Design issuesMost pneumatic system issues are caused by attempts to make a cylinder and related com-pressed air system components do something outside of the hardware’s design parameters. Some of the leading pneumatic system design errors are listed in Table 1 and described below. Low or varying air pressure can negatively impact the final product and overall machine sequence. This is often caused by insufficient capacity at the air compressor, and can also be caused by undersized plant air supply tubing and piping. Other low air-pressure problems can crop up due to operational issues involving air-driven motors and machines. For example,

a manufacturing plant was experiencing low air pressure in its facility at the end of the day shift, causing one of the machines to fault due to low air pressure in its pneumatic actuation system. The problem was found to be high volume air consumers nearby, namely blow guns being used to clean machines at the end of each day. Lack of or improper use of flow controls can also cause pneumatic system problems. Without flow control, a cylinder may move too fast, eventually damaging the cylinder itself and/or surrounding tooling. If flow control is present but applied too vigorously, a cylinder may move too slowly to accom-modate the desired high-speed operation. Poor location of flow controls may

also cause poor cylinder speed control, for example by making it too easy for an operator to change flow rates. This can be analogous to giving everyone access to a thermostat regu-lating building temperature, which is never a good idea. If an operator adjusts airflow for one purpose, he or she may not know it will interfere with other machine operations, such as keeping a part from jumping out of a nest. Cylinders can bang at pneumatic system power-up if a load moves the cylinder to a re-tracted position when the air is shut off. Upon power-up of the pneumatic system, air can rush in and cause abrupt and possibly danger-ous operation. Another common pneumatic design issue is slow or inconsistent cylinder speed,

FPW_Pneumatics 10-15_Vs4 MG.MD.indd 64 9/30/15 5:13 PM

Pneumatic system guidelines for success


Pat PhillipsProduct ManagerFluid Power & Mechanical ProductsAutomationDirect

Figure 1. Pneumatic

grippers installed on

a robot end effector

are a common part-

handling option.


P N E U M A T I C S

which can lead to inconsistent stroke. This is sometimes caused by low pressure or an undersized cylinder. On the other hand, an oversized cylinder may stroke too slowly due to its large airflow requirement. Un-dersized valves and tubing can also restrict airflow, causing slow or erratic cylinder stroke. Loud pneumatic actuation is typically caused by a lack of flow controls or end-of-stroke cushions, with the exhaust at the so-lenoid valve bank just adding to the noise. Solenoid valves can also stick in position due to contamination, and water from the air supply can block small valve passages.

Controlling pneumatic air flowFor each problem identified, certain solu-tions and design guidelines are available to address the issue. While the application of pneumatic cylinders can be as simple as

Table 1: Common pneumatic system design issues

• Low or varying air pressure

• Improper use of flow controls

• Cylinders bang at power up

• Pneumatic actuators not dumping air properly

• Slow or inconsistent cylinder speed

• Loud pneumatic actuation

• Sticking solenoids


An AMFM Company MAF M

Ω Omega OneStainless Steel Ω Hydraulic Tube Ω Hose FittingsStandard Ω Non-Standard Ω AMFM Braid Bands

Wrapped Bands Ω Bulk Coil

Made In USA

Ω Omega One www.omegaone.net800.678.9187 Local 216.663.8424Fax 216.475.0870 [email protected]

QualityMade in the USA

Commitment to ExcellencePersonable and Professional Customer Service

Available When You Need ItStocking manufacturer, standards, non-standards, short or long run

FPW_Pneumatics 10-15_Vs4 MG.MD.indd 66 10/1/15 9:47 AM

Your perfect cylinder starts at nasoncylinders.com.Your perfect cylinder starts at

The perfect cylinder doesn’t come from a shelf.It comes from your head.After all, you know your application better than anyone.

That’s why Nason starts by doing something revolutionary.

WE LISTEN. Then we build it just for you.

NAS_0366 Trade Ad-Full Pg-DW.indd 1 3/21/14 2:47 PMNason 10-15.indd 67 9/30/15 2:00 PM

P N E U M A T I C S

determining the required force and speed, mechanical cylinder configuration and related pneumatic hardware must also be properly specified and installed. Design guidelines for pneumatic systems are listed in Table 2 and detailed below. A good place to start for pneumatic design practices is to ensure adequate plant air supply pressure. Consis-tent plant air pressure with suitable flow allows pneu-matic devices to operate as designed. Once consistent and correct pneumatic system air pressure and flow is established, plant supply air should be connected to a manual, lockable air dump valve at each use point. This lockout, tag-out capability is impor-tant for isolating a machine—or a module of a large ma-chine—for changeover, maintenance or tooling changes. A filter regulator should be installed at the air dump valve. The filter removes dust particles and water that can cause wear and operation problems for pneumatic system components. A regulator is required to throttle to the design air pressure at the use point, typically 60

Table 2: Good pneumatic design practices

• Ensure proper plant supply pressure

• Use a manual, lockable air dump valve

• Use a filter regulator

• Use an electric soft-start valve

• Don’t oversize the cylinder

• Use flow controls

• Use mufflers for noise control

• Use lubricators only if necessary


Air that moves the world.

Experience and quality

BRASS AND COMPOSITE PUSH-TO-CONNECT FITTINGS

AUTOMATION, PACKAGING, MATERIAL HANDLING

CUSTOMIZED SOLUTIONS

GLOBAL COMMERCIAL NETWORK

www.camozzi-usa.comA Camozzi Group Company

Camozzi Solutions Pneumatic Fittings

h&p ad for camozzi - pneumatic fittings - quarter page ad.indd 1 9/20/12 5:32 PM

Automated System Solutions

Industry-Leading Warranties

NOSHOK’s Measurement Solutions for plant automation include a wide variety of pressure & temperature transmitters and switches, and industrial RTDs.• Multiple connection options• Highly repeatable current &

voltage output pressure transmitters

• RoHS compliant OEM transducers

• Electronic indicating pressure & temperature transmitter/switches

• Probe type industrial RTDs available with connection head & RTD transmitter

1010 West Bagley Road I Berea, Ohio 44017 I P: 440.243.0888 I F: 440.243.3472www.noshok.com


P N E U M A T I C S

to 90 psi, as the plant air supply is usually higher, about 100 to 130 psi. Operating at the design pressure as opposed to plant pressure will reduce wear on pneumatic components. An electric, soft start valve down-stream of the regulator allows air pressure to gradually increase at start-up, preventing sudden banging or slamming of cylinders at power up. This is especially important if 4-way, 2-position valves are used because a 2-position valve spool maintains its position after power off and the removal of air. When power and air is reapplied, air will return to the cylinder. If all air was exhausted, no air is available on the other side of the cylinder. This makes speed control with flow controls non-functional. The uncontrolled speed of the cylinder could cause a high-speed stroke, commonly ending with a bang. When soft start valves are correctly applied, a machine will typi-cally return to its home position slowly and smoothly at power up. To avoid injury to an operator or main-tenance personnel, all air must be dumped from the cylinders during machine mainte-nance or changeover, and the pneumatic supply must be locked off and tagged out. A cylinder should be properly sized for the application. It’s wrong to assume bigger is better, as in many cases, machine operation won’t improve with an oversized cylinder. A cylinder that is much larger than required wastes money up front due to its higher cost, and every day thereafter because it consumes more air. Even when a cylinder is sized properly, it may stroke too fast and require use of a

Figure 2. This air preparation and valve manifold is a key component on many pneumatic systems.

flow control, typically by controlling flow of air leaving the cylinder. This also reduces noise problems caused by cylinders banging and reduces rapid exhaust racket. These flow controls are typically mounted directly to the cylinder, but can also be mounted inline near the cylinder, or at the valve if the hose between the valve and cylinder is less than about 3 ft. Specifying cylinders with built-in cushions can help provide long-term per-formance in high-speed pneumatic motion applications. The cushions allow a cylinder to stroke at high speed and only slow down near the end of stroke for a quiet, low-impact stop. Adjustable pneumatic cushions are often the best solution, comprised of specially designed end caps with built-in flow controls. Mufflers can also be used to quiet cylinder or valve exhaust noise, and they are often a simple and low cost solu-tion. Lubricators should be used sparingly and only when necessary. Most modern pneumatic components come lubricated from the factory and do not need oil. Although not necessary for most pneumatic devices, pneumatic motors on air tools and other equipment always require a lubricator.

Air control in actionA well-designed pneumatic application starts with consistent air pressure where the plant’s compressed air system connects to the equipment or the machine. Pneumatic pick-and-place is a common pneumatic application. A typical use for this function might be transferring items from


Cut to Width Roll Slitting

Custom Lamination

Custom Sheeting

Custom Belting

Custom Shape Die Cutting

We don’t just sell the high endmaterials your company needs,

we cut to order, so you are neverstuck with wasted material again

With a comprehensive selection of specialized materials such as Teflon®, Kapton®, Silicone, PEEK, Kevlar®, FEP, and PTFE coated fabrics, if your appli-cation demands performance, we can

provide a solution.

800 461 4161


one conveyor belt to another. Unlike a more sophisticated unit that uses servomotors, a pneumatic-powered unit can only repeat a sequence of operations to hard-stop locations. Although limited in flexibility as compared to a servo system, a pneumatic unit is less expen-sive by a wide margin, and is much simpler to implement and maintain. This system should start with a good air prep setup including a locking air dump valve, an air filter, a pressure regulator and an electrically operated soft start valve (Figure 2). Air from the air prep assembly will feed into a bank of solenoid valves. A good choice for this application would be a 5-way, 3-position, center-exhaust valve. The air should always be dumped when an emergency stop is pressed, releasing all trapped air that could cause an operator to be pinched. With a 5-way, 3-position valve, the center-off position dumps air to both sides of the cylinder. Also, resetting the emergency stop won’t cause motion until cycle start is pressed. One valve with two 24-Vdc solenoids con-trols each cylinder. The off (center) condition of each valve dumps air from the cylinders. Energizing individual solenoids extends or retracts its corresponding cylinder. Sometimes to protect tooling, an anti-drop check valve is mounted to the cylinder; this can be used to prevent the cylinder from dropping due to gravity when air is dumped. However, never trap air where an operator may be pinched or crushed. Using a modular valve bank allows one common exhaust port for the system, and a good quality muffler on the exhaust port reduces noise. Common cylinders used in pick-and-place applications are guided rod or twin rod cylinders (Figure 3). These cylinders typically have rectangular bodies, and a fixed plate on the end of the piston rod that does not allow any rotation of the load. A basic system might travel in the X and Z directions, with some type of gripper to pick up the items. Adding a third cylinder allows travel along all three axes. When cylinders are integrated into au-tomated equipment and the overall machine sequence, as is often the case in pick-and-place applications, cylinder speed can become important for proper product handling. Most

7 0 FLUID POWER WORLD 10 • 2015

P N E U M A T I C S

P.O. Box 9070 • Fort Wayne, IN 46899 USA

Quality components for long life.Pneumatic & Electric Actuators

High-Precision Compact DesignsUnique Medical SolutionsFDA-Approved Materials

Fast Delivery

In the medical industry, the ability to produce product faster with less down time is critical. PHD actuators offer the quality your manufacturing demands with rugged design, high precision, approved materials and fast delivery.

pharmacy

endoscopic surgical devices

non-invasivesurgical devices

orthopedic implants

syringes

devices

IV bags

lab automation

dental

To learn more, visit phdinc.com/fp1015 or call 1-800-624-8511

FPW_Pneumatics 10-15_Vs4 MG.MD.indd 70 10/1/15 11:33 AM

www.fluidpowerworld.com 10 • 2015 FLUID POWER WORLD 715 6 FLUID POWER WORLD 10 • 2015

cylinders should include flow controls to both ports, which the exhaust air regulates as it leaves the cylinder, rather than the supply air. Cylinder position switches are also extremely helpful to avoid beginning the stroke of one cylinder before the previous cylinder’s stroke is complete. Using timers to control a sequence instead of position sensors should be avoided in this and most cases. One stuck or slow cylinder during an automated sequence can cause a machine crash, costing much more than the cost of buying, installing and programming end-of-stroke sensors. When it comes to pneumatic system design, watch out for the common issues, and be sure to supply, prep and distribute the air properly. When properly applied, your pneumatic devices and actuators will


Discuss This

Figure 3. Proper design and selection of pneumatic ac-tuators, tubing and flow controls ensures robust pick-and-place operation.

have a long life with limited operational issues along the way, and with minimal required maintenance. FPW

AutomationDirectautomationdirect.com

www.mocap.com • [email protected]®

Wide Variety of Sizes & Styles forMetric, SAE, BSP, JIC, NPT Threads & Fittings

Protect EVERYTHINGFluid Power

CAPS • PLUGS • GRIPS • PROTECTION • FINISHING • MASKING

Many Sizes and Styles in Stock Order Mini-Packs & Micro-Packs for Smaller Quantities


E D U C A T I O N

Davis’ quote applies to many industries besides fluid power. There needs to be a push toward

hands-on project-based learning across all fields. “My experiences in college, what I remember,

are the things where I was immersed in a project … as opposed to a professor standing in front of

a class and explaining which of the then quadratic equations to use in various forecasting scenari-

os. I’d never remember that, but I did remember where I was immersed in a project,” said Davis. That type of project-based learning is one of the key motivators behind programs like the NFPA’s Fluid Power Challenge. “There are a couple of things going on there,” Davis said. “One is to im-merse kids in a project-based mechanical engineering and hydraulic project where they start to learn that learning about this stuff can be really fun. And those kids, on the day that the challenge occurs, after it’s all over and they’re ready to start the [competition], all their building is done, we ask them if they’ve ever done anything more difficult in school … they say, ‘No.’ And you ask them: Have you ever done anything that was more fun in school? And they say, ‘No!’ So it’s really neat stuff. To give kids the opportunity to learn the way they do during the Fluid Power Challenge is one thing, but we’re also trying to influence the teachers and demonstrate to teachers what project-based learning looks like and how impactful it can be.”

“Most education is theoretical; the practical application for what’s being taught never comes through.” — Larry Davis, President, Daman Products

engineers tomorrow:


Michelle DiFrangia • Assistant Editor

Our future lies in their education

Students today,

FPW_Education 10-15_Vs7.MD MG.indd 72 9/30/15 5:43 PM

Photo courtesy of FESTO 10 • 2015 FLUID POWER WORLD 73


E D U C A T I O N

“When it comes to who we want to hire,” he continued, “we’re hiring for values and intelligence and ability to problem solve and people who are energetic and want to work in teams … The values that come out of the Fluid Power Challenge, kids working together, learn-ing about team dynamics, and not in a formal way, just trying to get something done with five kids and one of them doesn’t want to pull their weight, how difficult that is and those kinds of issues; it’s really powerful learning. [It] is an experience that they will remember for the rest of their lives and they’ll call on that in ways they can’t imagine throughout their careers. It stands in stark contrast to the talking head methodology of teaching.” The Fluid Power Education Foundation (FPEF) encourages educators to become more involved in programs like the Fluid Power Chal-lenge and others offered by the NFPA. “I believe that instructors should be informed about the new developments in fluid power and should do the best they can to become involved with fluid power organizations like NFPA or IFPS so that their teaching material is updated and their skills and knowledge are current,” said FPEF Trustee Jose Garcia, Certified Fluid Power Hydraulic Specialist and assistant professor at Purdue University.

“The technical stuff is easy to teach … It’s those soft skills, the ability to think, to reason and to compromise and find information, that’s what’s hard to teach. I should say, it’s hard to teach under the models we traditionally have tried to teach kids. There’s a way to do it, but I believe it’s project-based,” added Davis. Fortunately, associations like the NFPA and its member companies, along with other companies in the industry, recognize the need for the immersive, project-based learning that Davis speaks so vehemently about, and they continue to develop a variety of programs aimed at middle school, high school and college level students to pique and sustain their inter-est in fluid power and technology in general.

NFPA Fluid Power ChallengeDuring the Fluid Power Challenge, eighth-grade students work in teams to design and build a fluid power mechanism, then compete against each other in a timed competition. The entire


2014 ASCO Numatics Engineering Scholarship winner Nicholas Aerni accepts his award at Pack Expo.

Alro SteelMetals Industrial Supplies Plastics

alro.com

Since 1948888-888-ALRO

Your Single Source for Fluid Power MaterialsProducing semi-precision, fixture-ready milled blanks,

eliminating the need for costly rough machining.


diagnose a problemCan your transmitter

with your machine?

The MH-3 pressure transmitter can help reduce downtime and warranty claims by giving you the ability to check the health of a pressure transmitter in the field. The next evolution in WIKA’s long line of rugged pressure transmitters, the MH-3 was specifically developed for the harsh demands of mobile working machines. With the added capability of diagnostics, the MH-3 can be configured to your specific application and needs.

Contact a WIKA specialist today to learn more at (855) 362-9452 or visit www.wika.com/mh3.

Introducing the MH-3 from WIKA. The World’s First Pressure Transmitter With Diagnostics for Mobile Working Machines.

© 2015 WIKA Insturment, LP. All Rights Reserved.

WIKA 10-15.indd 75 9/30/15 2:01 PM

Bob Hammond (Deltrol Fluid Products) works with a student from Leyden High School to build a hydraulic robotic arm during the SCC event held at Triton College.

E D U C A T I O N

event is divided into two portions: work-shop day and challenge day. On workshop day, teams build a pneu-matic filter, developing skills needed for the competition. Afterward, students return to school with their workshop kits and spend several weeks preparing for the competition by working with the Challenge scenario, developing a portfolio, and building and testing a prototype of their mechanism. The teams reconvene on Challenge day, when they must use the same tools and kits to recreate their mechanisms, which will be used to pick up a weighted object and place it on a platform. “The Fluid Power Challenge is an excellent channel to attract the newer generations of engineers, technologists and technicians, not only in fluid power, but in STEM fields in general,” said Garcia. In the first half of 2015 alone, nine events were held, seven of which were new, with a total of 634 students partici-pating. South Milwaukee school held the first Fluid Power Challenge for high-school students—34 participated.

NFPA Career Connections“The new NFPA Student Career Connections (SCC) program is an easy way for members to connect with students,” said Lynn Beyer, NFPA workforce program manager.

Overview of the SCC program: • Students and teachers from local middle or high schools will get a tour of an NFPA member company.• An employee from the company will speak


to students about careers, what a day in the life is like, how to get into the industry and so on.• Employees will work with students to put together a basic fluid power classroom kit. • NFPA can provide teachers with fluid power curriculum that has been used in several PLTW (Project Lead the Way) schools before the group leaves.

The first SCC program took place in March at Price Engineering. A group of 30 students from Arrowhead High School toured the facility. Students worked with employees to put together a fluid power classroom kit. Through this visit, one student was offered an internship at Price. The second event was held at Triton College in May. Thirty students from Leyden High School Industrial Technology Dept. met with Antigone Sharris, chair of the Triton College Engineering Dept., and Bob Ham-mond, manifold and systems engineering manager at Deltrol Fluid Products. Together, Sharris and Hammond spoke to the students about careers in fluid power and why this pathway is a great decision that leads to many promising opportunities.

Companies contributing to educationBosch Rexroth recently supplied a funding grant of $80,000 to the Olympic Com-munity of Schools in Charlotte for the new Advanced Manufacturing and Technol-ogy Center. High-school students will gain hands-on experience using state-of-the-art manufacturing equipment, including milling machines, saws and grinders, metal-cutting

Sw

itch Y

our S

wive

l ® Sw

itch Y

our S

wive

l ®

Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime

cutting the overall cost of hydraulics.

TM

1-763-784-5531 www.SuperSwivels.com

No Kinks No Hose Twisting

Hydraulic Live Swivels Inline & 90° Heavy Duty Ball Bearing Design

• Rated To 10,000 P.S.I. • Heat Treated • Available In 304 & 440 Stainless Steel

• Custom Design & Sizes Available • Rebuildable Ball Bearing Design

• Withstands Heavy Side Loads• Superior Quality Alloy Steel

• Full Flow — Low Pressure Drop

Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423

Email: [email protected]

Available In BSPP


ReadyChain® is a pre-harnessed system that is ready to plug-and-play upon delivery. Shipped in 24 hours!Request a free sample: Tel: [email protected]

E-Chains® + Chainflex® Motion Cables

= ReadyChains®

... plastics for longer life®

Ready-to-install cable carrier systems:

igus 8-15_FPW.indd 77 10/1/15 8:35 AM

and finishing technology, and quality-con-trol stations. It opened for students at the start of the fall semester. This isn’t the first time Bosch has contributed to an educational program. The company has several apprenticeship programs established throughout Germany. “Children are made aware of the career possibilities early in life and the structure has been well established to support the development of it, no matter [the] technical area,” said Mark Rohlinger, technical plant manager, Bosch Rexroth. “A good local ap-prenticeship program needs to be available and supported by local advanced manu-facturers, and also by the local community colleges and universities. … To create the awareness early on … it needs to extend down into the K–12 grades,” he continued. “That is why we are teaming up with other local manufacturing companies to

E D U C A T I O N

develop a common on-going program for students to get into. One of the main goals is to … get more and more students inter-ested and filling seats at the local colleges and universities. This then also supports all the local manufacturers, our suppliers and other business partners who may not be able to support an apprenticeship them-selves, but most likely will have the need for skilled workers at some time.”

In Cincinnati, Hydrotech, a fluid power and motion automation solutions provider, also recently donated four brand-new hydraulic training stands to Cincinnati State Technical and Community College. Be-tween 300 and 350 students will use these stands per year. The training assemblies, valued at $30,000 per unit, will be used by students in Cincinnati State’s Electro-Mechanical Engineering Technologies program. In 2014

the company donated pneumatic training stands to the same program.

“These students may be working for us someday or for one of our local clients or partners,” said Pete Jones, Hydrotech CEO. “It’s a blessing to us that we can help them develop the crucial skills necessary to be successful.”

Educating students on sensing technologyBalluff is involved in on-going fluid power education in a number of ways. The com-pany donates to myriad university pro-grams’ laboratories, including a donation of sensing equipment for process control, such as linear transducers, pressure sensors and capacitive sensors. Balluff also supports several STEM initiatives in local communi-ties and participates in TECHFIT (Teaching Engineering Concepts to Harness Future

While touring Balluff, students from Grant County Middle School learned how industrial electronics are manufactured, the basics of logistics and about the various career opportunities available in manufacturing.

SERVO KINETICS, INC.

3716 Plaza Drive Ann Arbor, MI 48108

Phone: 800.824.0808

SERVO VALVESSKI services servo valves, proportional, pressure and flow devices including all types of cartridge valves.

BRANDS WE REPAIR: Bosch/Rexroth, Continental, Moog, MTS, Parker, Star, Tokyo Precision, Vickers/Eaton, Yuken (US Authorized), And many more.....

PUMP & MOTORSKI services many brands of pumps and motors including piston, gear and vane style designed units.

BRANDS WE REPAIR: Atos, Bosch/Rexroth, Continental, Denison, Kawasaki, Parker, Oil Gear, Racine, Vickers/Eaton, And many more....

ACTUATORSSKI services most brands of hydraulic cylinders, rotary actuators and other linear actuator devices. Call us.

BRANDS WE REPAIR: Atlas, Hanna, Hydro-Line, Linde, Miller, Milwaukee, MTS Parker/Schrader, Vickers/TJ, And many more....

GEAR BOXESSKI services many brands of gear box designs and manufacturers. Contact SKI today for more details.

BRANDS WE REPAIR: Baldor, Bayside, Cleveland, Fairchild, Falk, Foote Jones, Ohio Gear, Sterling, Walker, And many more....

HYDRAULIC REPAIR SERVICESNew Customers 20% OFF First Order

Reference Ad Code 100

35 Years Service

Veteran Owned

Free Evaluations

24 Hour Service

Free Test Reports

ISO 9001-2008

www.servokinetics.com

ServoKinetics 10-15 (1/2 H - NEW).indd 1 10/1/15 11:23 AMFPW_Education 10-15_Vs7.MD MG.indd 78 10/1/15 11:28 AM

K A R - T E C H . C O M

Kar-Tech_FULL.indd 1 5/20/15 9:19 AMKar-Tech 10-15_FPW.indd 79 9/30/15 2:03 PM

Innovators and Technologists) programs at Purdue University and The College of Charleston. Lastly, the company offers a paid training class on sensor fundamentals, including fluid power related technologies like magnetic field sensors, proximity sen-sors and linear position sensors. In July, this class was offered to six students from North Cobb Christian High School in Atlanta. The students were a part of the school’s Math, Science and Tech-nology Academy. Students participated in hands-on labs that dealt with object detection, linear position management and I/O-Link technologies, as well as basic programming. Through a partnership with Gateway Community College and PLTW, Balluff also hosted 30 students from Grant County Middle School in Kentucky this past April.

Students participated in tours of the manufacturing facility, technical labs and logistics center; product demonstrations; and a Q&A session with several engineers and marketing managers. “We spent time discussing … how sensors play a vital role in automating the [manufacturing] process,” said Will Healy III, strategic marketing man-ager and coordinator of the event. “The students saw real-world examples of how this can be applied in laboratory automa-tion, automotive, metal working, welding, robotics, timber, packaging and assembly. They received basic instruction on the prin-ciples of inductive, capacitive, photoelectric and cylinder sensor technology.” Healy said future plans might incorpo-rate more hands-on experience by hooking up and using the sensors in a few on-site applications.

“We would happily offer this as an on-going program targeted at middle school, high school or college-level students … and we recognize that inciting interest in STEM careers is a vital activity for our industry,” said Healy. “Our goal is to excite our local students about manufacturing and to spark interest for their future plans through education and the workforce,” added Leah Cridlin, Balluff’s training and development special-ist, who also helped coordinate the event.

Career Exploration DayApproximately 600 middle and high school students attended the first Career Explora-tion Day at Northfield Middle School on May 19. The event, organized by FORCE America CEO John Stenz and his team, featured booths and displays provided by


E D U C A T I O N

Teams participating in the Fluid Power Chal-lenge are graded based on portfolio ideas, designs and teamwork, among other factors.

Your Reliable Hydraulics & Electronics

Remote mounted load limiting, Proportional

sequencing valve, for control of variable

displacement piston pumps.

Max Flow: 20 liter per min

Max Pressure: 450 Bar

Visit us at: www.wandfluh-us.com • 909 High Street • Mundelein, IL 60060 • 847.566.5700

Product Description: KFVSSC/2-450-G24/MEA1-S-S08Also available in Inverse function

WANDFLUH 10-15_new ad #1REV5.indd 1 9/30/15 12:13 PM


Re-

man

ufac

turi

ng

Rep

air

Pri

vate

labe

l: N

ew

Rep

lace

men

t

24 H

our

Em

erge

ncy

Ser

vice

Hyd

raul

ic P

umps

&

Mot

ors

Con

trol

Val

ves

Tra

nsm

issi

on

Pum

ps

Par

ts &

Spa

res

Kee

p th

e in

dust

ry f

low

ing-

sel

l us

your

cor

es!

AAH Fluid Power 10-15.indd 81 9/30/15 2:04 PM

HYDRAULIC REPAIRIS ALWAYS AN OPTION.At Hydraulex Global our expertise goes far beyond standard hydraulic sales. The true depth of our knowledge lies within the diagnosis and repair of hydraulic products such as pumps, motors, valves, servo/prop valves and cylinders. Whether we have your unit in stock or not, repair is always an option. In fact, it may be your best option for obsolete and hard to find hydraulic pumps, motors and valves. Letting us repair your unit can also be drastically cheaper than replacing it, especially if parts are hard to come by. We have the experience, technical expertise, inventory and equipment necessary to provide you the most efficient, highest quality repair possible. We’re here to serve your immediate hydraulic needs.Experience the one-stop shop at HYDRAULEx.COm.

www.hydraulex.com © Hydraulex Global. All Rights Reserved.

1-800-422-4279REmAN HYDRAULIC UNITS. AFTERmARKET UNITS. PARTS. REPAIRS.WE’VE GOT YOU COVERED.

Hydraulex 10-15 FPW.indd 82 9/30/15 2:06 PM

8 2 FLUID POWER WORLD 8 • 2014 10 • 2015 FLUID POWER WORLD 8 3

E D U C A T I O N

roughly 30 area businesses and organizations. Inside the school students could try out the NFPA’s hydraulic excavator, see videos of the Fluid Power Challenge and use FORCE America’s joystick and spreader control system like a video game to control a snow fighting vehicle. Outside, they could sit in the cab of a road grader or a dump truck and drive a dune buggy.

ASCO Numatics Engineering ScholarshipOver the past eight years, ASCO Numatics has awarded $70,000 in scholarships to 14 students (two per year). In addition, it has provided another $14,000 in grants to 12 U.S. schools of engi-neering. Each $5,000 scholarship goes directly toward students’ tuition. “Scholarships are merit-based and awarded on the candi-date’s potential for leadership and making a significant contribu-tion to the engineering, instrumentation, systems and automa-tion professions, particularly as they relate to the application of fluid control and fluid power technologies,” the website states.

Careers in distributionIndustrial Careers Pathway (ICP) is a program of an alliance of seven trade associations, one of which is NAHAD, who work together to drive the programs that will build awareness of the careers available in industrial distribution. “Our focus is on raising awareness of the incredibly rewarding careers in the field to 16 to 24 year olds who are mechanically inclined, like to work with their hands, enjoy working with people and who are not seeking a four-year college degree,” said Mary Jawgiel, ICP program manager.

Continuing efforts“As long as I’ve been hiring people and been in manufacturing, my colleagues have complained about the basic skills of people coming out of high school,” said Davis. According to a 2014 Manufacturing Skills and Training Study conducted by Accenture in conjunction with The Manufacturing Institute, Davis and his colleagues are not alone. More than 75% of manufacturers nationwide report a moderate to severe short-age of skilled resources. “But simply complaining about it doesn’t help; you have to be able to provide a model or idea on how it can be better,” he continued.

As demonstrated by the many programs already imple-mented, now more than ever, employers and educational insti-tutions are working together to ensure students are graduating with the proper knowledge and skill set to succeed in the work-force. In addition, these programs help spark a genuine interest in fluid power and related technologies in the next generation of engineers. “Getting kids excited about learning is the ticket,” concluded Davis. FPW



Asking “what is a hydraulic valve?” is like asking “how long is a piece of string?” The variations available to the hydraulic designer are absolutely astounding, not only because of the myriad types of valves on the market, but also because of the numerous manufacturers making them. The most basic description of a valve is a mechanical device that opens and closes, most often to control the flow of fluid—liquid or air. Valves exist in nearly every industry, from automobile engines to the foundries that cast the engine’s valves; yes, there are valves on the machines that make valves. This article isn’t about the poppet valves in your 1999 Civic SI VTEC. This article is about hydraulic valves. Hydraulic valves are unique because they must be capable of withstanding 3,000 psi or more of fluid pressure, which require them to be manufactured from strong (and often heavy) steel and iron. Their construction must be such that hydraulic pressure is entirely contained, yet able to function smoothly and accurately, without being prevented from functioning because of the high forces imposed by that pressurized fluid. So a hydraulic valve is just a device that opens and closes to allow the flow that will move actuators and loads. It sounds simple, but there are various techniques used in hydraulics to allow this to occur. Valves can be mechanically operated (by handle, knob or cam), electric solenoid-operated, or pilot-operated (air or hydraulic pressure actuates the valve). Some valves use the pressure of the circuit’s fluid to actuate themselves, like with relief valves. Valves can also be actuated with cables, levers, plungers, torque motors and so forth. There are nearly as many types of hydraulic valves as there are ways to actuate them. You have solenoid valves, flow control valves and pressure control valves as the three primary groups of valves, but each of those also have their own sub-species. Solenoid valves can be poppets or spool valves, and either of those can

be electro-proportional or

servo-controlled. Flow control valves can be hydrostats (also known as

pressure-compensators) or simply needle valves, and can be used to meter-in or meter-out fluid. Pressure control valves are the most varied of the three primary groups. They open and close, just as other valves, but these are more dynamic, with linear rise and fall of performance, based on the pressure acting upon them. Most pressure valves (like relief valves, sequence valves, counterbalance valves, and so forth) are normally closed, meaning that it takes a rise in pressure to open them. However, the pressure-reducing valve is the only one that closes when pressure rises above a set point. There is a dizzying array of hydraulic valves available, and each one could warrant their own page. It’s hard to simplify a vast subject and answer “what is a hydraulic valve,” but as long as you understand they’re devices that open and close to control the pressure, flow and direction of fluid in a hydraulic system, then you’ve got the basics down. FPW

What is a hydraulic valve?

Josh Cosford • Contributing EditorCOMPONENT FOCUS

FPW 10-15 Component Focus_Vs3 MG.MD.indd 84 9/30/15 5:25 PM

Kawasaki Precision Machinery (U.S.A.) Inc.Grand Rapids, MIwww.kpm-usa.com616.975.3100DISTRIBUTION OPPORTUNITIES AVAILABLE

www.kpm-usa.com

Control doesn’tcost the earth Value built-inGetting the most out of your vehicle is important. That’s why Kawasaki hydraulic pumps, motors and valves always go the extra mile when it comes to fuel efficiency. Combining world-class R&Dwith global manufacturing, our components put you in control, bringing your construction and agricultural vehicles to life withbuilt-in efficiency, quality and value.

M5XSwing Drive Motor

PV48Pilot Control Valve

KLXLoad Sensing Valve

6655_Kaw_Excavator_Ad_9x10.875.pdf 1 9/28/15 9:27 AM

Kawasaki 10-15_FPW.indd 85 9/30/15 2:07 PM

PRODUCT WORLD

86 FLUID POWER WORLD 10 • 2015 www.fluidpowerworld.com 10 • 2015 FLUID POWER WORLD 87

PRODUCT WORLD

G-thread pneumatic fittingsAutomationDirectAutomationdirect.com

NITRA G-thread push-to-connect fittings and flow control

valves are made with strong thermoplastic (PBT) or nickel-

plated brass bodies and stainless-steel tube gripping

claws. Available in 4 to 10 mm, the components have a

working pressure of -29.5 in.-Hg to 150 psi and a working

temperature of 32 to 140° F. Polyurethane or nylon 12 tubing

is easily connected by simply inserting the tubing end into

the fitting.

Axial piston motorsEaton Eaton.com

Eaton’s DuraForce family of axial piston motors

features the HMV, HMR, HMA and HMF Series—

all offering high efficiency, precision control and

durability. Available in displacements ranging from

35 to 280 cm3 (2.14 to 17.1 in.3) per revolution at

operating pressures up to 420 bar (6,100 psi), these

cost-effective motors ensure maximum productivity

for any hydraulic system.

Space-saving hydraulic hoseKurt HydraulicsKurthydraulics.com

E-Z Bend Hose has half the bend radius

of standard hose for easier routing and

more space savings. Suited for high-

pressure hydraulic oil lines in mobile

hydraulic applications, its tube material

is oil-resistant synthetic rubber with

reinforcement of four spiral layers of

high-tensile steel wire braid. The working

temperature range for E-Z Bend Hose is

-40 to 212° F and meets flame resistant

MSHA designation. It is available in 5⁄8, 3⁄4, 1 and 11⁄4 in. inside diameters, with

corresponding 1.07, 1.27, 1.52 and 1.79

in. outside diameters. Working hose

pressures range from 5,000 to 6,000 psi;

minimum burst pressures range from

20,000 to 24,000 psi.

FPW_Product World_10-15_Vs3.MD.indd 86 9/30/15 5:27 PM


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

Valve systemAVENTICSAventics.com/us

AV03 and AV05 valve

systems feature diagonal

spool, flexible base plate and galvanic isolation in the

power concept. Up to 64 base plate valves can be added

modularly to the board, and configurable voltage and

compressed air circuits add to the system’s flexibility. A

compact, polymer-based construction reduces weight

and provides optimized compressed air balance.

Compact pneumatic cylindersBimba ManufacturingBimba.com

MACQ series cylinders are constructed with a robust,

extruded aluminum body. Double-acting, available in

10 different bore sizes and a wide range of standard

stroke lengths, the cylinders can also be obtained with

a magnetic piston to enhance position sensing. The

new compact line is suited for a broad range of general

automation processes, providing flexibility in space-

sensitive machine design applications.

INTRODUCING AMC FREE

LARGEST LEAD FREE INVENTORY IN THE INDUSTRY

OVER 800 LEAD FREE SKU’S AVAILABLE

NSF CERTIFIED TO ENSURE COMPLIANCE

FITTIFITTINGS ARE MARKED FOR EASY DISTINCTION

COMPRESSION, FLARE, HOSE BARB, GARDEN HOSE, PIPE FITTINGS &

NEEDLE VALVES

SAME DAY SHIPPING AVAILABLE

1-800-821-5672

™

[email protected]

FPW_Product World_10-15_Vs3.MD.indd 87 10/1/15 11:31 AM


AD INDEX

AAH Fluid Power, Inc. .............................81Advanced Technology Products .............54Aggressive Hydraulics, Inc. .....................17Alro Steel Corp. ......................................74Anderson Metals Corporation, Inc. .......87AutomationDirect ....................................1AVENTICS Corp. ......................................29Bimba Manufacturing Co. ........................9Brennan Industries, Inc. .........................15C.matic ...................................................66Camozzi Pneumatics Inc. ..................36,68CD Industrial Group Inc. .........................63Clippard Instrument Laboratory, Inc. ..................................BCCS Hyde Co. ............................................69DEL Hydraulics ........................................55DMIC - Delaware Manufacturing Industries Corp. ................................30FABCO-AIR, Inc. ......................................47FASTER, Inc .............................................32FESTO .....................................................12Firestone Industrial Products Co., LLC ...46 Flaretite Inc. ...........................................36

FluiDyne Fluid Power .............................59Gerdau Special Steel North America .....25HAWE Hydraulik .....................................35 Hengli America Co., Inc. / TECO Technology ...............................21Holmbury, Inc. ......................................IBCHunger Hydraulics C.C., Ltd. ...................62 Hy-pro Filtration .....................................83HYDAC International ..............................19HydraForce, Inc. .....................................61Hydraulex Global ....................................82IC-Fluid Power, Inc. .................................33igus, Inc. ................................................77Intertraco (Italia) S.p.A. ..........................11Kar-Tech, Inc. ..........................................79Kawasaki Precision Machinery (U.S.A.) Inc. ......................85Kocsis Technologies, Inc. ........................27Kuriyama of America, Inc. ........................2Kurt Hydraulics .......................................13Lillbacka USA, Inc. ..................................37Main Manufacturing Products, Inc. .........4MFP Seals ...............................................16

www.fluidpowerworld.com

LEADERSHIP TEAM

PublisherMike Emich508.446.1823 [email protected]@wtwh_memic

Managing Director Scott [email protected]@SMMcCafferty

EVP Marshall [email protected]@mmatheson

MOCAP ...................................................71Muncie Power Products ...........................5NASON ....................................................67NOSHOK, Inc. .........................................68OEM Controls, Inc. .................................71Omega One ............................................66OP USA Inc. ............................................43PHD Inc. ..................................................70Prince Manufacturing Corp. ..................53Rota Engineering Ltd. ............................26RYCO Hydraulics .....................................45Servo Kinetics, Inc. .................................78Smalley Steel Ring Co. ..............................3STAUFF Corp. ..........................................23Super Swivels .........................................76Tompkins Industries, Inc. ................... IFC,4Ultra Clean Technologies Corp. ..............48Veljan Hydrair Limited ............................49Wandfluh of America, Inc. .....................80WIKA Instrument, LP ..............................75Yates Industries ........................................7

Ad Index_FPW_10-15.indd 88 10/1/15 2:35 PM

VISIT US ATICUEE 2015

BOOTH 2217

TEL: (866) 465 6827FAX: (440) 578 1073EMAIL: [email protected]

HOLMBURY INC.33801 Curtis Blvd, Suite 104

Eastlake, OH 44095

Connect with quality - Connect with Holmbury

Holmbury has recently expanded their hydraulic quick coupling offering to include the HDB Series. The HDB Series is a connect under pressure block coupler designed specifically for the skid steer loader market and is interchangeable with the Faster

4BD4FH and Stucchi Saturn block couplers.

HDB Advertisement- Full Page v4.indd 1 29/07/2015 14:46:00

Holmbury 8-15_FPW.indd 1 9/30/15 2:09 PM

1 Next Gen Electronic Valves with Flows to 100 l/min!2 ”GV” Series High Flow Poppet Valves3 New Series Miniature Pressure Regulators4 New Stainless Steel Push-Quick Fittings5 “EGV” Electronic High Flow Poppet Valves6 ”EFB“ Electronic Fill & Bleed Circuits7 High Flow “E” Electronic Valves8 All Stainless Steel Pneumatic Cylinders9 Electronic Valves for Oxygen Applications

1

4

2

Clippard Instrument Laboratory, Inc.Providing innovative solutions for today’s engineering challenges.

877-245-6247 • www.clippard.com

9

1

Flows to 100 l/min!

Introducingnew products new solutions

more info

77

555

3

ectronic Valves with Fl

3

88

666

4

Clippard 10-15.indd 1 9/30/15 2:08 PM

fluid power world october 2015

Documents